NC0023981_More Information (Received)_20190522

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May 22, 2019
Ms. Anita E. Robertson, PE, Supervisor
Wastewater Projects Unit
NC Division of Water Infrastructure l
8th Floor Archdale Building
512 N. Salisbury Street
Raleigh, North Carolina 27604
RE: Project No. E-SRP-W-17-0044
Plans and Specs Resubmittal
Biosolids Facility Improvements
City of Lenoir, North Carolina
Dear Ms. Robertson:
We are in receipt of your review comments for the subject project that was received by email on
April 23, 2019. On behalf of the City of Lenoir, we hereby offer this letter and its enclosures to
support our responses to your comments. Enclosed are the following documents for your review:
• Comment-response format list for each comment
• One (1) set of revised Specifications Divisions 11 & 14
• One (1) set of revised Plan Sheets C-102 through C-302, C-501, and the Cover Sheet
• Revised Preliminary Opinion of Probable Costs
• Residuals Management Plan
• Revised Page 3 of Bid and Design Document Submittal Checklist
• Revised Page 2 of the Authorization to Construction Application
We trust that this revised submittal will address comments needed for approval of the plans and
specifications. Should you have questions, please contact us at 828-328-2024.
Sincerely,
MCGILL ASSOCIATES, P.A.
&WHITF D, PE
Senior Project Manager
JW:nwg
Enclosures
cc: Scott Hildebran, City Manager Trupti Desai, PE, DWI (via email)
Radford Thomas, Public Utilities Director Bing Bai, Ph.D., El, NPDES Unit (1/encl.)
L 1HickorylProtects12017 PROJECTS 117 01107 CITY OF LENOIR-Biosolids Facility Improvements102 Design Phase\Documents1EC11-LQS submittal Letter
MCGILL ASSOCIATES 1240 19tn STREET LANE NW, HICKORY, NC 28601 /828.328 2024/MCGILLASSOCIATES.COM

Responses to DWI / DWR Comments
A. General Review
1. Projects not approved by July 1, 2019 may lose assurance of funding and may reapply for
funding under the current competitive priority system.
Response: Noted
2. Submit the sludge management plan to provide information on current and proposed sludge
management practice.
Response: The Residuals Management Plan was included in the Authorization to
Construct Application to submitted DWR on March 29, 2019. The Residuals
Management Plan is also included in this resubmittal.
B. Review of Bid and Design Document Submittal Checklist
3. Include Distribution of Class A Residuals Permit in Section 4— D.Permits on page 2. Please
note that this permit needs to be modified due to changes in sludge treatment process.
Contact the Non-discharge Permitting Unit of the Division of Water Resources for more
information. The approval of plans and specifications and issuance of the Authorization to
Construct permit do not depend on the modification of this permit.
Response: Section 4.D has been revised accordingly. Page 3 of the Bid and Design
Document Submittal Checklist is included in this resubmittal.
C. Review of Calculations
4. What is the solid content of the dewatered sludge transported from other treatment plants
and fed directly to the thermal dryer (See drawing G-004)? If the solid content of this
transported sludge is too low, for example 3-5%, we recommend that it should be pumped to
the sludge storage tank and fed to the belt press for dewatering.
Response: Sludge cake from other treatment plants will be transported at 14% solids
or greater. Additionally, all trucks transporting sludge cake will be covered.
5. The Division has approved $6,600,000 loan for this project which is sufficient to fund base
bid items. What is the funding source for alternate bid items? Is the City of Lenoir planning
to request the Division for higher loan amount or using their own funds?
Response: The Preliminary Opinion of Probable Cost is expected to be conservative,
therefore allowing most alternate bid items to be funded by the $6,600,000 loan.
However, if bid costs are high, the City may choose to decline alternate bid items,
request additional funds, or use local funds.
D. Review of Plans
6. The proposed design does not include installation of a new 150,000 gallon sludge holding
tank which was approved in the engineering report. Provide reasons for excluding this item.
Response: The Engineering Report discussed a new 150,000-gallon sludge storage
tank. However, this item was removed to allow for the sludge cake receiving station
and conveyors. Plus, the City reported that the existing liquid sludge receiving tank/
pump system works well.
Page 1of3

.
7. Proposed addition to the residuals management building shown on drawings C-104 & 105 is
not listed in the eligible items list in the ER approval letter. Please explain reasons for
proposing this item.
Response: The building expansion is needed to provide covered space for the blower
and heat exchanger. This dryer arrangement was the most efficient layout and allows
the blower to be located outside of the main Residuals Building.Additionally, the City
preferred that the blower was placed in a separate area for noise attenuation.
8. Label the thermal dryer in drawing C-105.
Response: The thermal dryer has been labeled on Sheet C-104(Proposed Enlarged
Site Plan). Please note that Sheet C-105 was renumbered as Sheet C-104.
9. Edit drawing C-201 to remove section line A shown on the bottom left.
Response: Section A-A has been removed from Sheet C-201.
10. Edit drawing C-301 to update label for the sludge holding tank. It should be Sludge Holding
Tank Rehabilitation Plan instead of demolition plan.
Response: Sheets C-301 and C-302 have been revised accordingly.
E. Review of Specifications
11. Some section numbers are missing the last number i.e. zero. Please check sections
113110, 113150, 113610, 113750 etc. Please go through the whole document and match
section numbers with Table of Contents.
Response: The specifications have been revised accordingly.
12. Specifications for pumps in sections 113110, 113130 and 113150 are generic. Please
update them to include information specific to this project. These sections must include
number of proposed pumps, their capacity, HP, VFDs etc.
Response: The specifications have been revised accordingly. Regarding
Specification Section 113150,please refer to Article 2.01.A.
13. Add specifications for the vertical screen shown on drawing C-501. What is the purpose of
this screen? How will it be cleaned?
Response: Sheet C-501 has been revised to include a grate/screen box to receive
liquid sludge. The purpose of this liquid sludge receiving box is to capture debris in
the sludge to prevent the sludge pump from clogging. This grate/screen box will be
manually cleaned as needed by the City.
14. Will polymer pumps be replaced or existing ones will be reinstalled? Provide detailed
specifications including number of pumps, type, capacity etc. if they are new.
Response: The existing polymer pumps are being replaced with a liquid feed system.
The polymer feed system will be provided by the belt press manufacturer as noted in
Specification Section 113610, Article 1.02.A. Refer to Article 2.16 for the polymer feed
system requirements.
15. Update specifications to provide specific information such as RPM, HP etc. for submersible
mixers. Is this a like to like replacement?
Response: Specification 113740 has been revised accordingly. The mixers are like-
for-like size replacement.
Page 2 of 3

,
16. Prepare a table to show location, length of proposed conveyers and other important
information in Section 113750.
Response: Specification Section 145200(Shaftless Screw Conveyors) has been
revised to include a table indicating all relevant information for each screw conveyor.
F. Review of Cost Estimate
17. Provide the most recent cost estimate for the project.
Response:A revised preliminary opinion of probable costs is included in the
resubmittal.
18. Three mechanical surface aerators (in drawing C-302) are proposed in the alternate bid but
they are not included in the cost estimate and specifications document. Please update the
cost estimate and specifications.
Response: The specifications and preliminary opinion of probable costs have been
revised accordingly. Aerators are in Specification Section 113750.
19. Include the cost estimate for sludge/scum pump and screen shown on drawing C-501.
Response: The cost for the sludge/scum pump and screen is included in the revised
preliminary of probable costs.
G. Review of Authorization to Construct Application
20. Section 2.0 (Page 2)• Fill in NPDES permit number instead of the SRP project number.
Response: The NPDES permit number has been added. Page 2 of the Authorization to
Construct Application has been included as part of this resubmittal.
21. Section 4.B.5 (Page 10): Add all new tanks with volume.
Response: No additional tanks will be constructed as part of this project.
22. Section 4.B.6 (Page 10): Add all new and replacement pumps, unless they are in-kind •
replacement.
Response: Pumps are in-kind replacement.
23. Section 4.B.7 (Page 10): Add submersible mixers.
Response: Mixers are in-kind replacement.
Page 3 of 3

PRELIMINARY OPINION OF PROBABLE COST
BIOSOLIDS FACILITY IMPROVEMENTS
CITY OF LENOIR, NORTH CAROLINA
MAY 2019
-ITEM` =V vim, DESCRIPTION QUAN. ;UNIT. UNIT'PRICE TOTAL
1 Mobilization 1 LS 7% $ 210,000
2 Sludge Feed Pumps &Valves 2 EA $ 64,000 $ 128,000
3 Sludge Feed Piping& Meter 1 EA $ 75,000 $ 75,000
4 Dewatering System 1 EA $ 430,000 $ 430,000
5 Polymer Feed System 1 EA $ 150,000 $ 150,000
6 Sludge Cake Storage Hopper 1 EA $ 160,000 $ 160,000
7 Solids Conveying Systems 1 EA $ 380,000 $ 380,000
8 Biosolids Dryer- Equipment 1 LS $ 1,750,000 $ 1,750,000
9 Biosolids Dryer- Installation 1 LS $ 200,000 $ 200,000
10 Dewatering Building Improvements 1 LS $ 150,000 $ 150,000
11 Dryer Building Improvements 1 LS $ 250,000 $ 250,000
12 Sludge/Scum Pump &Screen 1 LS $ 60,000 $ 60,000
13 Odor Control Improvements 1 LS $ 180,000 $ 180,000
14 Biosolids Storage Improvements 1 LS $ 200,000 $ 200,000
15 Yard Piping/Drain Improvements 1 LS $ 100,000 $ 100,000
16 Site Grading& Paving 1 LS $ 120,000 $ 120,000
17 Electrical &Controls 1 EA $ 380,000 $ 380,000
CONSTRUCTION SUBTOTAL $ 4,923,000
Contingency $ 493,000
Provision for Extending Natural Gas to Site $ 100,000
Project Administration Costs $ 934,000
TOTAL BASE BID PROJECT COSTS $ 6,450,000
ALTERNATE BID ITEMS
2 Sludge Cake Receiving Station 1 EA $ 300,000 $ 300,000
3 RAS Pump Replacement 1 LS $ 60,000 $ 60,000
4 WAS Pump Replacements 2 LS $ 38,000 $ 76,000
5 DAF Unit Demolition 1 LS $ 60,000 $ 60,000
6 Sludge Holding Tank Mixers 2 EA $ 64,000 $ 128,000
7 Sludge Holding Tank Aerators 3 EA $ 65,000 $ 195,000
SUBTOTAL $ 819,000
Contingency $ 82,000
TOTAL ALTERNATE BID COSTS $ 901,000
TOTAL PROJECT COSTS $ 7,351,000
Notes:
1. All estimated costs are in 2016 dollars.
2. The Engineer maintains no control of labor costs,materials,equipment or services furnished by others,the
Contractor(s)'methods for determining prices,or competitive or market conditions.The estimates herein for project and
construction costs represent the Engineer's best judgment,and are based on experience and qualifications as a
Professional Engineer who possesses familiarity with the construction industry.The Engineer does not guarantee the
accuracy of the cost estimates,which may vary from bids or actual project and construction costs.

BIOSOLIDS FACILITY IMPROVEMENTS
CITY OF LENOIR, NORTH CAROLINA
RESIDUALS MANAGEMENT PLAN
The project generally includes improvements to the City of Lenoir's Lower Creek Wastewater
Treatment Plant which has a capacity of 6.0 million gallons per day(MGD).The existing residuals
process primarily includes a sludge holding tank, sludge feed pump, a belt filter press, and a lime
pasteurization system. The proposed project will overhaul the residuals processes to include two
(2)sludge pumps,belt filter press,dewatered solids storage,thermal drying equipment,conveyors,
improvements to residuals building,improvements to biosolids storage area,site work,demolition,
drainage improvements,paving,piping,valves,electrical,controls, SCADA programming,and all
related appurtenances. Natural gas will be extended to the site as the primary fuel source for the
thermal drying equipment.
The City originally stored lime pasteurized biosolids stored in a 2,400 square-foot shed near the
residuals management building prior to being hauled to local farmers and spread at the City's
expense. However, since the lime stabilization system equipment is now out of service, the City
has been hauling dewatered sludge to the landfill. The project includes the replacement of the belt
filter press(BPF)for dewatering sludge. Polymer will continue to be added to the sludge upstream
of the BFP. Sludge will be dewatered by the BFP to 16-18% before being conveyed to a storage
hopper. In order to continue the Class A biosolids program, the new thermal belt dryer will be
installed to replace the lime pasteurization system. Sludge cake will be conveyed to the new
thermal belt dryer to dry the material to greater than 90% solids and provide biosolids particles in
excess of 176°F for pathogen reduction. The system will also dry un-stabilized solids to over 90%
for vector attraction reduction. The thermal belt dryer is able to verify Class A biosolids
compliance by 1) monitoring of process temperatures, moisture contents, and cycle times, 2)
drying the solids to over 90% solids, and 3) verifying fecal coliform levels by lab analysis. Class
A biosolids will be stored in the 2,400 square-foot shed which will be enclosed on three (3) sides
as part of the project. Class A biosolids will continue to be provided to local farmers.
1

a, tea, Does this Permit match the
o If Not Issued Provide Design Documents for this
•
o .. 0 CO a Status and Expected Project as Submitted for
Permit/Certification z a In ina Issuance Date Review?
Railroad Encroachment X U Yes U No
Agreement
Sewer Extension* X ❑Yes❑ No
Soil Erosion and Sediment 3/4/19 5/15/19 ®Yes❑ No
Control
Stormwater Management X ❑Yes❑ No
Plan
USCOE/Section 10 X ❑Yes ❑ No
USCOE/Section 404 Permit X ❑Yes❑ No
Water Quality Certification X ❑Yes❑ No
(401)
Other:Distribution of Class
A Residuals Permit 5/30/2019 ®Yes No❑
*Provide application if not issued as of date of submittal of this package.
❑ If no,clearly describe any portions of the design that vary from the Permit and the reasons for the differences.
Note: Based upon the scope of differences,a permit revision may be required.
_. Easements
❑ All necessary easements have been acquired. ® Easements are not necessary.
❑ All necessary easements are anticipated to be acquired by
F. Cost Estimate
® For all project components provide a project line-item cost estimate that has been prepared or updated not more than 60
days prior to submittal of this package.This estimate should be at least as detailed as the bid form in the specifications.
® Does the project design include any bid alternates?®Yes❑ No.
If yes, provide a separate project line-item cost estimate for each bid alternate.
G. Compliance with North Carolina General Statutes Chapter 133: Public Works
® Project complies with NC§ 133-1 through 4: Public Works,Article 1-General Provisions.
H. Engineering Plans
Z Submit one set of detailed plans that have been signed,sealed and dated by a North Carolina Licensed Professional Engineer
on each sheet of the engineering drawings.
® Per 21 NCAC 56 .1103(a)(6),the name,address and License number of the Licensee's firm shall be included on each sheet of
the engineering drawings.
® Plans must be labeled as follows: FINAL DRAWING—FOR REVIEW PURPOSES ONLY—NOT RELEASED FOR CONSTRUCTION.
® The cover sheet of the plans must contain the Division provided Project Number.
® Plans shall include all applicable disciplines needed for bidding and construction of the proposed project.
Form PS-SUBMITTAL-07/18 Page 3

State of North Carolina
7.
,_; Department of Environmental Quality
Division of Water Resources
Water Resources
ENVIRONMENTAL QUALITY APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
Telephone number 828-328-2024
Email address [e-mail]
C. NPDES PERMIT
NPDES Permit number NC0023981
Current Permitted flow(MGD)—include permit " 6.0 MGD
flow phases if applicable
D. PROJECT DESCRIPTION
Provide a brief description of the project:The project generally consists of new sludge pumps, belt filter press,dewatered solids
storage,thermal drying equipment,conveyors, improvements to residuals building, improvements to biosolids storage area,site
work,demolition,drainage improvements, paving,piping,valves,electrical,controls,SCADA programming,and all related
appurtenances. Natural gas will be extended to the site as the primary fuel source for the thermal drying equipment.
SECTION 3:APPLICATION ITEMS REQUIRED FOR SUBMITTAL FOR ALL PROJECTS
A. Cover Letter
® The letter must include a request for the Authorization to Construct;the facility NPDES Number; a brief project description
that indicates whether the project is a new facility,facility modification,treatment process modification,or facility expansion;
the construction timeline;and a list of all items and attachments included in the application package.
® If any of the requirements of 15 NCAC 02H. 0100, 15A NCAC 02T, North Carolina General Statute 133-3, North Carolina
General Statute 143-215.1, and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment
Facilities are not met by the proposed design,the letter must include an itemized list of the requirements that are not met.
B. NPDES Permit
® Submit Part I of the Final NPDES permit for this facility that includes Part A(Effluent Limitations and Monitoring Requirements)
for the monthly average flow limit that corresponds to the work that is requested for this project.
C. Special Order by Consent
❑ If the facility is subject to any Special Orders by Consent(SOC),submit the applicable SOC.
® Not Applicable.
D. Finding of No Significant Impact or Record of Decision
❑ Submit a copy of the Finding of No Significant Impact or Record of Decision for this project.
❑ Provide a brief description of any of the mitigating factors or activities included in the approved Environmental Document
that impact any aspect of design of this project, if not specified in the Finding of No Significant Impact or Record of Decision.
® Not Applicable.
E. Engineering Plans
® Per 15A NCAC 02T.0504(c)(1),submit one set of detailed plans that have been signed,sealed and dated by a North Carolina
Licensed Professional Engineer.
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 2

SECTION 110513 COMMON MOTOR
REQUIREMENTS FOR EQUIPMENT
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and
Supplementary Conditions and Division 01 Specification Sections, apply to this
Section.
1.2 SUMMARY
A. Section includes general requirements for single-phase and polyphase,
general-purpose, horizontal, alternating-current, small and medium, squirrel-
cage induction motors, installed at equipment manufacturer's factory, and
motors shipped separately by equipment manufacturer for field installation.
1.3 COORDINATION
A. Coordinate features of motors, installed units, and accessory devices and
features to be compatible with the following:
1. Motor controllers.
2. Torque, speed, and horsepower requirements of the load.
3. Ratings and characteristics of supply circuit and required control
sequence.
4. Ambient and environmental conditions of installation location.
PART 2 - PRODUCTS
2.1 GENERAL MOTOR REQUIREMENTS
A. Comply with requirements in this Section except when stricter requirements are
specified in equipment schedules or Sections.
B. Comply with NEMA MG 1 unless otherwise indicated.
2.2 MOTOR CHARACTERISTICS
A. Duty: Continuous duty at ambient temperature of 40 deg C and at altitude of
3300 feet above sea level.
February 2019 . PROJECT#17.01107 110513-Page 1

B. Capacity and Torque Characteristics: Sufficient to start, accelerate, and operate
connected loads at designated speeds, at installed altitude and environment,
with indicated operating sequence, and without exceeding nameplate ratings or
considering service factor.
2.3 POLYPHASE MOTORS
A. Description: NEMA MG 1, Design B, medium induction motor.
B. Efficiency: Energy efficient, as defined in NEMA MG 1.
C. Service Factor: 1.15.
D. Rotor: Random-wound, squirrel cage.
E. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and
thrust loading.
F. Temperature Rise: Match insulation rating.
G. Insulation: Class F.
H. Code Letter Designation:
1. Motors 15 HP and Larger: NEMA starting Code F or Code G.
2. Motors Smaller Than 15 HP: Manufacturer's standard starting
characteristic.
2.4 POLYPHASE MOTORS WITH ADDITIONAL REQUIREMENTS
A. Motors Used with Reduced-Voltage and Multispeed Controllers: Match wiring
connection requirements for controller with required motor leads. Provide
terminals in motor terminal box, suited to control method.
B. Motors Used with Variable Frequency Controllers: Ratings, characteristics, and
features coordinated with and approved by controller manufacturer.
1. Windings: Copper magnet wire with moisture-resistant insulation varnish,
designed and tested to resist transient spikes, high frequencies, and short
time rise pulses produced by pulse-width modulated inverters.
2. Energy- and Premium-Efficient Motors: Class B temperature rise; Class F
insulation.
3. Inverter-Duty Motors: Class F temperature rise; Class H insulation.
4. Thermal Protection: Comply with NEMA MG 1 requirements for thermally
protected motors. ,
February 2019 PROJECT#17.01107 110513-Page 2

2.5 SINGLE-PHASE MOTORS
A. Motors larger than 1/20 hp shall be one of the following, to suit starting torque
and requirements of specific motor application:
1. Permanent-split capacitor.
2. Split phase.
3. Capacitor start, inductor run.
4. Capacitor start, capacitor run.
B. Multispeed Motors: Variable-torque, permanent-split-capacitor type.
C. Bearings: Prelubricated, antifriction ball bearings or sleeve bearings suitable for
radial and thrust loading.
D. Motors 1/20 HP and Smaller: Shaded-pole type.
E. Thermal Protection: Internal protection to automatically open power supply
circuit to motor when winding temperature exceeds a safe value calibrated to
temperature rating of motor insulation. Thermal-protection device shall
automatically reset when motor temperature returns to normal range.
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
February 2019 PROJECT#17.01107 110513-Page 3

SECTION 113110 VERTICAL CENTRIFUGAL SEWAGE PUMPS
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. Scope of Work
1. The Contractor shall furnish and install vertical dry-pit solids
handling pumping units as indicated on the drawings and described
in these specifications.
2. All materials and equipment supplied under this Section shall be
new, of good quality, and in good condition.
B. Codes, specifications, and standards referred to by number or title shall
form a part of this specification to the extent required by the references
thereto. Latest revisions shall apply, unless otherwise shown or specified.
C. Abbreviations:
1. ANSI - American National Standards Institute
2. ASTM - American Society for Testing & Materials
3. AWWA -American Water Works Association
4. AFBMA - Anti-Friction Bearing Manufacturer's Association
5. HI - Hydraulic Institute
6. NEMA - National Electrical Manufacturer's Association
7. NEC - National Electrical Code
1.03 SYSTEM DESCRIPTION
A. This specification includes the supply of vertical dry-pit solids-handlinq
pumps and motors.
B. Each unit shall be furnished with a pump, driver, and motor high ring base
with guard. Pumps are to be connected to drivers by suitably sized, solid
type intermediate shafting with steady bearings and shaft guards.
MAY 2019 PROJECT#17.01107 113110-Page 1

C. Each pump shall be capable of meeting the conditions described in this
section when pumping raw sewage at a maximum temperature of 100°F.
1. Return Activated Sludge (RAS) Pumps
a. Location: RAS/WAS Pump Station near Clarifiers
b. Quantity: One (1)
c. Operating Conditions: 2550 GPM @ 15' TDH
d. Suction: 12"
e. Discharge: 12"
f. Pump Motors: 15HP
i. Phase: 3
ii. Hz: 60
iii. Volts: 460
iv. Insulation Class: F
v. Service Factor: 1.15
vi. RPM: 1200
vii. Minimum Efficiency: 87.5%
viii. The pump shall be suitable for use with a Variable
Frequency Drive as specified in this section and in
accordance with Division 13 and Division 16 of these
specifications.
ix. Motor shall be immersible inverter duty rated motor.
2. Waste Activated Sludge (WAS) Pumps
a. Location: RAS/WAS Pump Station near Clarifiers
b. Quantity: Two (2)
c. Operating Conditions: 250 GPM @ 20' TDH
d. Suction: 4"
e. Discharge: 4"
f. Pump Motors: 3HP
i. Phase: 3
ii. Hz: 60
iii. Volts: 460
iv. Insulation Class: F
v. Service Factor: 1.15
vi. RPM: 710
MAY 2019 PROJECT#17.01107 113110-Page 2

vii. Minimum Efficiency: 85.5% 1
viii. Motor shall be an immersible TEFC motor.
D. Equipment shall be suitable for continuous operation at all operating speeds
specified and without external cooling fluid. Pumps shall also be free from
undue shock, vibration, cavitation, overheating, and noise throughout the full
range of pumping conditions.
E. All pumps'furnished shall be the product of one manufacturer and shall be
located as shown on the plans.
F. Each pump motor shall be adequately sized to be non-overloading
throughout entire pump performance curve.
G. Parts shall be readily accessible for inspection and repair, easily duplicated
and replaced, and suitable for service specified.
H. Codes, specifications, and standards referred to by number or title shall
form a part of this specification to the extent required by the references
thereto. Latest revisions shall apply, unless otherwise shown or specified.
1.04 QUALITY ASSURANCE
A. Manufacturer: The pumps shall be supplied by a reputable manufacturer
with at least twenty (20) years of experience with this type of pump. All
requirements of these specifications must be met by all Manufacturers.
B. Factory Tests: The pumps shall be tested at the factory under simulated
field conditions for excessive vibration, leaks, and operation of all automatic
systems. Pumps shall meet or exceed the requirements of the Hydraulic
Institute. The controls shall be adjusted to start and stop the pumps to satisfy
field conditions. For each unit, a pump performance curve shall be produced
from the factory testing. Its veracity shall be certified and the curves shall be
identifiable by serial numbers of pumps and motors. Manufacturer shall
submit size copies of the certified curves to the Engineer. Engineer will
judge adequacy of performance and distribute copies of curves
appropriately.
C. Field Pump Tests: The Contractor and Manufacturer shall perform the
following inspections and tests on each pump before final acceptance of
the pumping units:
1. Test each pump for mechanical and electrical correctness after
installation.
2. Hydraulically test each pumping unit after installation and establish an
actual pump curve.
3. Perform vibration testing as recommended by the manufacturer.
MAY 2019 PROJECT#17.01107 113110-Page 3

1.05 SUBMITTALS
A. Prequalification: Manufacturers wishing to supply pumping equipment for
this project must submit a prequalification submittal for approval to the
Engineer. The prequalification submittal must be received by the
Engineer by the date and time listed in the Instructions to Bidders to
receive consideration. The submittal shall demonstrate that the
proposed equipment meets the requirements of the Contract
Specifications and Drawings. The Engineer will issue an addendum prior
to the bid date listing all prequalified manufacturers. The prequalification
submittal shall include, as a minimum, the following information:
1. Literature and cut sheets from manufacturer(s) describing equipment
2. Pump operating curves (matching duty points in the data sheets)
3. Proposed motor sizes (HP) and speeds (RPM).
4. Proposed pump weights, efficiencies, bearing life, and NPSH
required.
5. Copy of warranties
6. List of at least five (5) references for installations of similar size and
complexity,'including contact names and current telephone numbers
t 7. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in
the Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and
compatible for this specific application.
8. A list of any deviations from or exceptions to the specifications.
9. A written statement describing the manufacturer's startup and
maintenance services and factory authorized service facility.
10. A 24-hour emergency service telephone number.
Note: The submittal of prequalification information does not omit the
requirement for the Contractor and manufacturers to submit complete
shop drawing submittals to the Engineer in accordance with the Contract
Documents. Incomplete submittal packages will result in the manufacturer
not being pre-qualified to supply equipment on this project.
B. Shop Drawings shall be submitted to the Engineer in accordance with
Section 013300 "Submittal Procedures". The shop drawings shall include
installation drawings, materials of construction, and catalogue cut sheets for
all materials being supplied. Standard submittals shall include:
1. Performance curves, horsepower required, pump efficiencies, NPSH
required.
MAY 2019 PROJECT#17.01107 113110-Page 4

2. Pump Outline Drawing
3. Control Data
4. Access Frame
5. Typical Installation Guides
6. Technical Manuals
7. Parts List
8. Verification of Pumping Application: As part of the shop drawing
submittal, the manufacturer shall supply a letter certifying that the
manufacturer has reviewed the Contract drawings and
specifications, including all addenda, and that the equipment and
accessories included in the shop drawing submittal are suitable for
installation in the pumping applications proposed for the project.
C. Operation and Maintenance Manuals shall be submitted to the Engineer in
accordance with Section 017820 "Operation and Maintenance Data".
1.06 DELIVERY, STORAGE AND HANDLING
A. The equipment and materials shall be delivered, stored and handled in
strict accordance with the manufacturer's recommendations.
1.07 WARRANTY
A. Pump Warranty: The manufacturer shall fully warrant the units being
supplied to the owner against defects in workmanship and material for a
period of one (1) year under normal use, operation and service. The
warranty shall be in printed form and apply to all similar units.
B. Appurtenances Warranty: All accessories and appurtenances shall be
warranted against defects in workmanship and materials for a period of
one (1) year.
C. All warranties shall begin upon written acceptance of the equipment by the
Owner.
MAY 2019 PROJECT#17.01107 113110-Page 5

1.08 MANUFACTURER AND SUPPLIER INFORMATION
A. Manufacturer Nameplate: A manufacturer's nameplate shall be securely
and permanently mounted to each individual piece of equipment furnished
under this Section. The nameplate shall be constructed of a durable, non-
corrosive material. Critical information shall be clearly engraved or
otherwise permanently stamped on the nameplate, and shall be fully
legible. The information contained on the manufacturer nameplate shall
include at least the following:
1. Manufacturer's Serial Number
2. Name, address and telephone number of equipment manufacturer
3. Model and/or Part Number, including pump impeller sizes, when
applicable
4. Performance Criteria (i.e., capacity, design point, etc.)
5. Motor size, speed and voltage
6. Enclosure Type or Rating
7. Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. Supplier and Service Information: A durable nameplate, stamp or sticker
shall be adhered to each individual piece of equipment containing the
name, address, and telephone number of the local business that supplied
the equipment, and the name, address and telephone number of the local
business that can provide service and replacement parts for the
equipment. A 24-hour emergency service telephone number should also
be included.
PART 2: PRODUCTS
2.01 MATERIALS
A. Pumps: Each pump shall be of one-piece, single suction, enclosed, two
part-two blade, non-clog radial flow design made of closed grain cast iron
ASTM A48 Class 30. The impeller shall be statically and dynamically
balanced and secured to a straight fit on the shaft by means of bolt, washer,
and key. The impeller waterways and clearance between the impeller
periphery and volute shall be capable of passing a 3" sphere.
Volute shall be one piece cast iron ASTM A48 Class 30, with bottom suction
and side flanged tangential discharge. Cleanout, prime, drain, flush and
MAY 2019 PROJECT#17.01107 113110-Page 6

gauge connections shall be provided. Volute will allow for rotation in 45°
increments to accommodate piping orientation independent of base location.
The discharge flange shall be Class 125 lbs. per ANSI standards.
A cast iron long radius reducing or reducing vortex-suppressing
suction elbow to match suction piping size shall be bolted directly to
the pump volute inlet. The elbow shall have a cleanout port and gauge
connection.
Separately cast backhead with integral sealing box designed for use with a
mechanical seal. The sealing box shall be furnished with a 1/4" injection
and vent tap for a clear water or grease connection to a water seal ring to
prevent air from entering the pump through the sealing box. Backhead
design,shall aid in back pullout of rotating assembly.
Mechanical seals shall be of the split type single cartridge seal, especially
designed for wastewater service Model 442 as manufactured by Chesterton,
or approved equal. Mechanical seals shall be provided with a
compatible spiral-trac bushing designed to prevent the buildup of
solids.
The pumps shall be provided with wear rings on both the impeller and front
head and shall be of the face-type fastened by an interference fit and Loctite.
1 Pump wear ring front head and wear ring shall be stainless steel with a
Brinnell Hardness of 410 (Impeller) and 450 (front head).
B. Adapter: An adapter with large access openings to the sealing box shall be
supplied and further serve to connect frame and backhead to the volute. A
3/4" minimum backhead drain tap shall be provided. Sealing box leakage
will be collected by the backhead drain trough and piped directly to drain, ,
eliminating any drippage to the floor.
C. Bearing Frame: Frame shall,be of rugged integrally ribbed design (ASTM
A48 CL3O Cast Iron), completely enclosing the shaft between bearings and
capable of carrying the bearings and machined for accurate and
permanent bearing alignment completely enclosing the shaft between the
bearings. Bearing housing shall be of dust proof design incorporating lip
seals in contact with the shaft. Provision for external impeller adjustment is
required. Grease taps for bearing lubrication shall be supplied at top and
bottom bearing housings.
Bearings shall be designed for an L1O life of 65,000 hours per AFBMA at
best efficiency point.
D. Shaft Assembly: Shaft shall be made from high strength alloy steel with a
minimum 100,000 PSI tensile and 75,000 PSI yield strength, of sufficient
diameter to carry two times (2X) maximum calculated loads imposed and to
prevent vibration and fatigue. No torsional or lateral natural frequencies
MAY 2019 PROJECT#17.01107 113110-Page 7

shall occur within a range extending from 20% below to 20% above any
exciting resonant frequency. Manufacturer shall provide calculations upon
request by the Engineer for verification of all lateral and torsional critical
speed analysis.
Shaft shall be of the universal joint style intermediate shaft to transmit power
from the driver to the pump rotating assembly. The shaft shall have a
section with splined slip-yoke for telescoping to permit removal of the
intermediate shaft without disassembly of any section of the shaft. Location
and orientation of universal joints shall allow easy access for lubrication
without any disassembly of the intermediate shaft.
Shaft shall be precision machined and dynamically balanced along its entire
length to within 1/2 once inch per 10 pounds of shaft weight per end.
Shaft assembly and all drive components shall be compatible for use with a
variable frequency driver and shall be supplied by the Manufacturer.
E. High Ring Base, Coupling and Sole Plate: A high ring pump base, with large
access openings, and flexible pin and buffer or flexible sleeve coupling shall
be supplied to mount and couple the driver to the pump. A coupling guard
and a lineshaft guard shall be designed and supplied by the pump
manufacturer.
High Ring Base shall be compatible for use with a variable frequency driver
and shall be designed and fabricated by the pump manufacturer, complete
with an adequate sole plate intended to span the existing 36-inch diameter
opening in the pump station upper floor level.
F. Pump Base and Suction Elbow: A- rugged, heavy-duty fabricated steel
base with openings large enough to permit access to the suction elbow
and cleanout, bolted directly to the volute, shall be provided. The base
shall be designed to support the assembled weight of the pump and
shafting. Base design shall incorporate welded lateral member to maintain
rigidity of the four legs. The base dimensions shall match the existing
concrete pump pedestal .
G. Fits: Casing adapter, frame, and high ring base shall be manufactured with
concentric shoulder fits to assure accurate centering.
H. Pump Rotation: Provide rotation as shown on the drawings.
MAY 2019 PROJECT#17.01107 113110-Page 8

I. Pump Station Controls: Provide in accordance with Division 13 sections.
J. Motor: Provide motor suitable for the pump required in these specifications.
K. Motor Support: Provide motor support designed by the pump
manufacturer to be qusseted for use with variable frequency drives as
applicable.
L. Appurtenances: All bolts, nuts, washers, and gaskets necessary for field
installation shall be furnished. All exposed metal items such as nuts, bolts,
screws, washer, supports, etc. shall be Type 316 stainless steel.
M. Coating: All iron and steel parts which will be in contact with the pumped
liquid or submerged after installation, including the inside of the casing, the
impeller, the discharge elbow, and the pedestal mount, shall be shop
cleaned in accordance with the coating manufacturer's recommendations
and painted with an epoxy coating system. The coating shall have a dry film
thickness of at least 10 mils and shall consist of a prime (first) coat and one
or more finish coats. At least 1 quart of the finish coat material shall be
furnished with each pump for field touchup.
PART 3: EXECUTION
3.01 INSTALLATION
A. Clean all debris, rubbish, and other deleterious material out of the
structures in which pumps will be installed.
B. Examine pump bases and correct any installation irregularities prior to
pump installation.
C. Contactor shall install pumps in accordance with the drawings,
Manufacturer's written instructions, and recommendations rendered under
the supervision of factory-trained Manufacturer's representatives.
D. Anchor bolts and nuts shall be supplied by the contractor and shall be
stainless steel of ample size and strength for the purpose intended and
shall be approved by a representative of the manufacturer. Anchor bolts
shall be accurately located and installed in the foundation. Pumping
equipment must be aligned, leveled and grouted as necessary to eliminate
vibration and the installation must be approved by a representative of the
manufacturer.
E. Lubricate moving parts in accordance with manufacturer's written
instructions.
MAY 2019 PROJECT#17.01107 113110-Page 9

3.02 QUALITY CONTROL AND FIELD TESTING
A. Quality Control: The pump manufacturer shall furnish the services of an
experienced and mechanically skilled representative to provide installation
instructions, check the pump installation, check pump assembly, adjust
the pumps, and supervise pump testing. The representative shall also
provide instructions to the Owner's operations and maintenance personnel
on the proper operation and maintenance of the pumps. The pump
manufacturer's representative shall be available for a minimum of two (2)
8-hour days.
B. Field Testing: All testing shall be coordinated, arranged and completed by
the Contractor and the Manufacturer. The Manufacturer's representative
shall check and approve all pump installations prior to initial start-up and
testing, and provide certificate of proper installation prior to initial start-up
and testing. The Manufacturer's representative shall perform vibration
testing and a pumping test of each pumping unit as soon as practical after
the pumping equipment is certified as properly installed per the Hydraulic
Institute standards. The pumping test shall determine the capacity,
discharge pressure, and horsepower draw of each pumping unit under
actual operating conditions. The duration of each pump test shall be
two (2) hours continuous operation. The Manufacturer shall provide and
install any gauges, meters or other devices needed for the field tests.
1. Run each pump in the installed condition, witnessed by the
Manufacturer's representative, Contractor, Owner, and Engineer to
verify proper operation under field conditions.
2. Any defects in the equipment or failure to meet the specified
performance shall be corrected by the Contractor. The Owner
reserves the right to reject the pump if: the Contractor fails or
refuses to make the corrections required to meet the specified
performance; the improved pumping units, when tested and verified
by the pump manufacturer's lab test, fail to meet the specified
performance.
3. All field tests shall be completed to the Owner's satisfaction prior to
Owner acceptance.
3.03 MANUFACTURER'S SERVICE AND START-UP CERTIFICATION REPORT
A. The Manufacturer shall provide the services of a qualified representative
to perform the following tasks for each pump provided:
1. Inspect the installation of the pump.
2. Place pump in operation, and make any necessary adjustments.
MAY 2019 PROJECT#17.01107 113110-Page 10

3. Perform tests and provide Certification Report as specified in this
Section, and as recommended by the Manufacturer.
4. Instruct Owner's personnel in the proper operation and
maintenance (O&M) of the equipment.
B. If equipment is not completed for proper start-up and training procedures,
the contractor shall reschedule another visit at no additional cost to the
Owner. Training will not be permitted prior to completion of proper start-
up and testing tasks. An abstract or outline of the start-up, testing, and
training procedures shall be provided to the Owner at least five (5) days
prior to the scheduled visit. Manufacturer's operation and maintenance
manuals shall be incorporated in the training procedures, with emphasis
on items or materials of greatest importance.
C. A typed, bound report covering the Manufacturer's representative's
findings shall be submitted to the Engineer for review and approval. The
report shall: (1) describe the start-up procedures taken; (2) include any
inspections performed; (3) outline in detail any deficiencies observed
along with the corrective measures taken; and (4) include the results of all
field tests, including necessary graphs, charts, tables, etc., specified in this
Section or required by the referenced standards. The report shall certify
that the equipment is properly installed and functioning for the purpose
intended.
D. The Manufacturer or Contractor shall bear all expenses associated with
the start-up, testing, and training procedures and report described above,
including labor, transportation, lodging, and material costs.
END OF SECTION
MAY 2019 PROJECT#17.01107 113110-Page 11

SECTION 113130 SUMP PUMPS
PART 1: GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, tools and equipment
necessary for the proper installation of sump pumps at the locations
indicated on the drawings, and as specified herein.
B. Unless otherwise noted, all materials and equipment supplied under this
Section shall be new, of good quality, and in good condition.
1.02 SYSTEM DESCRIPTION
A. This specification includes the supply of one (1) sump pump.
B. Each unit shall be furnished with a pump and motor intended for industrial
use including raw sewage.
C. The pump shall be rated for 10 qpm at 20 feet TDH. Each pump system
shall be equipped with a float that automatically operates the pump based
on water level.
1.03 QUALITY ASSURANCE
A. All sump pumps used in the work of this Section shall be produced by
manufacturers regularly engaged in the production of such items, and with
a history of successful products.
1.04 SUBMITTALS
A. Shop Drawings: Prior to shipment, the Contractor shall submit six (6) copies
of shop drawings that fully describe the proposed sump pump and clearly
show all dimensions required for the sump area.
1. Literature and cut sheets from manufacturer(s) describing equipment
2. Pump operating curves
3. Proposed motor sizes and speeds
4. Copy of warranties
5. List of at least five (5) references for similar installations, including
contact names and current telephone numbers
February 2019 PROJECT#17.01107 113130-Page 1

6. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in the
Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and
compatible for this specific application.
B. Operation and Maintenance Manuals: The Contractor shall submit three (3)
copies of operation and maintenance manuals to the Engineer.
1.05 DELIVERY, STORAGE AND HANDLING
A. All equipment shall be delivered, stored and handled in strict accordance
with the manufacturer's recommendations.
1.06 WARRANTY
A. The work covered under this Section shall be guaranteed to be free from
defects in materials and workmanship for a period of one (1) year after final
acceptance.
1.07 MANUFACTURER AND SUPPLIER INFORMATION
A. Manufacturer Nameplate: A manufacturer's nameplate shall be securely
and permanently mounted to each individual piece of equipment furnished
under this Section. The nameplate shall be constructed of a durable, non-
corrosive material. Critical information shall be clearly engraved or
otherwise permanently stamped on the nameplate, and shall be fully
legible. The information contained on the manufacturer nameplate shall
include at least the following:
1. Manufacturer's Serial Number
2. Name, address and telephone number of equipment manufacturer
3. Model and/or Part Number, including pump impeller sizes, when
applicable
4. Performance Criteria (i.e., capacity, design point, etc.)
5. Motor size, speed and voltage
6. Enclosure Type or Rating
7. Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
February 2019 PROJECT-#17.01107 113130-Page 2

B. Supplier and Service Information: A durable nameplate, stamp or sticker
shall be adhered to each individual piece of equipment containing the
name, address, and telephone number of the local business that supplied
the equipment, and the name, address and telephone number of the local
business that can provide service and replacement parts for the
equipment. A 24-hour emergency service telephone number should also
be included.
PART 2: PRODUCTS
2.01 EQUIPMENT
A. Sump Pump_
1. Each pump supplied shall be of the pedestal-mounted design with
brass column, strainer, and float rod. The pump shaft shall be
stainless steel and the volute, impeller, and base shall be red bronze.
Each pump shall be powered by a 1/3 horsepower electric motor
designed for 115 volt, 60 cycle, single phase power supply, and shall
come complete with thermal overload protectors in accordance with
the National Electrical Code.
B. Piping: All discharge piping shall be 1.5-inch PVC SDR 13.5 with glued
connections and a union between the pump and the check valve. Each
pump shall be installed with a check valve in the discharge piping to prevent
reverse flow through the pump.
C. High Water Alarm: the pump shall come with a high water alarm float that
shall connect to the SCADA system to alert the WTP operator that a vault
on site is about to flood.
PART 3: EXECUTION
3.01 INSTALLATION
A. The Contractor shall install each sump pump at the locations shown on the
drawings in strict accordance with the manufacturer's recommendations
and as approved by the Engineer.
3.02 QUALITY CONTROL AND FIELD TESTING
A. The Contractor shall demonstrate to the owner and the Engineer that the
equipment operates as designed and in accordance with the specifications.
3.03 SPARE PARTS
February 2019 PROJECT#17.01107 113130-Page 3

A. The Contractor shall provide to the Owner one (1) complete set of
recommended spare parts for each sump pump.
END OF SECTION
February 2019 PROJECT#17.01107 113130-Page 4

SECTION 113150 PROGRESSIVE CAVITY SLUDGE PUMPS
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. This section shall include the furnishing and installing of electrically
operated progressive cavity sludge pumps with all accessories and
appurtenances as specified herein and shown on the plans. All electrical
appurtenances shall be furnished and installed in accordance with the
Electrical Section of these specifications.
B. Unless otherwise noted, all materials and equipment supplied under this
Section shall be new, of good quality, and in good condition.
1.03 SYSTEM DESCRIPTION
A. This specification includes the supply of the progressive cavity pumps
and motors.
1.04 QUALITY ASSURANCE
A. All equipment shall be supplied by reputable manufacturers with at least five
(5) years of experience in the manufacture of progressive cavity sludge
pumps. The manufacturer shall have at least five (5) successful
installations of similar design, and shall submit evidence of experience if
requested by the Engineer.
B. Equipment shall be as manufactured by Moyno Inc., Netzsch Pumps North
America, LLC. Seepex Inc., or prequalified equal. Manufacturers are listed
only to denote the quality standard of product desired, general style, type,
character and do not restrict bidders to a specific manufacturer. All
requirements of these specifications must be met by all Manufacturers
whether named above or prequalified. Any manufacturer not specifically
named above wishing to supply equipment under this section shall submit
for prequalification in accordance section 1.04 below. Should any of the
named manufacturers above have any deviations or exceptions from this
specification, a letter stating the issues must be received by the Engineer
by the date and time listed in the Instructions to Bidders for prequalification
submittals to receive consideration. Any approved exceptions or deviations
will be addressed by Addendum only.
Rev.2/18/19 PROJECT#17.01107 113150-Page 1

1.05 SUBMITTALS
A. Prequalification: Manufacturers not listed above wishing to supply progressive
cavity pump equipment for this project must submit a prequalification submittal
for approval to the Engineer. The prequalification submittal must be received
by the Engineer by the date and time listed in the Instructions to Bidders to
receive consideration. The submittal shall demonstrate that the proposed
equipment meets the requirements of the Contract Specifications and
Drawings. The Engineer will issue an addendum prior to the bid date listing
the prequalified manufacturers. The prequalification submittal shall include,
as a minimum, the following information
1. Literature and cut sheets from manufacturer(s) describing equipment
2. Pump operating curves
3: Proposed motor sizes and speeds
4. Copy of warranties
5. List of at least five (5) references for similar installations, including
contact names and current telephone numbers
6. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in the
Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and -
compatible for this specific application.
Note: The submittal of prequalification information does not omit the
requirement for the Contractor and manufacturers to submit complete shop
drawing submittals to the Engineer in accordance with Contract Documents.
B. Shop Drawings shall be submitted to the Engineer in accordance with
Section 01330 "Submittal Procedures". The shop drawings shall include
installation drawings, materials of construction, and catalogue cut sheets for
all materials being supplied. Submittals shall include performance curves.
C. Operation and Maintenance Manuals shall be submitted to the Engineer in
accordance with Section 01782 "Operation and Maintenance Data".
1.06 DELIVERY, STORAGE AND HANDLING
A. All materials and equipment shall be delivered, stored and handled in strict
accordance with the manufacturer's recommendations.
1.07 WARRANTY •
A. All complete pumping units, including electric motors, auxiliary units, and
mounts shall be warranted by the Contractor against all defects in materials
Rev.2/18/19 PROJECT#17.01107 113150-Page 2

and workmanship for a period of one (1) year from the date of final
acceptance. The Contractor shall be obligated within one year at no cost
to the Owner.
B. The rotor drive train shall be warranted for three (3) years from final
acceptance. The universal joints shall carry a separate warranty of 10,000
operating hours. This warranty shall be unconditional in regard to damage
or wear.
C. The performance of all pumps, motors and auxiliary units shall be
guaranteed at the specified pumping conditions.
1.08 MANUFACTURER AND SUPPLIER INFORMATION
A. Manufacturers are listed only to denote the quality standard of product
desired, general style, type, character and do not restrict bidders to a
specific manufacturer. Substitution of equipment of equivalent or equal
design shall be submitted to the Engineer for approval or disapproval in
accordance with Article 11 of the Instructions to Bidders.
B. Manufacturer Nameplate: A manufacturer's nameplate shall be securely
and permanently mounted to each individual piece of equipment furnished
under this Section. The nameplate shall be constructed of a durable, non-
corrosive material. Critical information shall be clearly engraved or
otherwise permanently stamped on the nameplate, and shall be fully legible.
The information contained on the manufacturer nameplate shall include at
least the following: ,
1. Manufacturer's Serial Number
2. Name, address and telephone number of equipment manufacturer
3. Model and/or Part Number, including pump impeller sizes, when
applicable
4. Performance Criteria (i.e., capacity, design point, etc.)
5. Motor size, speed and voltage
6. Enclosure Type or Rating
7. Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. Supplier and Service Information: A durable nameplate, stamp or sticker
shall be adhered to each individual piece of equipment containing the name,
address, and telephone number of the local business that supplied the
Rev.2/18/19 PROJECT#17.01107 113150-Page 3

equipment, and the name, address and telephone number of the local
business that can provide service and replacement parts for the equipment.
A 24-hour emergency service telephone number should also be included.
PART 2: PRODUCTS
2.01 EQUIPMENT
A. Pump Design and Construction:
1. Pumps shall meet the following design criteria:
Belt Filter Press Feed Pumps
Quantity: Two (2)
Flow Rate: 180 gpm
Maximum Pressure: 45 psi
Maximum NPSH-Required: 10 ft
% Solids: 0.5-4.0%
Stages: 2
Motor: 20 hp
Drive Type: V-Belt Vertically Mounted above Pump
Inlet: ANSI Flange
Maximum Speed: 300 rpm
Gear Reducer Service Factor: 1.5
Designed with a thrust load capability of 150 percent of the actual
thrust load.
2. Each pump shall be cradle mounted with the suction port capable of
being rotated through a full 360°. The drive unit shall be electric motor
connected to the pump through a v-belt drive. The motor shall be
mounted vertically above the pump typical of the existing pumps.
Pump supplier shall supply a complete unit with steel base plate,
pump, v-belt drive with guard, motor and motor-mounting supports.
A 150-pound (ANSI B16.5) flanged connection shall be provided at
both the inlet and discharge ports. The suction and discharge
casings shall each be provided with a 3/8-inch (or larger) tap to
permit installation of pressure instruments.
3. Pumps shall be drive through V-belts and pulleys. V-belts and pulley
system shall include belt guard, and belt adjustment system. Pulleys
shall not have more than a 4:1 ratio of reduction. Each pump motor
shall be TEFC design for 480 volt, 3-phase service and rated for
inverter duty. A heat sensor thermostat shall be imbedded in top of
winding and be connected in series with the motor starter coil in
control box to stop motor if temperature rises in excess of the
Rev.2/18/19 PROJECT#17.01107 113150-Page 4

manufacturers recommendation for any reason. Each pump motor
will be controlled by a variable frequency motor controller.
4. Each pump casing shall be of cast iron with all exposed nuts and
bolts to be stainless steel. Each pump shall be constructed such that
a single helix rotor revolves eccentrically within a double helix stator
of twice the pitch length so that the formed cavities progress toward
the discharge end of the pump. The fit between the rotor and stator
at the point of contact shall compress the stator material sufficiently
to form a seal and to prevent leakage from the discharge back to the
inlet end of the pumping chamber. The suction and discharge
connections shall be 150-pound ANSI B16.5 flanged. The stator shall
be molded with a seal integral to the stator elastomer preventing the
metal stator tube and the bonding agent from the elastomer from
contacting the pumped liquid. Gaskets or 0-rings shall not be used
to form this seal. Stators for sludge pumps shall have Buna
elastomer. The sludge pump rotors shall be constructed of 316
stainless steel and shall have a chromium nitride coating with a
hardness of 1250 Vickers and a minimum thickness of 0.0108" or the
rotor can be 316 stainless steel chromium plated steel with gear-type
universal joint. Each pump shall be provided with oil lubricated thrust
and radial bearings, located in the drive casing, designed for all loads
imposed by the specified service. Also allowed shall be positively
sealed and lubricated pin joint designs. Both the gear-type universal
joint and the positively sealed and lubricated pin joint designs
will provide the owner with an unconditional 10,000 hour warranty.
5. Each pump shall be supplied with silicone-filled isolation ring with a
dual mounted gauge and single point pressure switch. The pressure
ranges for the switch and gauge shall be selected specifically for the
specified service. The isolation ring shall be mounted between the
ANSI flanges, be sized according to the discharge pipe as shown on
the plans and be constructed with a carbon steel body and fittings
with a Buna sleeve. The switch shall be SPDT, NEMA 4.
6. Each pump shall be supplied with a presence/absence detector with
. sensor flange to replace existing. Sensor wetted surfaces shall be
316 Stainless Steel. Sensor shall be rated for SPDT, NEMA 4.
7. Controls: Progressive Cavity pumps shall be controlled by the
existing Variable Frequency Drives (VFD's) and monitored/controlled
by the proposed SCADA panel, SPBCP-640. Contractor shall install
pumps and connect to the existing VFD's, as well as, the proposed
SCADA panel SPBCP-640.
Rev.2/18/19 PROJECT#17.01107 113150-Page 5

PART 3: EXECUTION
3.01 INSTALLATION
A. All equipment shall be installed as shown on the drawings and in strict
accordance with the manufacturer's recommendations.
3.02 QUALITY CONTROL AND FIELD TESTING
A. Quality Control: The manufacturer shall provide the services of a qualified
field representative for one (1) 8-hour day to inspect the installation and
provide start-up, field testing and operator training services.
B. Field Testing: The pump(s) shall be field tested after proper installation. The
field running tests shall be conducted by the Contractor and witnessed by
the Engineer and shall demonstrate the following under all conditions of
operation, insofar as the available flow will permit; that the unit has been
properly installed and has no mechanical defects, that the unit is in proper
alignment and has been properly connected, that the unit is free from undue
vibration over the full range of operating conditions, that the unit is free from
overloading or overheating of any parts; that the unit is performing in
accordance with the specifications. All power equipment, supplies,
materials, labor, and instruments required for the field running tests shall be
furnished by the Contractor.
3.03 SPARE PARTS
A. The Contractor shall furnish to the Owner one (1) complete set of
manufacturer's recommended spare parts. Parts shall include a minimum
of the following: One set of special tools required to service the pump, For
each pump size: one (1) stator assembly with TSE sensor sleeve; one (1)
rotor; one (1) set universal joint assemblies; one (1) mechanical seal or
packing.
B. The Contractor shall be responsible for furnishing any special tools and
lubrication devices required to perform maintenance or any pumping or
power unit. Three (3) copies of printed instructions for lubrication and other
preventive maintenance operations shall be furnished,to the Engineer with
the shop drawings.
END OF SECTION
Rev.2/18/19 PROJECT#17.01107 113150-Page 6

2.0 METER BELT FILTER
SECTION 113610 PRESS AND APPURTENANCES
PART 1: GENERAL
1.01 SCOPE OF WORK
A. This section shall include furnishing, unloading at the jobsite, handling,
storage and installing a complete sludge dewatering system including one
(1) belt filter press, complete with ancillary equipment, as specified and
indicated on the drawings and as required to meet the specified
performance requirements.
B. Equipment furnished and installed under this section shall be fabricated,
assembled, erected and placed in proper operating condition in full
conformity with the drawings, specifications, engineering data, instructions,
and recommendations of the equipment manufacturer, unless the engineer
notes exceptions. All electrical work shall be done in accordance with
electrical contract specifications and NEC.
C. All components of the sludge dewatering equipment shall be engineered for
long, continuous, and uninterrupted service. Provisions shall be made for
easy lubrication, adjustment, or replacement of all parts. Corresponding
parts of multiple units shall be interchangeable.
D. All equipment specified in this section and necessary to make up the sludge
dewatering system shall be furnished by one (1) supplier to ensure system
responsibility and equipment compatibility.
1.02 SYSTEM DESCRIPTION
A. The sludge dewatering system shall consist of one (1) belt filter press, one
(1) polymer feed system, and all related appurtenances. The belt filter press
shall be a complete prefabricated unit consisting of at least a sludge
conditioning system, a gravity drainage section, a pressure section, a belt
alignment and tensioning system and a belt washing system. Only units
having a measured belt width of 2.2, and an effective belt width of 2.0 shall
be considered acceptable under this specification.
B. The dimensions of the belt filter press shall be approximately 103 inches
high, 245 inches long, and 142 inches wide. The overall static weight of the
belt filter press shall be approximately 24,800 pounds. Deviations from
these dimensions and weight to meet manufacturer's standard equipment
will be allowed if approved by the Engineer during the pre-qualification
process.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 1

C. The minimum clearance requirements shown on the plans shall not relieve
the contractor from allowing additional clearances for the proper installation,
operation, and maintenance of the units. Should equipment other than that
specified be proposed, the contractor shall be responsible for any redesign
based on the requirements contained herein.
1.03 QUALITY ASSURANCE
A. MANUFACTURER
Consideration will be given only to products of manufacturers who can
demonstrate that their equipment fully complies with all requirements of the
specifications and contract documents, unless otherwise approved by the
Engineer. The equipment shall be supplied by a firm which has been
regularly engaged in the design, fabrication, assembly, testing, start-up and
service of full-scale belt filter presses, operating in the U.S., with similar
sludges, for a period of not less than ten (10) years prior to the bid date of
this contract. The bidder shall submit data to substantiate the manufacturers
experience in accordance with the contract documents.
Spare parts for the belt filter press and related appurtenances shall be
readily available from within the United States.
B. PRE-QUALIFICATION
The belt filter press and related appurtenances shall be supplied by
reputable manufacturers with at least ten (10) years of experience in the
manufacturing of such equipment. Manufacturers wishing to supply
equipment for this project must submit a pre-qualification submittal for
approval to the Engineer. The pre-qualification package must be received by
the Engineer no later than 5:00 p.m., on to receive consideration.
The submittal shall demonstrate that the proposed equipment meets the
requirements of the Contract Specifications and Drawings. The Engineer will
issue an addendum prior to the bid date listing the approved manufacturers.
The pre-qualification submittal shall include, as a minimum, the following
information:
• Literature and cut sheets from manufacturer(s) describing equipment
• Dimensions and weight of existing equipment
• Proposed motor sizes and speeds
• Copy of warranties
FEBRUARY 2019 PROJECT#17.01107 113610-Page 2

• List of at least five (5) references for similar installations, including contact
names and current telephone numbers
• Information on location and contact information for obtaining spare parts.
• A written statement from the manufacturer indicating that the manufacturer
has reviewed the proposed application as detailed in the Contract
Drawings and Specifications, and that all equipment, materials and
systems proposed to be supplied are appropriate and compatible for this
specific application
• A certificate stating that the equipment complies with all sections of this
specification, or a detailed list of deviations from the specification
Note: The submittal of pre-qualification information does not omit the
requirement for the Contractor and manufacturers to submit complete shop
drawing submittals to the Engineer in accordance with the Contract
Documents.
1.04 SUBMITTALS
A. SHOP DRAWINGS
The manufacturer, shall supply a minimum of six (6) sets of standard
Submittal Drawings and Parts List. At a minimum, the submittals shall include
the following information:
1. Complete outline dimension drawings, including front view, side view,
arrangement, and interface points for piping, foundation, and electrical
controls.
2. Complete electrical wiring and instrumentation diagrams and control
panel layouts showing dimensions and power requirements at each
connection.
3. The motor HP, RPM, dimensions, and other pertinent information.
4. Mounting details and foundation loads.
5. Auxiliary equipment performance information.
6. Weights of equipment.
7. Complete bill of materials.
8. Spare parts furnished by manufacturer.
9. Special storage or handling requirements.
10. A written statement from the manufacturer stating that the
manufacturer has reviewed the proposed application as detailed in the
Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and
compatible for this specific application
FEBRUARY 2019 PROJECT#17.01107 113610-Page 3

B. OPERATION AND MAINTENANCE MANUALS
The manufacturer shall furnish three (3) complete sets of operation and
maintenance manuals for the pumps supplied.
1.05 DELIVERY, STORAGE AND HANDLING
A. The equipment and materials shall be delivered, stored and handled in
strict accordance with the manufacturer's recommendations.
1.06 WARRANTY
A. The Contractor shall include in the bid price for this item a guarantee to the
Owner, from the manufacturer(s), for one (1) year from the date of final
acceptance by the Owner, that the belt filter press, including ancillary
equipment, apparatus and parts, shall be free from defective materials,
equipment or workmanship, including with respect to equipment, the services
of qualified factory trained servicemen, as may be required. Under the
guarantee, the manufacturer(s) shall furnish replacements for any component
which proves defective, except those items that are normally consumed in
service. The manufacturer shall be solely responsible for the warranty of the
system and all components. Components failing to perform as specified by
the Engineer, or as represented by the manufacturer(s), or proved defective
in service during the warranty period, shall be replaced, repaired, or
satisfactorily modified by the manufacturer without cost of parts or labor to the
Owner.
The warranty shall become effective upon the acceptance of the installation
by the Owner.
1.07 PATENTS
A. The manufacturer warrants that the use of this system and its equipment,
in the process for which the system has been expressly designed, will not
infringe any U.S. or foreign patents or patents pending. In the event of any
claim of infringement the manufacturer shall defend and indemnify the
owner free from any liabilities associated with the use of the patented
equipment or process.
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B. The Manufacturer hereby grants to ,the owner, in perpetuity, a paid-up
license to use any inventions covered by patent or patents pending, owned,
or controlled by the manufacturer in the operation of the facility being
constructed in conjunction with the equipment supplied under this contract,
but without the right to grant sublicenses.
1.08 CONDITIONS OF SERVICE
•
A. The sludge dewatering equipment shall be designed to adequately
condition and dewater the sludge so that a dewatered sludge cake is
produced that easily discharges from the unit without binding and that may
be handled by the shaftless screw conveyor.
B. The unit shall be designed to operate in the environment for which it is
intended, continuously or intermittently on demand, and shall perform the
required dewatering operations without spillage of water or sludge beyond
the nominal machine envelope.
1.09 PERFORMANCE REQUIREMENTS
A. The sludge dewatering equipment shall be designed to adequately
condition and dewater the sludge such that a dewatered sludge cake is
produced that easily discharges into the hopper without binding prior to
conveying using a shaftless screw conveyor.
B. The sludge to be dewatered consists of a blend of undigested waste
activated sludge from a municipal extended aeration plant, and 10-20%
alum sludge from a municipal water treatment facility. Solids concentration
of the sludge as fed to the dewatering unit is anticipated to be approximately
1.0 to 2.5 percent oven dried solids (ODS).
C. The performance requirements of the dewatering unit based on 1.0 to 2.5
percent minimum feed solids shall be as follows:
1. The minimum sludge cake consistency shall be 16% ODS at a feed
rate of 140 gallons per minute and a minimum solids loading rate of
878 dry lbs per hour.
2. The minimum solids capture rate shall be 95%
3. Sludge conditioning shall be accomplished using the type of liquid
polymer currently being utilized by the City, or an alternate polymer
selected by the Equipment supplier.
D. The manufacturer shall guarantee the above performance criteria, backed
by a performance bond or irrevocable letter of credit in the full amount of
FEBRUARY 2019 PROJECT#17.01107 113610-Page 5

the equipment price, presented with the submission of shop drawings. The
manufacturer will be allowed two (2) opportunities to demonstrate S _
compliance with the performance criteria. Should the equipment fail to meet
the performance criteria after the second test, the manufacturer shall forfeit
the bond or letter of credit and remove the equipment.
E. The performance test shall consist of two (2) test that shall last for three (3)
hours each. Samples shall be collected at the end of every hour. Both tests
shall be averaged and the installed equipment shall demonstrate that it can
meet or exceed the specified Performance Criteria.
PART 2: PRODUCTS
2.01 MATERIALS AND COATINGS
A. All materials used in the construction of the sludge dewatering equipment
shall be of the best quality and entirely suitable in every respect for the
service required. All structural steel shall conform to the ASTM Standard
Specification for Structural Steel, Designation A36/A36M. All iron castings
shall conform to the ASTM Standard Specifications for Gray Iron Castings,
Designation A48, and shall be of a class suitable for the purpose intended.
Other materials shall conform to the ASTM Specifications where such
specifications exist and the use of such materials shall be based on
continuous and successful use under similar conditions of service.
B. All electrical components shall be U.L. listed where such listing exists and
all electrical control panels shall be assembled in U.L. approved facilities.
All structural carbon steel plates and shapes shall have a minimum
thickness of 1/4 inch and shall be hot dip galvanized in accordance with
ASTM A-123.
C. Unless specified otherwise herein, all metals in contact with polyelectrolyte
or sludge, and all other components specified to be stainless steel, shall be
type 316L stainless steel.
D. The following materials and coatings shall be provided for the belt filter
press and related components unless specified otherwise herein:
Bearing housings Nylon coated, cast iron
Belt support grids Stainless steel, fitted with UHMW polyethylene wiper
bars
Belt wash housing Stainless steel, 14 gauge.
Belt wash spray tube and nozzles Stainless steel.
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Belt wash piping Schedule 80 PVC, 1 1/2 inch.
Chicanes Galvanized steel support rods, galvanized cast iron
holders and U.H.M.W. polyethylene blades.
Chutes (feed and discharge) Stainless steel, 10 gauge.
Doctor blades U.H.M.W. polyethylene.
Drain trays Stainless steel, 14 gauge.
Drain tray piping Schedule 40 PVC.
Electrical junction box Stainless steel or FRP
Electrical conduit SO Cord
Electrical switch enclosures NEMA 4, press mounted
Frame A36 steel, hot dip galvanized, ASTM A123,
minimum 3.9 mils.
Hardware, fasteners, 316 stainless steel.
springs, clips, etc.
Hydraulic cylinders:
body: FRP tube with high strength glass filled nylon head
rod: Solid 316 stainless steel with hard surface treatment
Miscellaneous Carbon steel surfaces to be hot dipped
galvanized per ASTM A123
Polymer mixer housing Cast 316ss
Counterweight Cast iron, galvanized
Injection ring UHMW polyethylene
Splitter Manifold UHMW polyethylene
Rollers (solid) Carbon steel, 1/2 -inch wall, with 3/4-inch end plates.
Drive rollers coated with Buna N rubber, 1/4 inch,
other solid rollers coated with thermoplastic nylon,
25 mils.
Rollers (perforated) 1/4 —inch wall carbon steel, nylon coated
FEBRUARY 2019 PROJECT#17.01107 113610-Page 7

Roller shafts Forged steel ASTM 572 Grade 50, perforated roller
shall have 8620
Sludge containment barriers Stainless steel, 14 gauge.
Other types of protective coatings shall not be acceptable. All hot dip galvanizing shall
be applied in accordance with ASTM-A123. Zinc flame spray shall not be considered an
acceptable substitute to this specification.
E. The heat setting thermoplastic nylon coating, specified herein, shall have the
following properties:
Coating Properties Test Method Value
Hardness, Shore D ASTM D-2240 77
Specific Gravity ASTM D-792 1.06-1.20
Impact, RT & 45 F ASTM D-2794 160 in lbs
Direct Pass
Tensile Strength ASTM D-638 6000 PSI
Elongation ASTM D-638 15%
Melting Point ASTM D-789 370°F
Abrasion Resistance ASTM D-4060 8-18 mg. Wt. loss
(varies with color) CS17/1000/1000 Taper Abrader)
Buna N rubber coating shall have the following properties:
Tensile strength, ASTM D-412 2500 psi
Tear strength, die C, ASTM D-624 250 psi
Elongation at break, ASTM D-412 160%
Hardness, Shore A, ASTM D -676 90
2.02 SLUDGE CONDITIONING SYSTEM
A. The belt filter press shall be provided with a sludge conditioning system,
designed to efficiently mix polymer with the sludge and to adequately
condition the sludge, for optimum dewatering.
B. The sludge conditioning system shall be mounted upstream of the press
and shall consist of one (1) in-line, non-clog, static mixer with a variable
orifice and a vortex polymer injection ring. The belt filter press manufacturer
shall be required to provide, to the engineer, a proper layout for the system.
The sludge conditioning system shall be capable of providing the following
performance:
1) The polymer and sludge must be instantly mixed (less than 1.0 seconds
at 60 GPM).
2) Mixing energy must be independently adjustable during operation.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 8

3) Flocculation time must be independently adjustable, by the
displacement of flanged pipe sections, with the mixer, at a minimum of
three locations in the sludge feed piping.
C. The sludge conditioning system shall meet the following mechanical
specifications:
1) The in-line mixer shall have a flanged, cast housing, an adjustable orifice
plate with shaft and 0-ring seal connected to an externally mounted
lever and counterweight and a removable side plate for inspection and
cleaning. ,
.2) The open throat area shall be fully adjustable downward and shall open
automatically to prevent clogging.
3) The position of the counterweight on the externally mounted orifice plate
lever shall be fully adjustable, within a 360 degree circle, to allow for
adjustment of the mixing energy, regardless of the mounting angle, while
the unit is in operation.
D. The polymer mixer shall be designed specifically for its intended use. The
use of modified check valves or mixers requiring electrical motors and
controls shall not be acceptable to this specification.
2.03 STRUCTURAL MAIN FRAME
A. The structural main frame shall be fabricated of steel members conforming
to AISC Standard Specifications for Structural Steel, into a rigid structure,
adequately braced to withstand intended loads without excessive vibration
or deflection.
B. The frame shall have a minimum safety factor of >5 and maximum
deflection of 0.025 inches under maximum loading. The moment of inertia
of the structural members shall be adequately chosen to provide the safety
factor and deflection rate specified herein.
C. Maximum load on the frame shall be based on the summation of forces
applied to the frame from roller mass forces, weight of the rollers including
the sludge and belts and belt tension forces. Belt tension forces shall
include, but not be limited to, a belt tension of 50 pli per belt plus the tension
produced by the driving torque of the motor at nameplate ph. Certified
calculations, showing the frame to be in compliance with the specification,
shall be submitted as set forth in the contract documents.
D. The framework shall be of welded and/or bolted construction. All welding
shall conform to the American Welding Society Structural Welding Code.
FEBRUARY 2019 PROJECT-#17.01107 113610-Page 9

E. The structure shall be designed for installation on a prepared concrete
foundation and secured with anchor bolts. Permanent lifting lugs shall be '
provided as necessary to allow installation and removal of the belt filter
press.
F. The construction shall allow easy access and visual inspection of all internal
components.
G. The manufacturer shall warrant the frame and the coating for a period of
three years from the date of start-up, not to exceed three and a half years
from the date of delivery. The frame shall not require preventive
maintenance during the warranty period. Any defects or corrosion occurring
within the warranty period shall be repaired or replaced at no additional cost
to the owner.
2.04 GRAVITY DRAINAGE SECTION
A. The belt filter press shall be furnished with a gravity drainage section to
accept sludge from the sludge conditioning system. The gravity drainage
section shall be furnished with a sludge feed chute and an inlet distributor
to evenly distribute the conditioned sludge over the effective width of the
moving filter belt.
B. The conditioned sludge shall be contained on the belt with adjustable
containment barriers equipped with replaceable rubber seals to prevent
leakage. Rubber seals are designed to be attached to the containment
barriers, with a friction fit, to allow for easy replacement without the use of
tools.
C. The gravity drainage section shall have a minimum dewatering area of 93
square feet.
D. The filter belt, while in the gravity drainage section, shall be supported by a
steel grid fitted with high-density polyethylene wiper bars. The wiper bars
shall be spaced at a maximum of two and one half inches and shall have a
nominal wear thickness of one half inch, to minimize the frequency of
replacement. The wiper bars shall be arranged in a chevron pattern, with
the apex toward the sludge inlet, to reduce the possibility of belt creasing.
The belt support grid shall be a minimum of 2 inches wider than the belt on
each side and so designed to reduce belt wear. Wiper bars constructed of
fiberglass, other high friction materials, or table rollers, which require extra
maintenance due to coatings, and additional bearings shall not be
considered an acceptable substitute to this specification.
E. The gravity drainage section shall be furnished with chicanes (plows) to -
adequately furrow the conditioned sludge to facilitate drainage. Each row
FEBRUARY 2019 PROJECT#17.01107 113610-Page 10

of chicanes shall be provided with a single lifting handle, designed to
remove the entire row of chicanes at least 6 inches from the belt, out of the
sludge flow, to facilitate cleaning. Chicanes shall be designed to be
individually adjustable laterally and shall pivot to allow them to pass over
obstructions on the belt. The minimum of number of chicanes shall be 84,
and the minimum number of rows shall be 10.
F. The manufacturer shall be required to demonstrate that each individual
chicane shall be capable of allowing a one-inch vertical obstruction on the
belt to pass under them without damage to the equipment.
G. Vacuum assisted, inclined gravity drainage sections, which are subject to
flooding, or independent gravity drainage sections,which require a separate
belt drive motor and tensioning device will not be considered an acceptable
substitute to this specification.
2.05 PRESSURE SECTION
A. The belt filter press shall be furnished with a pressure section following the
gravity drainage section. The pressure section shall consist of two stages.
B. The first stage of the pressure section shall be the increasing pressure
(wedge)zone, where the upper and lower belts gradually converge, creating
a belt/sludge sandwich. In the wedge zone the sludge cake is prepared for
the shear pressure zone by generating continuously increasing pressure on
the sludge as it travels through the zone.
C. For process flexibility, the amount of pressure exerted on the sludge and
the rate at which the increasing pressure is applied shall be independently
adjustable while the machine is in operation utilizing an adjustable steel
wedge plate located between the belts, pressing down on the sludge.
These adjustments shall be capable of being performed without causing
undue wear on the belts or other components and without causing the belts
to be moved from their normal path between rollers. The sludge inlet height
at the entrance to the wedge plate shall be adjustable between one and
three inches.
D. The minimum effective dewatering area in the increasing pressure zone
shall be 59 square feet. The belt in the increasing pressure zone shall be
supported in the same manner as supported in the gravity drainage section.
E. The second stage of the pressure section shall be the shear pressure zone
consisting of a 12" radius curved grid and a minimum of eight pressure
rollers arranged to provide a serpentine pattern of belt travel.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 11

F. The curved grid shall further enhance dewatering by causing the pressure
on the sludge between the belts to increase and press out free water. The
horizontal wiper bars shall give a wiping action to the bottom of the belt in
the wedge zone that will quickly remove water from the belt allowing faster
drainage. The belt-supporting grid in the wedge zone shall be horizontal for
the first several feet and blend into a gradual downward curve, which shall
be tangent to the perforated pressure roller that follows.
G. The first roller in the increasing pressure zone shall be a 16" perforated
roller. Rollers shall be constructed as specified under"Rollers". The rollers
shall be supported by bearings mounted on the end shafts as specified
under "Bearings".
H. The minimum effective dewatering area in the shear pressure zone shall be
121 square feet. The effective dewatering area in the shear pressure zone
shall be defined as the area of curved grid and rollers in contact with the
belts, meaning full width of the belt.
2.06 ROLLERS
A. Construction
1) All Solid Rollers shall be constructed using one-piece forge shafts
and end plates. The forged stub shaft unit shall eliminate all
welding of the roller shafts in the region of highest stress where the
shafts join with the end plates. Welded up constructions of round
bar and flat plates that create built in stresses and stress
concentrations will not be acceptable. The forged stub shaft unit
shall be welded to the roller shell with a machine-applied weld
using the submerged arc process. The weld depth shall be equal
to the wall thickness of the roller shell. The roller shall be machined
so that the total indicated runout of the shell relative to the journals
is 0.010 inch maximum. Total surface machining is required to
provide a smooth surface for the coating of thermoplastic nylon or
to prepare the roller for cladding.
2) The perforated roller, which is the first roller in the pressure section,
is designed to allow water to escape out both ends. It shall be
constructed with a solid through shaft and at least five (5) radial
vanes to support the perforated shell.
B. Materials
1) The forged stub shaft unit shall be made of ASTM A572 Grade 50
Type 2 or equal. The roller shells may be ASTM A53 or equal. The
perforated roller shall have a solid shaft of cold drawn carbon steel,
FEBRUARY 2019 PROJECT#17.01107 113610-Page 12

AISC 8620 and the shell and radial vanes shall be ASTM A36 or
equal, or stainless steels may be substituted on special order.
2) Drive rollers shall be coated up to the point of insertion into the
bearings by a 1/4-inch minimum thickness of Buna-N rubber. Solid
and perforated rollers shall be coated with a 30-mil minimum
thickness of thermoplastic nylon.
3) Solid rollers may also be clad with 304 or 316 stainless steel. The
cladding will be welded to the fully machined roller entirely covering
the roller up to the point of insertion into the bearings. Welded
stainless steel shafts in lieu of the forging are not acceptable for
this application due to the lower strength and higher stress.
C. Dimensions
1) All solid roller shells shall have a mill spec minimum wall thickness
of 1/2 inch. Heavier walls shall be used where required to meet
the maximum stress and deflection limits. The roller bearing
journals shall be turned to 75 mm to accept direct mounted 75 mm
bore bearings. The minimum thickness of the forged flange that
forms the end plates shall be one (1) inch.
2) The perforated roller shall have punched holes of 1 1/4 inch
diameter minimum to prevent bridging of solid material. The
punched shell shall be rolled with the smooth side out. The shell
shall be a minimum 1/4-inch thick.
D. Stress and Deflection:
1) The rollers shall be analyzed using finite element stress analyses.
Certified calculations, showing the maximum stress to be less than
1/5 the yield strength of the material and the maximum deflection at
mid span to be less than 0.050 inch shall be submitted as set forth
in the contract documents. The standard load case for the
pressure rollers shall be a distributed load in the belt contact area
equivalent to 50-pli belt tension, weight loading and drive torque.
The standard load case for the other rollers shall be a distributed
load in the belt contact area equivalent to 50-pli belt tension and
weight loading.
2.07 BEARINGS
A. All rollers shall be supported by greaseable type, high capacity design roller
bearings, in sealed, splash proof, horizontal split case pillow block housings.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 13

The bearings shall be direct mounted on the shaft with a shrink fit backed
by a retaining snap ring.
B. Bearings supporting the steering rollers shall be non-self aligning cylindrical
roller bearings in pivot mounted pillow block housings.
C. All other rollers shall be supported by self-aligning Type "E" spherical roller
bearings with metallic cages, (plastic cages in spherical roller bearings are
not acceptable) mounted in fixed pillow block housings.
D. Bearings supporting all the rollers except the steering rollers shall be 75mm
bore double row spherical bearings (type E construction) AFBMA size
number 22215 with a dynamic radial capacity of 41,500 lb.. Bearings
supporting the steering rollers shall be 75mm bore single row cylindrical
roller bearings AFBMA size number 2215 with a dynamic radial capacity of
36,500 lb.
E. Bearing housings shall be cast iron with two mounting bolts and four cap
bolts. The outer side of the housing shall be solid, without end caps or filler
plugs. The housings shall be designed with an integrally cast water trough
which, when shrouded by a shaft mounted water flinger, shall divert water
from the bearing seal area. The housings shall be cleaned, iron
phosphated, and coated with nylon to a thickness of 8-12 mil.
F. The bearing seal in the pillow block housing shall be of nonmetallic
construction with a carrier/flinger, which rotates with the roller shaft. A static
sealing arrangement between the carrier/flinger and the shaft shall be a
triple rubber seal, constructed in a manner that prevents relative rotation
between the seal and the shaft. A dynamic sealing arrangement between
the carrier/flinger and the bearing housing shall consist of a primary
dynamic contact seal of ozone resistant rubber which shall seal by rotational
contact with'a machined housing surface. A secondary dynamic seal shall
be a labyrinth seal between the carrier/flinger and the bearing housing
which utilizes a nonmetallic retaining ring to hold the seal assembly in
position within the housing.
G. Bearing lubrication shall be performed through stainless steel grease fittings
mounted on each bearing housing. All bearings shall be outboard
(externally mounted) and shall be greaseable while the unit is in operation.
Lubrication shall not be required more often than once every six months.
H. The manufacturer of the belt filter press shall warrant the complete bearing
assembly, as specified herein, for a period of five years from the date of
start-up, or acceptance of the equipment, whichever occurs first. The
warranty shall include all parts and labor for repairing or replacing any
bearing that fails during the warranty period.
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2.08 BELT WASH SYSTEM
A. The belt filter press shall be equipped with individual belt wash stations for
both the upper and lower belts. Each station shall consist of a spray pipe,
fitted with spray nozzles, contained within a fabricated housing which
encapsulates a section of each belt. The housing and nozzle assembly
shall be readily removable.
B. Nozzle spacing and spray pattern shall be such that the sprays from
adjacent nozzles overlap one another at the belt surface. Individual spray
nozzles shall be replaceable.
C. The housing shall be sealed against the belt with rubber seals. The spacing
between the upper and lower housing shall be adjustable to insure
continuous contact between the seals and belt. The seals shall be
replaceable without disassembly of the wash station.
D. Each belt wash station shall be furnished with a drain valve having an
external handwheel to which is mounted a stainless steel cleaning brush
located inside the spray pipe. One full turn of the handwheel shall cause
the brush bristles to enter each spray nozzle, and dislodge any solid
particles which have accumulated, open the valve and allow the solids
particles to be flushed into the drainage system.
E. Each belt wash station shall be positioned such that the washing is
performed after the cake has been discharged from the belt. The belt wash
station shall extend over the full width of the filter belt by a minimum of two
(2) inches. The belt shall be cleaned by the belt wash with no blinding. The
belt wash system shall be suitable for use with plant effluent water supplied
at a minimum pressure of 85 psig and shall be designed to operate at a flow
of up to 80 gpm.
F. Washwater pressure shall be supplied to a washwater pump at psig,
and the belt press manufacturer shall furnish a separately mounted in line
booster pump rated at sufficient capacity and discharge head to meet the
process requirements. All controls and equipment necessary to provide a
complete and operating system shall be provided for the pumps by the belt
press manufacturer, including the controls from the machine control panel
as specified hereinafter.
F. The belt filter press shall be provided with a 1 1/2-inch female PVC
connection for belt wash water.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 15

2.09 BELT ALIGNMENT SYSTEM ,
A. Each belt shall be provided with an automatic belt alignment system to
assure proper alignment of both belts at all times. Belt alignment shall be
accomplished using a self-contained system that does not require an
external power source, except for electrical power.
B. The belt alignment system shall be provided with sensing devices designed
with a counter-weighted arm fitted with a ceramic plate, which rides on the
edge of the belts to detect their position. The arm shall operate a pilot valve,
which in turn affects the position of a hydraulic actuator connected to a
pivoted belt alignment roller. The pivoting action of the belt alignment roller
shall cause this roller to skew from its transverse position to guide the belts
centrally along their path.
C. The alignment systems shall function as a continuous automatic belt
guidance system and shall be an integral part of the press. The alignment
system shall operate with smooth and slow motions resulting in a minimum
of belt travel from side to side. The use of electrical servos or systems
which utilize devices that maintain alignment by a large snap action type
alternating movement of the alignment roller shall not be considered
acceptable to this specification.
D. Rollers for the belt aligning system shall be constructed as specified under ( ,
"Rollers". Support bearings for these rollers shall be as specified under
"Bearings".
E. Backup limit switches for the belt alignment system shall be provided on the
machine with sufficient contacts to de-energize all drives and sound an
alarm in case of belt over-travel.
F. A hydraulic unit shall be provided, as specified under "Hydraulic Power
Unit".
2.10 BELT TENSIONING SYSTEM
A. Each belt shall be provided with a belt tensioning system. The belt
tensioning system shall be hydraulically actuated. The design of the
tensioning system shall be such that adjustments in tension shall result in
immediate changes in dewatering pressure.
B. The belt tensioning system shall be furnished with a control station located
on the press so that shutoff of belt tension is possible. Actual belt tension,
shall be maintained automatically despite process changes or belt
stretching and not require additional adjustment by the operator to maintain
the setpoint.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 16

C. The belt tensioning system shall be designed to accommodate maximum
belt stretching during the useful life of the belt.
D. The tensioning system shall.have two hydraulic cylinders for each belt,
directly connected to a rigid tensioning yoke, to provide absolute parallel
tension across the entire width of the belt. The tension force shall be
constant over the full range of the cylinder.
E. Manual tensioning systems or pneumatic bellows systems, which do not
automatically maintain a pre-set pressure on the sludge despite process
changes, are not acceptable. Furthermore, air bladders change diameter
and, as a result, force as they extend.
F. Sensing devices shall be furnished for each belt with sufficient electrical
contacts to de-energize all drives and sound an alarm in the event of failure
of the belt or the tensioning system.
G. Rollers for the belt tensioning system shall be constructed as specified
under "Rollers". The roller shaft bearings shall be as specified under
"Bearings".
2.11 HYDRAULIC POWER UNIT
A. The belt filter press system shall be provided with a dedicated hydraulic
power system to provide pressurized oil for the steering and tensioning.
The unit shall consist of a one-gallon reservoir; variable-displacement
pressure compensated hydraulic oil pump and drive motor, hydraulic oil
filter (reusable), pressure gauges, piping, valves and cylinders to make a
complete operational system.
B. The pump, motor, reservoir, oil filter and valves shall be mounted directly to
the belt press frame to minimize excess piping runs, fittings and hoses. All
hydraulic lines shall be properly sized for the pressure and flow of the unit.
Pressurized hydraulic lines shall be 316ss tubing and shall be rigidly
supported on the structural frame of the press. Flexible lines to cylinders,
low-pressure connections to the reservoir, etc. shall be hose of the material
and construction appropriate to the application. The hydraulic reservoir
shall be made of high-density polyethylene (HDPE) and shall be translucent
to allow visual inspection of the oil level.
C. The pump motor shall be a 1 hp and shall not exceed a noise level of 70
DbA. The motor shall be a cast iron TEFC 1,200 rpm, NEMA B design with
a "C" face mounting for the hydraulic pump adapter.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 17

D. Maximum system pressure shall be set equal to the highest pressure
required to obtain the desired operating belt tension. The maximum system
operating pressure is 1,000 psi.
E. Hydraulic system controls shall be grouped for easy access and ease of
operation. There shall be means provided to retract the belt tension
cylinders for service. The valves, fittings, manifold and associated parts
shall be of non-corroding materials such as FRP, glass filled Nylon and
stainless steel.
F. The oil pressure gauge(s), one for each pair of belt tension cylinders (upper
& lower belt) shall indicate oil pressure in PSI and the belt tension in PLI.
Normal operating limits shall be indicated on the face of each gauge. Low-
pressure switch (es) shall be provided to sense the absence of belt tension
pressure.
G. Hydraulic cylinders shall have a non-corrosive body and 316 stainless
hardware and cylinder rod. The cylinder rod shall be solid stainless with a
hardened polished seal contact surface. Chrome or nickel plated rods are
not acceptable.
2.12 BELT DRIVE
A. Input power to the drive roller shaft shall be supplied through an A.C.,
variable frequency drive unit. Speed shall be controlled through cyclical
variation in motor current, which is operator set at the control panel. The
drive roller speed reduction is obtained through a helical gear reducer.
Belt Press Drive Motor Data:
Quantity per Machine 1
Maximum Horsepower 3 horsepower
Power Requirements 230/460 v.a.c., 3 phase, 60 cycle.
Rated Speed 1740 r.p.m.
Nema Design B .
Insulation Class F
Enclosure TEFC
Service Factor 1.0 (INVERTER DUTY RATED)
Special Features Severe duty rating
B. The variable input power shall be transmitted through a helical bevel gear
reducer connected to the drive roller. The drive roller shall be constructed
as specified under "Rollers" and shall be surfaced with a Buna-N rubber
coating to permit slip free transmission of driving torque to the belt.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 18

2.13 DEWATERING BELTS
A. The belt filter press shall incorporate the use of two dewatering belts. Belts
shall be fabricated of monofilament polyester and shall have 316 Stainless
Steel seams. The mesh design shall be selected for optimum dewatering
of the sludge to be processed and provide for a 2,000-hour belt life when
operated in accordance with the manufacturer's instructions.
B. Belt selection shall be based on the manufacturer's experience obtained
from testing the sludge during start-up of the belt filter press and at other
installations dewatering similar sludges with similar polyelectrolyte
conditioning chemicals.
C. Each belt and connecting seam shall be designed for a minimum tensile
strength equal to five times the normal maximum dynamic tension to which
the belt shall be subjected. The seam shall be designed to fail before the
belt.
D. Belts shall be designed for ease of replacement with a minimum of belt filter
down time. Belt replacement shall be such that disassembly of the
equipment is not required.
2.14 DISCHARGE BLADES
Discharge blades shall be provided to scrape dewatered sludge from the belt at
the final discharge rollers. The blades shall be of ultra-high molecular weight
polyethylene (UHMW) construction and shall be readily removable.
2.15 DRAINAGE PANS
Drainage pans shall be provided as necessary to contain filtrate from all
dewatering areas within the belt filter press without splashing and to prevent
rewetting of downstream cake. All drainage piping shall be furnished, adequately
sized for the intended service, and rigidly attached to the press frame. Drainage
piping shall terminate inside the structural frame at the bottom of the press. Drain
connection shall be self-venting to prevent overflow. Drainage pans shall be
located so that the moving belts do not come into contact with the pans under any
condition.
2.16 POLYMER FEED SYSTEM
A. GENERAL REQUIREMENTS
The polymer feed system shall automatically meter, dilute, activate and feed
emulsion polymer and water. Concentrated polymer and water shall be
blended in a completely mixed environment that shall meet polymer
supplier's recommendations at maximum throughput. The equipment
furnished shall be installed at the location indicated on the plans.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 19

B. POLYMER SYSTEM
The system shall include two (2) progressive cavity type polymer metering
pump capable of pumping emulsion type polymer at an output range as
recommended by the belt press manufacturer. The system shall include a
metering pump calibration assembly with isolation valves. The system shall
have a solenoid valve for on-off control of dilution water supply and a flow
indicator equipped with an integral rate adjusting valve. The water flow rate
shall be adjustable, in a flow range as recommended by the belt press
manufacturer.
C. POLYMER STORAGE
Polymer shall be fed from pre-mixed 275 gallon totes provided by the
Owner.
D. CONTROLS
A control panel shall be provided for the operation of the system. Provision
shall be made for both manual and automatic control with individual stop
and start pushbuttons for all motor-driven components and actuation of the
water supply. The controls shall be arranged such that in the event of water
supply failure during the system filling cycle, it shall shut down automatically ,
and on restoration of the water supply, or of power after power failure, the '
system may be restarted in the automatic mode. Timing controls shall be
provided for adjustment of polymer feeding and mixing cycles. Control
panel shall be designed to accept 120/240 V, 1 phase, 3 wire power supply.
2.17 SPLASH GUARD
A. The screw conveyor manufacturer shall provide a stainless steel splash
guard and inlet chute to connect discharge of belt press to the horizontal
screw conveyor. The screw conveyor manufacturer shall coordinate the
dimensions and elevations of the hopper and chute with the belt press
manufacturer. Stainless steel splash guard and chute shall prevent
dewatered cake spillage and shall be designed to provide consistent feed
of dewatered cake to the horizontal screw conveyor.
2.18 MAGNETIC FLOW METER
The contractor shall provide a magnetic flow meter at the location shown on the
plans. Acceptable flow meters include:
Foxboro.
Krohne.
ABB.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 20

B. Materials:
Service Meter Lining Material
Alum Sludge /WAS Polyurethane or Ceramic
C. Design and Fabrication:
Utilize characterized field principle of electromagnetic indication to
produce signal directly proportional to flow rate.
High input impedance pre-amplifiers.
Minimum impedance: 1010 ohms.
Provide flanged end connections per ANSI B16.5.
Splash and drip proof and capable of temporary submersion for a period
of 24 hrs under 15 ft. of water.
Operating pressure: 50 psig.
Operating temperature: 100°F.
Grounding requirements:
Nonmetallic or lined pipe: Inlet and outlet grounding rings of same
material as electrode.
Conductive piping: Conductive path between the meter and the
piping flanges.
Provide cable between magnetic flow meter and transmitter.
Pulsed DC magnetic field excitation.
Automatic zero.
Adjustable low flow cutoff.
Minimum signal lock (empty tube zero) to prevent false measurement
when tube is empty.
Accuracy:
+1.0 percent of rate below 1 fps.
+ 0.01 percent of scale above 1 fps.
4-20 mAdc isolated output into maximum 800 ohms.
Power supply: 120 V± 10 percent, 60 HZ.
Flow indication at transmitter.
Meter operable as specified in liquids with 5.0 micro mho/cm or more
conductivity.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 21

D. Schedule
Tag Service Range Size Transmitter
Mounting
FE/FIT-1 Alum 0-500 gpm 6" Separate
Sludge/WAS
2.19 ACCESS PLATFORM
The manufacturer shall design and provide stairs and an elevated access platform
along two (2) sides of the belt filter press for installation by the Contractor. The
access stairs and platform shall have a clear width between the handrails of at
least 4'-0". The platform and stairs shall be designed for a height above the floor
of the existing dewatering facility as recommended by the belt press manufacturer
to allow adequate operation and maintenance of the press. Complete, functional
units shall be provided, including aluminum structural supports,
2.20 CONTROL SYSTEM
A. The belt filter press shall be provided with a control panel that will contain
the necessary control devices and equipment for controlling the dewatering
process as described herein. Controls for the exit horizontal screw
conveyor shall also be incorporated into the belt press control panel. The
belt press manufacturer shall coordinate these controls with the sludge cake
pump manufacturer.
B. GENERAL CONSIDERATIONS
The control panel shall accept a 460 VAC, 60 hertz, 3-phase power input.
A main disconnect circuit breaker and operator mechanism shall be
included. When the disconnect is in the open position, all power shall be
removed from the control system. NEMA rated motor starters shall be
provided for the hydraulic unit. A VFD will be supplied for each belt drive.
Short circuit protection for each motor shall be accomplished utilizing
thermal magnetic circuit breakers. Individual thermal overload protection
shall be provided (except for the belt drive). A control power transformer
shall be included that will provide 120 VAC control power to the system.
Primary and secondary protection provided for control power. All logic
functions for the system shall be performed by an industrial programmable
logic controller (PLC) located in the control panel.
Located on the front of the control panel shall be a CONTROL POWER
OFF/ON switch. When in the ON position, the CONTROL POWER ON pilot
FEBRUARY 2019 PROJECT#17.01107 113610-Page 22

light will be illuminated and control power shall be distributed to the control
system. When in the OFF position, the control system shall be held
de-energized. Also located on the control panel shall be an EMERGENCY
STOP pushbutton. It shall be an illuminated mushroom head style
pushbutton that when depressed shall immediately de-energize all moving
equipment in the system. An alarm horn shall be included for audible alarm
annunciation.
C. SYSTEM OPERATION
As a minimum, the following control pilot devices shall be located on the
front of the control panel:
HAND/OFF/AUTO MODE selector switch
HAND MODE indicator
AUTO MODE indicator
AUTO START pushbutton
AUTO STOP pushbutton
SYSTEM RESET pushbutton
ALARM SILENCE pushbutton
LAMP TEST pushbutton
PRESS READY indicator
DEWATERING OFF/ON selector switch
WASHDOWN CYCLE ON indicator
BELT INSTALLATION OFF/ON selector switch
HYDRAULIC PUMP START pushbutton
HYDRAULIC PUMP STOP pushbutton
HYDRAULIC PUMP RUNNING indicator
BELT DRIVE START pushbutton
BELT DRIVE STOP pushbutton
BELT DRIVE RUNNING indicator
CONVEYOR START pushbutton
CONVEYOR STOP pushbutton
CONVEYOR RUNNING indicator
BELT DRIVE SPEED controller (0-100%)
SLUDGE PUMP START pushbutton
SLUDGE PUMP STOP pushbutton
SLUDGE PUMP RUNNING indicator
SLUDGE PUMP SPEED controller (0-100%)
POLYMER PUMP START pushbutton
POLYMER PUMP STOP pushbutton
POLYMER PUMP RUNNING indicator
POLYMER PUMP SPEED controller (0-100%)
LOW WASHWATER PRESSURE indicator
LOW HYDRAULIC PRESSURE indicator
BELT MISALIGNED indicator
FEBRUARY 2019 PROJECT#17.01107 113610-Page 23

BELT BROKEN indicator .f -`
NO CAKE indicator
EMERGENCY STOPPED indicator
BELT DRIVE FAIL indicator
The control panel shall require the following discrete signal inputs from
others. The signals shall be normally open dry contacts and shall close
when the equipment is running.
a) Sludge pump running
b) Polymer pump running
c) Conveyor running •
The control panel shall provide the following discrete signals for use by
others. The signals shall be dry contacts.
a) Press running (N.O. close when running)
b) Press fault (N.O. close on alarm)
c) Conveyor run (N.O close to run)
d) Sludge pump run (N.O. close to run)
e) Polymer pump run (N.O. close to run)
The control panel shall require the following analog signals from others.
a) Sludge pump speed or flow (4-20 mA) ,
b) Polymer pump speed or flow (4-20 mA)
The control panel shall provide the following analog signals.
a) Sludge pump speed (4-20 mA)
b) Polymer pump speed (4-20 mA)
D. SEQUENCE OF OPERATION
The press may be operated in the automatic mode by placing the
HAND/OFF/AUTO selector switch in the AUTO position. The AUTO MODE
indicator will illuminate and the operator will press the AUTO START
pushbutton. At this time, the hydraulic pump and washwater valve will be
energized and a belt tensioning time delay will start.
After the belt tensioning timer times out, the belt drive will be energized and
a belt pre-wet time delay will start. After the pre-wet timer times out, the
conveyor PRESS READY pilot light will be illuminated and, if the
DEWATERING ON/OFF selector switch is in the ON position, the sludge
and polymer pumps will be energized.
Pressing the AUTO STOP pushbutton will de-energize the sludge and
polymer pumps, illuminate the WASHDOWN ON pilot light and start a wash
FEBRUARY 2019 PROJECT#17.01107 113610-Page 24

down time delay. After the wash down timer times out, the belt drive,
washwater valve, hydraulic pump and conveyor will be de-energized.
To operate the press in the manual mode, the operator will place the
HAND/OFF/AUTO selector switch in the HAND position. The HAND MODE
indicator will be illuminated. The operator will start the hydraulic pump by
pressing the HYDRAULIC PUMP START pushbutton.
The operator should not proceed until the belts have been fully tensioned.
No interlock is provided to prevent the operator from starting the belt drive
in the manual mode. Pressing both BELT DRIVE START pushbuttons will
energize the belt drives and after a pre-wet time delay will illuminate the
PRESS READY pilot light. At this time, the operator will start the conveyor
by pressing the CONVEYOR START pushbutton, start the sludge pump by
pressing the SLUDGE PUMP START pushbutton and start the polymer
pump by pressing the POLYMER PUMP START pushbutton.
Pressing the respective STOP pushbutton in the reverse order stated above
will stop the system.
E. FAULTS
When any of the following fault conditions occur, in automatic or manual
mode, the appropriate fault indicator will be illuminated, the alarm horn will
sound and the belt filter press and associated equipment will be
de-energized.
EMERGENCY STOP
LOW WASHWATER PRESSURE
HYDRAULIC PRESSURE FAULT
BELT MISALIGNED
BELT BROKEN
PRESS BELT DRIVE FAIL
BELT DRIVE FAIL
The following fault conditions will'cause the wash down cycle to be
initiated in the automatic mode (annunciation only in the manual mode):
' NO CAKE
F. ENCLOSURES
Control panel enclosures shall be fabricated of type 304 stainless steel and
shall be suitable for NEMA 4X service.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 25

G. WIRING
All power and control wiring shall be 600 volt, type THHN/THWN insulation
stranded copper and shall be sized for the required load, 12 AWG minimum
for power and 14 AWG minimum for control.
H. CIRCUIT BREAKERS
The circuit breaker for the main disconnect shall be thermal magnetic
molded case units.
I. MOTOR STARTERS
Motor starters shall be full voltage, non-reversing, NEMA style
across-the-line units. Coils shall be 120 VAC.
J. SELECTOR SWITCHES
All selector switches shall be heavy duty, oil tight/watertight, corrosion
resistant units rated for NEMA 4X service. Contact blocks shall be rated for
10-ampere continuous service.
K. PUSHBUTTONS
All pushbuttons shall be heavy duty, oil tight/watertight, corrosion resistant
units rated for NEMA 4X service. Contact blocks shall be rated for 10-
ampere continuous service.
L. PILOT LIGHTS
Pilot lights shall be heavy duty, oil tight/watertight, corrosion resistant units
rated for NEMA 4X service. Units shall be 120 VAC transformer type.
M. TERMINAL BLOCKS
Terminal blocks shall be high density, solderless box lug style, with 600 volt
rating.
N. SPEED CONTROLLERS
The speed controllers shall be capable of outputting a 4-20ma DC or 0-10v
DC setpoint control signal and accept a 4-20ma DC or 0-10v DC status
signal. The controller shall be capable of PID control.
•
FEBRUARY 2019 PROJECT#17.01107 113610-Page 26

O. PROGRAMMABLE LOGIC CONTROLLER (PLC) _
The PLC shall be a modular type with discrete and analog capabilities. The
CPU shall have 4K minimum RAM for user instructions. The unit shall have
battery backed RAM and EEPROM backup. PLC shall be Allen-Bradley
CompactLogix.
P. VARIABLE FREQUENCY DRIVE (VFD)
The VFD shall be UL listed and shall be Allen Bradley Powerflex 400 style
provided with line reactor.
Q. UN INTERRUPTIBLE POWER SUPPLY
Provide an uninterruptible power supply to the control power portion of the
control panel.
2.21 SPARE PARTS
A. The following spare parts shall be furnished with the belt filter press:
1. One set of filter belts
2. Two complete sets of doctor blades
3. One of each size and type of roller bearing complete
4. Two complete sets of rubber seals
5. Two complete sets of belt wash box seals
For all additional equipment, provide the manufacturer's recommended
spare parts.
2.22 ODOR CONTROL HOOD
The belt filter press manufacturer shall provide an odor control hood for the belt
filter press to contain odors. The odor hood shall be constructed of 14 gauge
-stainless steel and cover the entire gravity section, without interfering with the
discharge. The hood shall have side panels hinged for viewing the gravity section.
The support rails and brackets shall be of the same material as the belt press
frame. A central vent opening shall be provided at the top of the belt press for an
extraction system to be supplied by others.
FEBRUARY 2019 PROJECT#17.01107 113610-Page 27

PART 3: EXECUTION
3.01 INSTALLATION
A. All equipment and materials shall be installed in strict accordance with the
manufacturer's recommendations.
3.02 START-UP AND OPERATOR TRAINING
A. Services of the manufacturer's factory trained representative, who is
specifically knowledgeable in the type of equipment specified herein, shall
be provided during the equipment installation period. Upon complete
installation of equipment by installing contractor, including placement of
equipment, setting and leveling the equipment, piping and electrical
connections to all the equipment specified herein, the manufacturer's
service representative will approve the installation and begin start up and
training.
B. Upon approval of the installation, the services of the manufacturer's factory
trained representative shall be provided at the project site for equipment
start-up and calibration. During the start-up and calibration phase the
manufacturer's representative shall inspect all system components for
proper connection and alignment and assist the installation contractor in
placing the equipment in a proper operating condition.
C. Upon satisfactory completion of the start-up and calibration, a
representative of the manufacturer shall be provided to instruct Owner's
personnel in the proper operation and maintenance of the equipment. The
manufacturer's representative who will be providing the instruction shall
have prior operation, maintenance and instructing experience acceptable to
the Engineer. The contractor shall submit the individual's name and
qualifications to the Engineer for approval at least one week prior to the
scheduled operating and maintenance instruction sessions. The number of
days listed below for services of the manufacturer's factory trained
representative shall be provided as a minimum when requested by the
Owner or the Engineer during the contract period.
D. The manufacturer's representative shall complete all of the above sessions
in a minimum of two trips to the jobsite. All start-up and operator training
services shall be coordinated between the contractor and the press
manufacturer, and shall be included in the contractor's lump sum bid price.
Period Number of 8-hour days
Inspection / Start Up and Calibration 4
Operator Training 2
END OF SECTION '
FEBRUARY 2019 PROJECT#17.01107 113610-Page 28

SECTION 113740 SUBMERSIBLE MIXERS
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. General: The Contractor shall furnish and install mixers at the locations shown
on the drawings. All materials and equipment supplied under this Section
1.03 SYSTEM DESCRIPTION
A. Each mixer shall be capable of meeting the conditions described in this
section when operating.
Submersible Mixer
a. Location: Sludge Holding Tank
b. Quantity: Two (2)
-c. Mixer Motors: 24.5HP
i. Rotations: 1740 rpm
ii. Phases: 3
iii. Volts: 460 V
iv. Frequency: 60 HZ
v. Insulation Class: F
B. Equipment shall be suitable for continuous operation at all operating speeds
specified and without external cooling fluid. Mixers shall also be free from
undue shock, vibration, cavitation, overheating, and noise throughout the full
range of mixing conditions.
C. All mixers furnished shall be the product of one manufacturer and shall be
located as shown on the plans.
D. Parts shall be readily accessible for inspection and repair, easily duplicated
and replaced, and suitable for service specified.
FEBRUARY 2019 PROJECT#17.01107 113740-Page 1

E. Codes, specifications, and standards referred to by number or title shall
form a part of this specification to the extent required by the references '
thereto. Latest revisions shall apply, unless otherwise shown or specified.
1.04 QUALITY ASSURANCE
A. Mixing equipment shall be as manufactured by Aqua-Aerobics, Siemens
prequalified equal. Manufacturers are listed only to denote the quality
standard of product desired, general style, type, character and do not
restrict bidders to a specific manufacturer. All requirements of these
specifications must be met by all Manufacturers whether named above or
prequalified. Any manufacturer not specifically named above wishing
to supply equipment under this section shall submit for
prequalification in accordance section 1.04 below. Should any of the
named manufacturers above have any deviations or exceptions from
this specification, a letter stating the issues must be received by the
Engineer by the date and time listed in the Instructions to Bidders for
prequalification submittals to receive consideration. Any approved
exceptions or deviations will be addressed by Addendum only. The mixers
shall incorporate design enhancements that provide operation for three
years without routine maintenance (greasing).
B. Manufacturers shall have a minimum of 25 installations of similar equipment
that meets all technical and performance requirements of this specification.
These installations shall be in successful operation for a minimum of 5 years.
The supplier shall furnish evidence of experience consisting of a complete list
of installations.
C. In lieu of this experience, a manufacturer who meets the requirement of this
specification may provide an unconditional guarantee, underwritten by a
bonding agency acceptable to the Owner and Engineer for a period of three
(3) years.
D. Equipment and/or components failing within this period due to deficiency in
design, workmanship or material shall be replaced at no cost to the Owner,
and the replacement shall be guaranteed for the three-year warranty period.
E. All welding is to be performed by welders certified by the A.W.S. in
accordance with the requirements set forth in the A.W.S. D1.1 Structural
Welding Code. Certification of both the A.W.S. and employment by the
manufacturer must be provided with submittals.
FEBRUARY 2019 PROJECT#17.01107 113740-Page 2

1.05 SUBMITTALS
A. Prequalification: Manufacturers not listed above wishing to supply equipment
for this project must submit a prequalification submittal for approval to the
Engineer. The prequalification submittal must be received by the
Engineer by the date and time listed in the Instructions to Bidders to
receive consideration. The submittal shall demonstrate that the proposed
equipment meets the requirements of the Contract Specifications and
Drawings. The Engineer will issue an addendum prior to the bid date listing
the prequalified manufacturers. The prequalification submittal shall include,
as a minimum, the following information:
1. Literature and catalog cut sheets of all equipment to be supplied,
including technical and performance requirements of the equipment
components.
2. List showing materials of construction of all components.
3. Information on field erection requirements, including total weight of
assembled components.
4. Copy of the warranty.
5. A certificate of compliance or a complete list of deviations from the
drawings and specifications.
6. A complete list of modifications required for installation of the
equipment.
7. All equipment shall be supplied by a reputable manufacturer, with at
least ten (10) years experience in the manufacture of mixers. The
manufacturer shall provide a list of ten (10) installations of similar
units in the United States, including contact names and current
telephone numbers.
8. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in the
Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and
compatible for this specific application.
Note: The submittal of prequalification information does not omit the
requirement for the Contractor and manufacturers to submit complete shop
drawing submittals to the Engineer in accordance with the Contract
Documents. Incomplete submittal packages will result in the manufacturer
not being pre-qualified to supply equipment on this project.
FEBRUARY 2019 PROJECT#17.01107 113740-Page 3

B. Shop Drawings shall be submitted to the Engineer in accordance with ,
Section 01330 "Submittal Procedures". The shop drawings shall include
installation drawings, materials of construction, and catalogue cut sheets for
all materials being supplied. Submittals shall include the following:
1. Descriptive literature including catalog cuts of all the equipment and
accessories.
2. Erection drawings (plan, elevation and sectional views) for the
system, materials of construction, location and size of anchoring
eyes, and data on power section.
3. Vibration test reports.
4. System piping and wiring diagrams.
5. Installation instructions and operation and maintenance instructions.
6. Written assertion from equipment manufacturer stating that the
specified performance requirements can be met across the range of
flows as specified in Article 1.02.
7. Provide certification by Manufacturer that motor nameplate data is
valid pertinent to that particular motor originating from motor
manufacturer and that no nameplate data has been changed
subsequent to shipment from motor manufacturer.
8. For manufacturers not meeting the requirements of Part 1.03.B 1
above, submit a copy of the unconditional guarantee underwritten by
a bonding agency as required in Part 1.03.C. (Addendum 4, Item 10)
C. Factory Testing:
1. Each mixer shall be dynamically balanced and tested for vibrational
velocity levels prior to shipment. Submit test results to the Engineer.
2. Dynamically balance the power section (motor, its support base,
extended shaft and propeller) after assembly, and take
measurements at a frequency equal to the motor speed (rpm).
Peak-to-peak maximum amplitude shall not exceed 2.0 mils (0.20
inches/second velocity, maximum) measured at the top and bottom
motor bearings.
FEBRUARY 2019 PROJECT#17.01107 113740-Page 4

D. Operation and Maintenance Manuals shall be submitted to the Engineer in
accordance with Section 01782 "Operation and , Maintenance Data". In
addition to meeting Section 01782 requirements, the following guidelines
are provided:
1. Provide specific instructions for receiving and handling, assembly,
mooring, wiring, installation, repair and service, storage, trouble-
shooting, detailed exploded drawings of the unit, and a full parts list.
2. In addition, the manual shall contain complete detailed instructions on
the balancing procedure to be used for rebalancing to the propeller after
it has been in service for an extended period of time. These instructions
shall include, a general procedural description, a detailed explanation of
preparing the unit for balancing and the balancing procedure for
propellers.
1.06 DELIVERY, STORAGE AND HANDLING
•
A. No shipment shall be made until the equipment has been reviewed by the
Engineer. All equipment shall be properly protected so that no damage or
deterioration shall occur during shipment or storage. All storage and
handling shall be in strict accordance with the manufacturer's
recommendations.
1.07 WARRANTY
A. All equipment shall be warranted to be free from defects in workmanship,
design and materials for a period of three (3) years. If any part of the
equipment shall fail during the warranty period, it shall be repaired or
replaced at no cost to the Owner.
1.08 MANUFACTURER AND SUPPLIER INFORMATION
A. Manufacturer Nameplate: A manufacturer's nameplate shall be securely
and permanently mounted to each individual piece of equipment furnished
under this Section. The nameplate shall be constructed of a durable, non-
corrosive material. Critical information shall be clearly engraved or
otherwise permanently stamped on the nameplate, and shall be fully legible.
The information contained on the manufacturer nameplate shall include at
least the following:
1. Manufacturer's Serial Number
2. Name, address and telephone number of equipment manufacturer
3. Motor size, speed and voltage •
4. Enclosure Type or Rating
FEBRUARY 2019 PROJECT#17.01107 113740-Page 5

Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. Supplier and Service Information: A durable nameplate, stamp or sticker
shall be adhered to each individual piece of equipment containing the name,
address, and telephone number of the local business that supplied the
equipment, and the name, address and telephone number of the local
business that can provide service and replacement parts for the equipment.
A 24-hour emergency service telephone number should also be included.
1
PART 2: PRODUCTS
2.01 SUBMERSIBLE MIXERS
A. MIXER DESIGN AND PERFORMANCE
1. The mixer design is based on the performance requirements for the
sludge holding tank; consideration of the future long-term operational
and maintenance costs to the Owner; minimum pumping rate required
per basin; optimization of mixing efficiency (HP/MG) and long-term
power use (e.g., geared units); efficiency and hydraulic profile of the
polyurethane or stainless steel blade design; and specific features
(e.g., silicon carbide mechanical seals, pre-chamber) to protect
against moisture intrusion into the unit. No exceptions will be made to
these performance requirements as specified in this section.
2. Each submersible mixer shall be given a factory test during which the
mixer shall be run for a minimum of one-half hour. Tests shall show
that the mixer has the general characteristics of amp draw, starting
capability, and such other properties as appear on the approved
submersible mixer shop drawings without overheating or excessive
vibration.
3. One copy of all test data shall be submitted with the Operation &
Maintenance manuals. As a minimum, shop test results shall include
the following information:
a. Tests for each submersible mixer showing:
1) Mechanical and electrical integrity check established by
physical inspection and by megger prior to applying power.
2) Power leads shall be applied and the motor started to verify
proper rotation.
3) Mixer shall be run in the submerged condition to verify amp
draw, starting capability, mechanical and electrical integrity.
FEBRUARY 2019 PROJECT#17.01107 113740-Page 6

4) After running, the unit shall again be checked by megger and
by physical inspection.
B. MIXER ASSEMBLIES
1. The submersible mixers for the System shall be supplied by the same
manufacturer, and, where possible, shall be of the identical model.
Each mixer shall be constant speed driven by squirrel cage induction
motors that are inverter duty rated. Each mixer shall be mounted in
the basin and each unit shall have a hoist and rail retrieval system that
does not require anyone entering the basin to install or remove the
mixer. Each mixer shall be submersible provided with a non-clogging
propeller, designed for mixing raw or processed sewage and furnished
by the mixer manufacturer.
2. General Mixing Unit Requirements:
a) The submersible mixers shall be non-clogging, with backward
curved propeller blades of a cross section which reduces drag
while eliminating fibrous build up. A planetary gear section
connected to an integral squirrel cage, electric induction motor,
shall drive the mixer's propeller. Each mixer shall include a
motor, gear reduction section, bearings, mechanical seals,
stainless steel shafts, A48 class 35 or 40 Cast Iron housing, and
machined fits for circular cross section 0-rings.
b) The mixers shall be the submersible type and shall be installed in
location(s) as shown in the plans. The manufacturer shall design
the mixer motors for full load continuous operation. All major
components of the mixing unit shall be manufactured from close-
grained ASTM A48 class 35 or 40 cast iron. All nuts, bolts,
washers, and other fastening devices supplied with the mixers
shall be AISI Type 304 stainless steel. All mating surfaces of the
major castings requiring a watertight seal shall be machined for
fit and fitted with Buna-n 0-rings. Sealing shall be done via
.smooth surface (surface finish 250 or higher) while the 0-rings
are used as back-up sealing system for each joint. Mixers shall
be furnished with polyurethane propellers as detailed in the
equipment listing above. Mixer support frame (including angular
adjustment brackets) shall be manufactured from hot dipped
galvanized steel as detailed in the submersible mixer tabulated
data above.
3. Mixer Stator and Seal Casings:
a) Casings shall be manufactured from ASTM A48 Class 35 or 40
close-grained cast iron. The outside contours of the mixer(s)
shall be shaped to reduce hydraulic losses and to aid in mixing
efficiency. Each casting shall be free from porosity, voids, casting
FEBRUARY 2019 • PROJECT#17.01107 113740-Page 7

fins, and other casting quality defects. The surface shall be i ,
smooth to the touch and free from all sharp edges and coated
with ceramic base coating for chemical and abrasion resistance. .
Corners shall have smooth radius contours to avoid sharp edged
corners and surfaces. .
b) The entire body of the mixer assembly shall be abrasive blasted
to SSPC-SP10 with a minimum 2.5 mil profile. The mixer shall
then be immediately coated with a minimum of 15 mils of Ceramic
compound. The Ceramic compound shall be a two-part
polymer/ceramic design for airless spraying, cold-curing, solvent
free and include reinforcing with special fillers and extenders.
The corrosion resistance below the surface of the coating shall c
be capable of withstanding ASTM salt spray test for over 3000
hours. Epoxy, enamel coatings or,stainless steel sheet covering
a cast iron body will not be considered as equal to the specified
coating system and will not be accepted.
4. Propellers: Mixer propellers shall be stainless steel or PUR
(polyurethane resin) that is resistant to chemical effects and provides
the highest mixing efficiency due to the blade cross section. Welded
steel propellers shall not be accepted. The propeller vanes shall be
smooth, finished throughout, and shall be free from sharp edges.
The surface of the propeller shall be free from defects and surface
protrusions and shall be smooth. Propellers shall be statically and
dynamically balanced after assembly to the rotor. Propellers shall
be slip fit and securely held to the shaft by a stainless steel washer
and bolt assembly that is enclosed in a separate hub chamber. The
hub chamber is fitted with an 0-ringed cap that seals the entrance of
the propeller hub chamber device. The output shaft shall be splined
to mate with the matching spline insert of stainless steel that forms
the hub of the propeller. The arrangement shall be such that the
propeller cannot unscrew or be loosened by torque from either
forward or reverse rotation. Designs based on threaded connection
between mixer shaft and impeller will not be considered.
5. Shafts: Mixer shafts shall be series 421 stainless steel with a
minimum 1.375" diameter. Shafts shall be supported by bearings for
axial and radial thrust and bearing life shall be designed to provide
minimum B1O = 100,000 hours at design flowrate. All shafts shall be
dynamically balanced and shall be amply sized to minimize shaft
deflection. Shaft overhang shall not exceed 2.5 times the shaft
diameter where it passes through the mechanical seal area and the
overhang shall be the length of the shaft from the propeller side of
the last bearing closest to the hub of the propeller. The Engineer
reserves the right to require submission of a sample of the output ,
shaft detail drawing details to independently verify submittal
FEBRUARY 2019 PROJECT#17.01107 113740-Page 8

calculations. Carbon steel shafts with or without shaft sleeves are not
acceptable or equal to stainless steel.
6. Sealing Devices:
a) Each submersible mixer shall be provided with two separate
seal oil chambers. The inner chamber shall be located
between the motor and the gear reducer and the outer
chamber shall be located between the gear reducer and the
propeller. The mixer shall have the outer chamber only
between the motor and the propeller. Each mixer shall be
provided with a set of independent mechanical seals running
in an oil bath. The sealing system shall require failure of one
set of mechanical seals prior to moisture entering the motor.
b) The two mechanical seals shall be interchangeable from one
location to the other and each set shall have solid silicon
carbide seal face material on both the stationary and rotating
components. The metal components of the mechanical seal
case shall be constructed of 316 stainless steel. A moisture
sensor probe shall be furnished in the seal oil pre-chamber of
each mixer. The sensor shall be wired to the control panel or
motor control center and wired to shut down the motor if
moisture is sensed.
7. Power and Control Cables: Power and control cables shall be
furnished in lengths to run continuously from the mixer to the mixer
• control panel as shown on the Contract Drawings and as specified
herein. Cables shall terminate with conductor sleeves. Cables shall
be of the "SO"type and shall conform to industry standards for loads,
resistance under submersion against sewage, and be of stranded
construction. The cables shall enter the mixer through a heavy-duty
entry assembly that shall be provided with an internal grommet
assembly to protect against tension once secured and must have a
strain relief assembly as part of standard construction. The cables
for each mixer shall be bundled in 10 ft segments for overall neatness
and ease of mixer removal.
8. Motors: Each mixer shall be furnished with a squirrel cage, induction
motor enclosed in a watertight housing suitable for use and
compatible with variable frequency drive systems. The motors shall
be furnished with moisture resistant Class F insulation treated to be
moisture resistant, NEMA B design, 1.13 service factor, designed for
continuous duty and shall be non overloading throughout the entire
mixer range of operation without utilizing the motor service factor.
Motors shall be capable of sustaining 15 starts per hour (unlimited
starts with VFD) at a minimum ambient temperature of 40°C. Motors
shall be capable of uninterrupted operation with a voltage drop of
FEBRUARY 2019 PROJECT#17.01107 113740-Page 9

10%. The power cables entering the motor housing shall prevent the
moisture from gaining access to the motor even in the event of
complete power or control cable break while under water. The motor
rotor and stator, as well as all bearings shall be located in an air filled
chamber that is isolated from the seal chamber. Motor cooling shall
be accomplished by submergence in the mixed liquid. Thermal
switches shall be furnished to monitor stator temperatures. The
stator shall be equipped with two (2) thermal switches, embedded in
the end coils of the stator winding. Thermal switches shall
automatically de-energize the motor when its, temperature exceeds
a preset limit. The mixer manufacturer's nameplates shall be
engraved or stamped on stainless steel and fastened to the motor
casing with stainless steel screws or drive pins.
9. Gear Reduction Drive System For Mixer: The motor shall drive the
submersible mixer propeller through a planetary gear reduction drive
system that aligns the motor shaft with the propeller shaft. The motor
shaft shall be fitted with a gear that uses high efficiency teeth to
engage the gear section. The gear system shall be custom matched
to allow for propeller speed changes by ordering and installing new
gearing. The gear section shall be designed to withstand 100 % lock
stress from the propeller without gear or bearing damage. Each gear
shall be supplied with precision bearings, which are lubricated by the
gear lubricant in the gear chamber. The gear section shall be fitted
to the output propeller shafting by the use of a straight spline
connection. The gear section design shall be such that with regular
oil changes, no further maintenance should be required during the
life of the submersible mixer in the installation. Gear oil changes
shall be easily made using external stainless steel pipe plugs that
are sealed via nylon washers. Standard 80 to 90-weight gear oil
either normal or synthetic shall lubricate the gear section.
10. Mixer Mount Assembly: Each mixer shall be provided with a 304
stainless steel mixer mount assembly to serve as a guide mast for
the mixer during installation and to guide the mixer for removal from
the liquid for service. The assembly shall consist of a minimum 3
inch by 3 inch tube and an upper and lower bracket constructed of
304 stainless steel. The assembly shall also contain a hot dipped
galvanized floor-mounted bracket to support and securely hold the
mast assembly and shall allow horizontal rotation of the mast through
not less than 120 degrees. The mast bearings shall be constructed
of Teflon.
11. The mast assembly shall be capable of proper operation with the
mixer operating in any direction. The mixer mast shall be designed
in such a way that the mixer can be lowered onto and off of the mast.
The upper guide holder assembly shall secure the system to the top
FEBRUARY 2019 PROJECT#17.01107 113740-Page 10

platform/wall and shall provide lateral support for the guide pile and
a securing device for the electrical motor cable.
12. Each mixer shall be provided with a crane assembly permanently
located at the top of the basin over each mixer.
13. The boom arm of the mixer shall be designed to properly reach and
locate the mixer and to alter the angle of the mixer to assure proper
mixing angles. The boom shall include a rotational turning handle
and shall be capable of rotating a minimum of 360 degrees within the
receiving box by means of a Teflon bearing. Each crane assembly
shall include a winch and a minimum 1/4", 316 stainless steel lift
cable with proper length to remove and set the mixer on the walkway.
The winch assembly shall be capable of manual lift. All anchor bolts
for the rail, mast and crane assembly shall be 304 stainless steel.
14. The manufacturer shall be responsible for coordination and supply
of each and every mixer hoist. The rated capacity and design loading
for each mixer is the responsibility of the manufacturer but shall at a
minimum consider the dead load, live load, hoist load and inertial
forces caused by movement of the crane, components and loads
during standard operation of each specific hoist.
15. The units shall be supplied with the following spare parts: One (1)
set of bearings, one (1) set of mechanical seals set, and one (1) set
of 0-rings.
PART 3: EXECUTION
3.01 INSTALLATION
A. All equipment shall be installed in strict accordance with the manufacturer's
recommendations.
3.02 FIELD TESTING AND INSPECTIONS
A. Quality Control —Technical Services:
1. Provide a service engineer for the following periods of time:
a. During installation of equipment—one (1) two-day trip.
b. For start-up and performance testing —one (1) two-day trip.
c. Six months after acceptance of equipment—one (1) one-day trip.
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3.03 SPARE PARTS
A. For each size, provide two (2) impeller assemblies consisting of propeller
prop, pin, and set screw.
END OF SECTION
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SECTION 113750 FLOATING SURFACE AERATORS
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. General: The Contractor shall furnish and install floating surface aerators at
.the locations shown on the drawings, complete with motor, direct drive
impeller, integral floatation unit, mooring cables, anchors, and all other
necessary equipment required for a complete installation. All materials and
equipment supplied under this Section shall be new, of good quality, and
in good condition.
B. Performance Requirements:
1. Sludge Holding Tank
a. No. & Size: Three (3) 25 HP aerators
b. Operating Depth: Maximum 16 feet with a minimum of 7 feet
c. Volume: 500,000 Gallons
d. Basin Contents: Waste activated sludge at 1 to 2 percent solids
C. System Description:
1. Performance: Each aerator shall transfer a minimum of 3.0 pounds of
oxygen per brake horsepower per hour, in clean tap water at standard
conditions of 20°C and zero (0) dissolved oxygen, and shall provide
sufficient kinetic energy to the basin to provide uniform oxygen
dispersion such that any given dissolved oxygen sample taken at
random from the basin shall not vary more than 2.0 mg/I or 20%
(whichever is greater) from the average of 10 samples simultaneously
drawn at random from the basin.
2. Each aerator shall deliver a minimum of 88% and a maximum of 94%
of nameplate horsepower as evidenced by measured operating amp
load and voltage readings. Horsepower shall be computed by:
Hp = (1.732) (amps) (volts) (E) (P.F.)
746
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Where: Hp = Delivered horsepower
E = Efficiency of motor(nameplate rating)
P.F. = Power factor of motor (certified by motor manufacturer)
1.03 QUALITY ASSURANCE
A. Aerator equipment shall be as manufactured by Aqua-Aerobics, Siemens
prequalified equal. Manufacturers are listed only to denote the quality
standard of product desired, general style, type, character and do not
restrict bidders to a specific manufacturer. All requirements of these
specifications must be met by all Manufacturers whether named above or
prequalified. Any manufacturer not specifically named above wishing
to supply equipment under this section shall submit for
prequalification in accordance section 1.04 below. Should any of the
named manufacturers above have any deviations or exceptions from
this specification, a letter stating the issues must be received by the
Engineer by the date and time listed in the Instructions to Bidders for
prequalification submittals to receive consideration. Any approved
exceptions or deviations will be addressed by Addendum only. The
aerators shall incorporate design enhancements that provide operation for
three years without routine maintenance (greasing).
B. Manufacturers shall have a minimum of 25 installations of similar equipment
that meets all technical and performance requirements of this specification.
These installations shall be in successful operation for a minimum of 5 years.
The supplier shall furnish evidence of experience consisting of a complete list
of installations.
C. In lieu of this experience, a manufacturer who meets the requirement of this
specification may provide an unconditional guarantee, underwritten by a
bonding agency acceptable to the Owner and Engineer for a period of three
(3) years.
D. Equipment and/or components failing within this period due to deficiency in
design, workmanship or material shall be replaced at no cost to the Owner,
and the replacement shall be guaranteed for the three-year warranty period.
E. All welding is to be performed by welders certified by the A.W.S. in
accordance with the requirements set forth in the A.W.S. D1.1 Structural
Welding Code. Certification of both the A.W.S. and employment by the
manufacturer must be provided with submittals.
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1.04 SUBMITTALS
A. Prequalification: Manufacturers not listed above wishing to supply Floating
Surface Aerator equipment for this project must submit a prequalification
submittal for approval to the Engineer. The prequalification submittal
must be received by the Engineer by the date and time listed in the
Instructions to Bidders to receive consideration. The submittal shall
demonstrate that the proposed equipment meets the requirements of the
Contract Specifications and Drawings. The Engineer will issue an addendum
prior to the bid date listing the prequalified manufacturers. The
prequalification submittal shall include, as a minimum, the following
information:
1. Literature and catalog cut sheets of all equipment to be supplied,
including technical and performance requirements of the equipment
components.
2. List showing materials of construction of all components.
3. Information on field erection requirements, including total weight of
assembled components.
4. Copy of the warranty.
5. A certificate of compliance or a complete list of deviations from the
drawings and specifications.
6. A complete list of modifications required for installation of the
equipment.
7. All equipment shall be supplied by a reputable manufacturer, with
at least ten (10) years experience in the manufacture of floating
surface aerators. The manufacturer shall provide a list of ten (10)
installations of similar units in the United States, including contact
names and current telephone numbers.
8. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in
the Contract Drawings and Specifications, and that all equipment,
materials and systems proposed to be supplied are appropriate and
compatible for this specific application.
Note: The submittal of prequalification information does not omit the
requirement for the Contractor and manufacturers to submit complete
shop drawing submittals to the Engineer in accordance with the Contract
Documents. Incomplete submittal packages will result in the manufacturer
not being pre-qualified to supply equipment on this project.
MAY 2019 PROJECT#17.01107 113750-Page 3

B. Shop Drawings shall be submitted to the Engineer in accordance with (-
Section 01330 "Submittal Procedures". The shop drawings shall include
installation drawings, materials of construction, and catalogue cut sheets
for all materials being supplied. Submittals shall include the following:
1. Descriptive literature including catalog cuts of all the equipment and
accessories.
2. Erection drawings (plan, elevation and sectional views) for the
system, materials of construction, location and size of anchoring
eyes, and data on power section.
3. Vibration test reports.
4. System piping and wiring diagrams.
5. Installation instructions and operation and maintenance
instructions.
6. Written assertion from equipment manufacturer stating that the
specified performance requirements can be met across the range
of flows as specified in Article 1.02.
7. Provide certification by Manufacturer that aerator motor nameplate
data is valid pertinent to that particular motor originating from motor
manufacturer and that no nameplate data has been changed
subsequent to shipment from motor manufacturer. ,
8. For manufacturers not meeting the requirements of Part 1.03.B
above, submit a copy of the unconditional guarantee underwritten
by a bonding agency as required in Part 1.03.C. (Addendum 4,
Item 10)
C. Factory Testing:
1. Each aerator shall be dynamically balanced and tested for
vibrational velocity levels prior to shipment. Submit test results to
the Engineer.
2. Dynamically balance the power section (motor, its support base,
extended shaft and propeller) after assembly, and take
measurements at a frequency equal to the motor speed (rpm).
Peak-to-peak maximum amplitude shall not exceed 2.0 mils (0.20
inches/second velocity maximum) measured at the top and bottom
motor bearings.
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D. Operation and Maintenance Manuals shall be submitted to the Engineer in
accordance with Section 01782 "Operation and ,Maintenance Data". In
addition to meeting Section 01782 requirements, the following guidelines
are provided:
1. Provide specific instructions for receiving and handling, assembly,
mooring, wiring, installation, repair and service, storage, trouble-
shooting, detailed exploded drawings of the unit, and a full parts list.
2. In addition, the manual shall contain complete detailed instructions on
the balancing procedure to be used for rebalancing to the propeller
after it has been in service for an extended period of time. These
instructions shall include, a general procedural description, a detailed
explanation of preparing the unit for balancing and the balancing
procedure for propellers.
1.05 DELIVERY, STORAGE AND HANDLING
A. No shipment shall be made until the equipment has been reviewed by the
Engineer. All equipment shall be properly protected so that no damage or
deterioration shall occur during shipment or storage. All storage and
handling shall be in strict accordance with the manufacturer's
recommendations.
1.06 WARRANTY
A. All equipment shall be warranted to be free from defects in workmanship,
design and materials for a period of three (3) years. If any part of the
equipment shall fail during the warranty period, it shall be repaired or
replaced at no cost to the Owner.
1.07 MANUFACTURER AND SUPPLIER INFORMATION
A. Manufacturer Nameplate: A manufacturer's nameplate shall be securely
and permanently mounted to each individual piece of equipment furnished
under this Section. The nameplate shall be constructed of a durable, non-
corrosive material. Critical information shall be clearly engraved or
otherwise permanently stamped on the nameplate, and shall be fully
legible. The information contained on the manufacturer nameplate shall
include at least the following:
1. Manufacturer's Serial Number
2. Name, address and telephone number of equipment manufacturer
3. Motor size, speed and voltage
4: Enclosure Type or Rating
MAY 2019 PROJECT#17.01107 113750-Page 5

Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. Supplier and Service Information: A durable nameplate, stamp or sticker
shall be adhered to each individual piece of equipment containing the
name, address, and telephone number of the local business that supplied
the equipment, and the name, address and telephone number of the local
business that can provide service and replacement parts for the
equipment. A 24-hour emergency service telephone number should also
be included.
PART 2: PRODUCTS
2.1 EQUIPMENT
A. AERATOR DRIVE MOTOR
1. Sizes:
a: The three (3) motors located in the shall deliver 25 horsepower
and shall be wired for 460 Volt, 60 cycle, 3 phase service.
2. The motor shall be totally enclosed; fan cooled, and generally rated
for severe chemical duty, and shall have a 1.15 service factor.
3. The motors shall be designed and warranted as 3-year "no
maintenance" motors.
.4. The motor windings shall be nonhygroscopic, and insulation shall
equal or exceed NEMA Class "F".
5. A condensate drain shall be located at the lowest point in the lower
end-bell housing.
6. All motor frame parting surfaces shall be deep registered and
Permatex (or equal) sealed.
7. All through bolts, nuts, and screws shall be of type 18-8 stainless
steel.
8. Each motor will have a rain cap constructed of cast iron or non-
corrosive 304 stainless steel. Painted or plated carbon steel rain
caps will not be acceptable.
9. A stainless steel nameplate shall be provided with each motor and
shall be securely fastened thereto. The voltage, speed, insulation
class, amperage, service factor, wiring diagram, motor serial
number, and the manufacturer's name and address shall be steel
stamped or otherwise permanently marked. The motor shall be an
MAY 2019 PROJECT#17.01107 113750-Page 6

Aqua-Aerobic Systems, Inc., "Centaur" model supplied by Reliance
Electric, or "Endura" model supplied by Teco-Westinghouse.
10. Heat sensor thermostats shall be imbedded in windings and be
connected in series with the motor starter coil in control box to stop
motor if temperature rises in motor to an over temperature limit.
Thermostat will reset automatically when temperature drops to a
safe limit.
B. MOTOR SHAFT
Unit shall have a one-piece motor shaft continuous from the top motor
bearing, through the lower bearing and down to and through the propeller.
This shaft will have a minimum diameter of 2-1/2" (greater than 25 HP
aerator motors) and 2-1/8" (25 HP and smaller aerator motors) and be
manufactured from 17-4 PH stainless steel, or comparable stainless steel
having a minimum yield strength of 100,000 psi.
C. MOTOR SPEED
1. Units shall operate at the lowest RPM offered in this size by the
manufacturer. In no case shall nominal RPM exceed 1200 RPM.
- D. MOTOR BEARING
1. Motor bearings shall be regreasable. Sealed bearings are not
acceptable. Top bearing shall be shielded on the bottom side only.
Bottom bearing shall be open.
2. The top and bottom motor bearings shall be of the combined radial
and axial thrust type and shall be packed at the factory with "high
performance" grease.
3. The lower motor bearing inner race shall be locked to the motor
shaft via a special washer and locking nut arrangement. The shaft
shall be threaded just below the lower bearing and shall have a
keyway cut into the motor shaft. This key shall accept a tab from
the I.D. of the locking washer, and the locking nut shall have
recesses to accept a tab from the O.D. of the locking washer to
prevent the nut from backing off. Snap ring type bearing retainers
will not be acceptable.
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E. DIFFUSION HEAD 1
1. The design of the diffusion head shall be such that the liquid spray will
discharge at angle of 90° to the motor shaft, and over a 360° pattern in the
horizontal plane, and shall be a stainless steel monolithic casting. The
diffusion head casting shall act as a base for the aerator motor, and
alignment of the motor to this base shall be controlled by machined index
fittings that engage the P-base of the motor. Diffusion head/motor
arrangements that are dependent upon bolt holes only for alignment will
not be acceptable. All diffusion head hardware will be 304 stainless steel
and safety wired.
3. The diffusion head shall absorb all normal and shock loads encountered
by the propeller and transmitted to the diffusion head via the motor shaft
and lower motor end-bell. The diffusion head shall distribute these forces
into the float via webs that terminate in a flange or ring that is an integral
part of the diffusion head. This flange shall mate with a similar flange that
is an integral part of the float/volute to spread the stresses generated by
the propeller uniformly around the float so that no point loading of the float
is allowed. These flanges shall be machined flat to provide proper bearing
surfaces. The alignment of the diffusion head flange to the float/volute
shall be by use of a 360° index pilot.
4. Specifically, diffusion head designs that employ studs and spacers,
shoulder bolts or fiberglass are not allowed. Load bearing, machined flat, '
flange-to-flange connections will be mandatory.
5. The diffusion head shall contain an anti-deflection journal insert to limit the
radial deflection of the motor shaft.
6. This anti-deflection journal insert shall be located in the lower extremity of
the diffusion head, approximately one-half the distance between the motor
base and the lower end of the shaft.
7. The journal insert shall be machined from Delrin or molded from moly-
filled urethane and shall be a minimum of 0.060" larger through the bore
than the diameter of the motor shaft.
8. Units featuring a one-piece unsupported shaft will not be acceptable.
9. There shall be a fluid deflector located on the motor shaft immediately
below the anti-deflection journal, which shall cover completely the anti-
deflection journal insert and the lower portion of the diffusion head.
10. This fluid deflector shall be molded from black neoprene and shall be
press fit onto the motor shaft.
11. Low Trajectory Diffuser: Each unit shall be furnished with a low trajectory
diffuser of high density polyethylene. This assembly shall be attached to
the top of the diffusion head and shall be used to lower the aerator spray
pattern and reduce windblown spray. (Addendum 1, Item 15)
MAY 2019 PROJECT#17.01107 113750-Page 8

F FLOTATION
1. Each aerator shall have 1,340 lbs reserve buoyancy to ensure stability
and to provide support flotation required during aerator servicing. Floats
shall be one-piece, i.e.; segmented floats are not acceptable.
2. Flotation stability will be mandatory. Under no circumstances will unstable
flotation designs requiring counterbalancing, ballast of liquid, solid mass or
submerged major fabricated assemblies to stabilize the operation of the
aerator be allowed. Only aerators demonstrating stable operational
characteristics, without rocking or oscillating will be acceptable.
3. The float shall be a minimum of 82.875" in diameter. The float shall be a
minimum of 13.5" thick and shall be fabricated of a minimum of 14 gauge,
304 stainless steel.
4. All floats shall be constructed so that the internal void can be filled full of
closed cell polyurethane foam having a, minimum 2.0 lbs/ft3 density and
shall be completely sealed watertight.
5. All floats shall have six mooring points, spaced for 3 or 4-point mooring
around the outer circumference. No mooring connections will be allowed
to attach to the upper or lower float covers. Only tension type connections
perpendicular to the • outer sidewall will be approved. All mooring
connections shall be stainless steel.
6. The float construction shall be such that the volute will distribute the load
of the entire motor, drive, diffusion head and volute static load, plus the
entire dynamic load from the propeller thrust and radial forces by
spreading these forces uniformly around the full 360° circumference of the
float's central core. Point connected joints or point stressed connections
will not be accepted.
7. A high profile, non-skid surface shall be factory applied to the top of
the stainless steel float. Coating shall consist of angular silica sand
embedded in a two (2) component polyamide epoxy coating.
G. PROPELLER
1. The propeller shall be a two-blade, left-handed, marine type precision
casting of 316 stainless steel, 14.5" in diameter, and shall be specifically
designed for the application intended. It shall be a self-cleaning type that
will not accumulate fibers, rags, stringy materials, etc. The propeller will
have a diameter not allowing a greater clearance with the volute of 1/4".
2. Each propeller blade shall be pitched so that the pitch angle and rake
angle are within ± 2 percent of the other blade(s).
3. The propeller shall be pitched so that the drive motor is loaded between
88% and 94% of full load nameplate horsepower.
MAY 2019 PROJECT#17.01107 113750-Page 9

4. Units using inclined screw impellers will not be acceptable.
5. The propeller must be attached to the motor shaft with a hardened
stainless steel pin and set screw. No tapered, threaded shafts with nut
fasteners will be acceptable.
H. VOLUTE
1. The propeller shall operate in a volute made of 304 stainless steel and
shall be a minimum of 15" in diameter. It shall be round and true so that
propeller blade tip clearance is uniform within the volute as it rotates. The
volute shall have a minimum of 3/16" wall thickness, and a minimum of
four full-length stainless steel gussets shall be welded on a 90° spacing
around the circumference of the volute between the top and bottom
flanges.
2. The volute shall have a large machined flange at its top extremity that
completely encircles the volute, and this flange shall match a similar
flange on the bottom of the diffusion head to provide for a bolted,
machined flange-to-flange fit to provide uniform distribution of the dynamic
loads generated by the propeller and the static weight of the motor and
drive. A 360° machined index in the upper flange shall provide concentric
alignment of the propeller in the volute by engaging the inside diameter of
the mating flange on the diffusion head. Bolt holes alone will not be
acceptable to locate the important alignment of the propeller.
3. Fiberglass volutes or carbon steel volutes that are fiberglass, steel or
stainless steel lined are not acceptable.
I. INTAKE CONE
1. The intake cone shall be fabricated from 0.105" thickness 304 stainless
steel having a gradually expanding opening outward to the intake end.
The length and inlet diameter shall be sufficient to provide uniform inlet
hydraulics so that no increase in vibration is caused due to its shape or
size. The minimum acceptable length is 12" minimum inlet diameter is
21.5".
2. The material used to fabricate the intake cone shall be structurally
sufficient to support the weight of the entire aerator assembly when the
aerator is freestanding on dry ground.
3. For maximum in-depth mixing efficiency, the intake cone shall be designed
so that the suction lift from the aerator propeller is vertical from the liquid
depth below the aerator. Unless specifically required for anti-erosion
requirements, side or angle entry suction inlets will not be approved.
Fiberglass intake cones are not allowed. All aerators must provide anti-
vortex crosses welded inside the cones. ,
MAY 2019 PROJECT#17.01107 113750-Page 10

J. BALANCING
1. The entire rotating assembly including the motor rotor, shaft, shaft
accessories, and impeller shall be dynamically balanced to within 2.0 mils
peak-to-peak horizontal displacement measured at the upper and lower
motor bearing. Measurements shall be taken at a frequency equivalent to
the motor RPM.
2. Measurements shall be taken with the motor in a vertical, shaft down
position and with the entire power section mounted on resilient pads.
K. MOORING
1. Mooring Cables
a. The anchor cable shall be installed as recommended by the
manufacturer so the aerator shall be permitted to rise and fall with
some water level variations, but will have a minimum of lateral
movement.
b. The maximum amount of anticipated water level variation is nine (9)
feet.
c. Anchor cable shall be 7 x 19 construction, 304 stainless steel, and 1/4"
diameter (25 HP and larger aerators) and 3/16" diameter (under 25 HP
aerators).
d. Mooring hardware (thimbles, clips and springs) shall be of stainless
steel. Galvanized hardware is not acceptable.
2. Mooring Posts
a. To allow for water level variation, a 304 stainless-steel restrained mooring
frame shall be utilized. A triangular mooring frame shall be fastened to the
bottom of the aerator float, and will consist of 304 stainless steel mooring
arms to which are attached removable U-bolts which shall fit around 304
stainless steel posts (posts provided by Contractor with diameter per the
drawings, which shall permit the unit to rise and fall with the varying water
level. Mooring arms attached to side skins of the float are not acceptable.
b. A 304 stainless "J" bolt shall be utilized to connect the frame to the
flotation unit. A minimum of three (3) connections are required.
c. A 304 stainless steel mooring stop frame shall be installed at the elevation
specified in the drawings.
d. The anticipated water level variation is shown on the drawings.
MAY 2019 PROJECT#17.01107 113750-Page 11

L. ELECTRICAL SERVICE CABLE
1. Electrical service cable shall be provided and shall be a continuous length
(non-spliced) to go from the aerator motor to the motor disconnect switch.
The cable shall have three power conductors and a ground conductor.
2. Conductors shall be flexible type annealed copper stranded. Each
conductor, including the ground conductor, shall be insulated. Cables
containing an un-insulated ground conductor will not be acceptable.
3. The insulated conductors shall be assembled together with a non-
hygroscopic filler material.
4. Outer jacket shall be high quality CPE, PVC, TPE or equal, and shall be
rated at a conductor operating temperature of not less than 90°C.
5. The cable shall be rated for hard usage outdoor service and shall be
resistant to oil, sunlight, ozone, grease, acids, water, abrasion and impact.
PART 3: EXECUTION
3.01 INSTALLATION
A. All equipment shall be installed in strict accordance with the
manufacturer's recommendations.
3.02 FIELD TESTING AND INSPECTIONS
A. Quality Control —Technical Services:
1. Provide a service engineer for the following periods of time:
a. During installation of equipment—one (1) two-day trip.
b. For start-up and performance testing —one (1) two-day trip.
c. Six months after acceptance of equipment—one (1) one-day trip.
3.03 SPARE PARTS
A. For each aerator size, provide two (2) impeller assemblies consisting of
propeller prop, pin, and set screw.
END OF SECTION
MAY 2019 PROJECT#17.01107 113750-Page 12

SECTION 141150 SOLIDS CONVEYING SYSTEMS
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SCOPE OF WORK
. A. The Contractor shall furnish and install equipment complete and operable,
in accordance with this section of the Contract Documents. The
equipment shall be of the latest design and shall be fabricated of materials
and in a fashion which will fully perform the functions described herein.
B. The equipment shall be installed as shown on the drawings. Contractor
shall field verify all existing equipment and support dimensions prior to
equipment submittals. The Contractor shall verify and coordinate all
dimensions of the equipment with the System Manufacturer. Any
modifications to existing concrete foundations or supports, steel supports,
concrete pads, or concrete structures required by the System
Manufacturer to adequately install the new system equipment must be
included in the Contractor's lump sum bid price.
C. The system receives dewatered sludge generally ranging from 15% to
20% solids.
D. The following equipment and conveying systems shall be supplied to the
Contractor by a single System Manufacturer as one (1) complete system:
a. Shaftless Screw Conveyors (Section 145200)
b. Live Bottom Hoppers (Section 147000)
c. Bucket Elevator (Section 148000)
February 2019 Project#17.01107 141150-Page 1

E. The following list includes specific proposed equipment and conveying
system components, the proposed work and process description for the
equipment:
Item °Proposed,` Process Description
` Work
Screw Conveyor 1 Base Bid Screw Conveyor receives dewatered sludge from belt filter press
Screw Conveyor 2 Base Bid Screw conveyor transports dewatered sludge from the new Belt Filter
Press to Sludge Hopper 1
Sludge Hopper 1 Base Bid Hopper for storage and feed of dewatered biosolids from the Belt Filter
Press
Screw Conveyor 3 Base Bid Screw conveyor transports material from Sludge Hopper 1 to the
Thermal Belt Dryer
Screw Conveyor 4 Base Bid Screw conveyor allows sludge to bypass the Thermal Belt Dryer
Sludge Hopper 2 Alternate Bid Hopper for storage and feed of dewatered biosolids from the Water
Plant and other entities
Screw Conveyor 5 Alternate Bid Screw conveyor transports material from Sludge Hopper 2 to the
vertical screw conveyor
Screw Conveyor 6 Alternate Bid Vertical screw conveyor
Screw Conveyor 7 Alternate Bid Screw conveyor transports material from the vertical screw conveyor to
the Thermal Belt Dryer
Bucket Elevator Base Bid Bucket Elevator transports dried biosolids from the Thermal Belt Dryer
exit screw to the screw conveyor
Screw Conveyor 8 Base Bid Screw conveyor transport biosolids from the Bucket Elevator to the
Dump Truck Loading Area
Main Control Panel Base Bid Integrated control and power for all components included in the system.
1.03 RELATED SECTIONS
A. Section 099000
B. Section 113610
C. Section 145200
D. Section 147000
E. Section 148000
F. Division 26 Sections
G. Division 40 Sections
1.04 QUALITY ASSURANCE
A. Manufacturer: All equipment shall be supplied by a reputable
manufacturer, with demonstrated experience in the manufacture of similar
equipment. System Equipment shall be as manufactured and supplied by
Jim Myers & Sons, KWS, or prequalified equal. Manufacturers are listed
February 2019 Project#17.01107 141150-Page 2

only to denote the quality standard of product desired, general style, type,
character and do not restrict bidders to a specific manufacturer. All
requirements of these specifications must be met by all Manufacturers
whether named above or prequalified. Any manufacturer not specifically
named above wishing to supply equipment under this section shall submit
for prequalification in accordance with Article 1.05 below. Should any of
the named manufacturers above have any deviations or exceptions from
this specification, a letter stating the issues must be received by the
Engineer by the date and time listed for prequalification submittals to
receive consideration. Any approved exceptions or deviations will be
addressed by Addendum only.
B. Standardization: All parts of the complete mechanical installation shall be
provided by one manufacturer experienced in the design and fabrication of
this type of equipment.
C. Coordination: The contract documents provide details of a complete
equipment installation for the purpose specified. It shall be the
responsibility of the Contractor to coordinate all the details required for a
complete operating system, such as protective coatings, piping, supports,
and wiring. The Contractor shall include all work required to properly
install, adjust and place into operation a complete working system.
1.05 SUBMITTALS
A. Prequalification: Manufacturers not listed above wishing to supply the
Solids Conveying equipment for this project must submit a prequalification
submittal for approval to the Engineer. The prequalification submittal
must be received by the Engineer at least fourteen (14) calendars
days prior to the date and time specified for receipt of bids to receive
consideration. The submittal shall demonstrate that the proposed
equipment 'meets the requirements of the Contract Specifications and
Drawings. The Engineer will issue an addendum prior to the bid date
listing the approved manufacturers. The prequalification submittal shall
include, as a minimum, the following information for this section and
Shaftless Screw Conveyors (Section 145200), Live Bottom Hoppers
(Section 147000), and Bucket Elevators (Section 148000):
1. Literature and catalog cut sheets of all equipment to be supplied,
including technical and performance requirements of proposed
equipment and conveying systems.
2. List showing materials of construction of all components.
3. Information on field erection requirements, including total weight of
assembled components.
4. Copy of the warranty.
February 2019 Project#17.01107 141150-Page 3

5. A certificate of compliance or a complete list of deviations from the
drawings and specifications.
6. A complete list of any modifications required to the existing
concrete supports, steel supports, concrete pads, or concrete
structures for installation of the proposed equipment and conveying
systems.
7. All equipment shall be supplied by a reputable manufacturer, with
demonstrated experience in the manufacture and supply of similar
equipment. The manufacturer shall provide a minimum of five (5)
installations of systems of similar complexity, including contact
names and current telephone numbers for the Owner, operator,
and Engineer.
8. A written statement from the manufacturer indicating that the
manufacturer has reviewed the proposed application as detailed in
the Contract Drawings and Specifications, and that all equipment
conveying systems, materials and systems proposed to be supplied
are appropriate and compatible for this specific application.
Note: The submittal of prequalification information does not omit the
requirement for the Contractor and manufacturers to submit complete
shop drawing submittals to the Engineer in accordance with the Contract
Documents. Incomplete submittal packages will result in the manufacturer
not being pre-qualified to supply equipment on this project.
B. Shop Drawings
1. Shop Drawings shall be submitted to the Engineer in accordance
with Section 013300 "Submittal Procedures". The shop drawings
shall include installation drawings, materials of construction, and
catalogue cut sheets for all materials being supplied.
2. Detailed information shall be provided in the shop drawings for all
components including but not limited to equipment, conveying
systems, motors, reducers, motor controllers, wiring diagrams,
instrumentation, anchor bolt locations, etc. The shop drawings shall
also include manufacturer's installation requirements and a list of
included spare parts.
3. Complete layout and dimensional drawings of equipment with all
elevations, dimensions, and connection details to existing concrete
support and structures.
4. A written statement shall be provided from the manufacturer stating
that the manufacturer has reviewed the proposed application as
detailed in the Contract drawings and specifications, and that all
February 2019 Project#17.01107 141150-Page 4

equipment, materials, and systems proposed to be supplied are
compatible with this specific application.
5. Electrical Hardware Submittals:
a. Provide a block diagram and description of the system
configuration showing all components and their interconnections
etc. Label each diagram and specify all external power and
communications interfaces. All diagrams shall be 11 X 17
format and be developed in AutoCAD DWG file format.
b. Provide an equipment list with descriptive literature identifying
component name, manufacturer, model number, a description of
the operation, quantity supplied and any special characteristics.
c. Drawings of equipment to be supplied shall include, as a
minimum, overall dimension details for each panel, console,
etc., including internal and external arrangements and door
mounted operator devices with nameplate
designations. Elementary and wiring diagrams of equipment
including field device connections shall be included with specific
installation/wiring requirements identified. Provide detailed bills
of materials with spare parts provided.
6. Control Panels:
a. Bill of Materials: A list of all components. Group components
by type and include:
i. Component manufacturer, model number and part
number.
ii. Component description.
iii. Quantity supplied.
iv. Reference to tag on drawings.
b. Descriptive Information: Provide catalog information,
descriptive literature, performance specifications, internal wiring
diagrams, power and grounding requirements, power
consumption, and heat dissipation for all the equipment. Clearly
mark all options and features proposed for this project.
c. Interconnecting Wiring Diagrams: Provide diagrams shall show
all control panel components, their interconnecting cables,
wiring terminations, and terminations to all interacting elements
and subsystems. Terminations shall be numbered.
d. Outline Drawings: Provide equipment drawings
showing: external dimensions, enclosure materials, conduit
connections, and installation requirements.
February 2019 Project#17.01107 141150-Page 5

e. Installation Details: Provide any modifications or further details
as may be required to supplement the Contract Documents and
adequately define the installation of the Control Panel.
f. Input/Output List: Provide for each I/O point list point type, tag
number of the source or final control element, equipment
description, terminal identification, and address.
C. Operation and Maintenance Manuals shall be submitted to the Engineer in
accordance with Section 017823 "Operation and Maintenance Data". The
manuals shall include the following information as a minimum
requirement:
1. Assembly, installation, and adjustment instructions.
2. Lubrication and maintenance instructions.
3. Complete descriptive literature of all materials and components
furnished.
4. Erection drawings with equipment mark numbers.
5. Complete control panel fabrication drawings with wire numbers and
field modifications. Control panels drawings shall include control
schematic.
1.06 DELIVERY, STORAGE AND HANDLING
' All equipment shall be delivered, stored and handled in strict accordance with the
manufacturer's recommendations.
1.07 WARRANTY
A. The Contractor shall include in the bid price for this item a warranty to the
Owner, from the manufacturer, for one (1) year from the date of final
acceptance by the Owner, that the complete system including ancillary
equipment, apparatus and parts, shall be free from defective materials,
equipment or workmanship, including with respect to equipment, the
services of qualified factory trained servicemen, as may be required.
System Manufacturer shall provide a single warranty to the Owner
covering all components of the Solids Conveying System. Separate
warranties from suppliers of individual components will not be considered
equal and will not be acceptable. Under the warranty, the manufacturer
shall furnish replacements for any component, which proves defective,
except those items that are normally consumed in service, such as oil,
grease, packing, gaskets, etc. Components failing to perform as specified
by the Engineer, or as represented by the manufacturer, or proved
defective in service during the warranty period, shall be replaced, ` ,
February 2019 Project#17.01107 141150-Page 6

repaired, or satisfactorily modified by the manufacturer without cost of
parts or labor to the Owner.
B. The warranty shall become effective upon the acceptance of the
installation by the Owner.
1.08 MANUFACTURER AND SUPPLIER INFORMATION
A. MANUFACTURER NAMEPLATE
A manufacturer's nameplate shall be securely and permanently mounted
to each individual piece of equipment furnished under this Section. The
nameplate shall be constructed of a durable, non-corrosive material.
Critical information shall be clearly engraved or otherwise permanently
stamped on the nameplate, and shall be fully legible. The information
contained on the manufacturer nameplate shall include at least the
following:
• Manufacturer's Serial Number
• Name, address and telephone number of equipment manufacturer
• Model and/or Part Number, including pump impeller sizes, when
applicable
• Performance Criteria (i.e., capacity, design point, etc.)
• Motor size, speed and voltage
• Enclosure Type or Rating
• Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. SUPPLIER AND SERVICE INFORMATION
A durable nameplate, stamp or sticker shall be adhered to each individual
piece of equipment containing the name, address, and telephone number
of the local business that supplied the equipment, and the name, address
and telephone number of the local business that can provide service and
replacement parts for the equipment. A 24-hour emergency service
telephone number should also be included.
February 2019 Project#17.01107 141150-Page 7

PART 2: PRODUCTS
2.01 EQUIPMENT
A. MATERIALS OF CONSTRUCTION
1. Refer to individual equipment and conveying system specification
sections listed in Article 1.02.0 of this specification section.
B. MOTORS
1. Provide motors meeting requirements of NEMA MG 1.
2. Minimum service factor of 1.15.
3. Insulation: Class F with Class B rise at nameplate horsepower and
designated operating conditions
4. Enclosure Type: Class I Division II, Group D; suitable for indoor or
outdoor installation in severe-duty applications including high
humidity, chemical (corrosive), or dirty atmospheres.
C. ELECTRICAL CONTROLS
1. All equipment included in the Solids Conveying System shall be
supplied by the System Manufacturer. This is to keep continuity and
single source responsibility for the entire system.
2. The controls shall be designed for high reliability. The system
manufacturer shall provide the programming with logic functions to
match the process and operational requirements of the system. The
controller shall allow the system to operate the equipment without
excessive speed changes or excessive switching.
3. The control panel shall be UL Listed and built according to Section
409513 of these specifications.
4. Panel shall include physical HOA switches to allow operator to
start/stop all equipment as necessary.
5. The panel shall include all starters, overloads, circuit breakers sized
in accordance with the latest version of the NEC.
6. The control panel shall communicate with the System. Refer to the
System Architecture plan sheets. I/O shall be provided as shown on
the I/O list attached to Section 409610 and shall be monitored by the
SCADA System.
7. Controls shall provide fully automated operation for startup, running,
and shutdown sequences.
8. Controls shall include safety maximums to limit feeder conveyor
speeds to avoid overloading downstream equipment in automatic
operation.
February 2019 Project#17.01107 141150-Page 8

9. Operation of any emergency stop shutoff shall immediately shut off
all equipment and manual reset shall be required to continue
operation.
2.02 ACCESSORIES
A. ANCHOR BOLTS: All anchor bolts and other hardware shall be Type 304
stainless steel. Contractor shall coordinate bolt sizes and lengths with
equipment manufacturer.
2.03 PROTECTIVE COATINGS
A. All gearboxes and motors will have manufacturer's standard machinery
paint finish, to be top coated with final coatings as per Specification
099000 of these specifications. Verify compatibility of coatings. In lieu of
field coating for motors and gearboxes, factory applied chemically
resistant coating equivalent to those specified in 099000 are acceptable
with Engineer's approval.
B. Stainless steel surfaces shall not be painted.
C. The manufacturer shall provide a heavy-duty fabricated steel support
stand, hot dipped galvanized, and 304 stainless steel anchorage for
mounting control panels in accordance with Section 260529 - Hangers
And Supports For Electrical Systems.
PART 3: EXECUTION
3.01 INSTALLATION
The system shall be installed in strict accordance with the drawings,
specifications, and manufacturer's recommendations.
3.02 QUALITY CONTROL AND FIELD TESTING
A. QUALITY CONTROL: The installation, alignment, and testing shall be
checked and approved by a factory representative before acceptance.
1. The Contractor shall include in the lump sum base bid the services
of a factory trained representative for a period of five (5) days and
two (2) trips. The manufacturer's representative shall inspect the
completed installation, and assist the Contractor in aligning, start-
up and testing.
2. A written report shall be furnished by the equipment manufacturer
and shall describe the representative's observations. The report
shall describe in detail any deficiencies noted. All such
February 2019 Project#17.01107 141150-Page 9

deficiencies, whether by the manufacturer or Contractor, shall be
corrected at no expense to the Owner.
3. Prior to final approval, the manufacturer shall submit a letter
certifying that the installation meets all requirements of the
manufacturer.
B. FIELD TESTING: The manufacturer shall demonstrate to the Owner and
Engineer that the system functions effectively and that all electrical and
mechanical equipment functions as intended.
3.03 OPERATOR TRAINING
A. Provide a minimum of three (3) eight-hour days of operator training for
owner's personnel after the system is operational. Operating training is to
be separate time on site from Quality Control and Field Testing. Training
shall take place while manufacturer's representative is at the job site for
equipment inspection before placing the system into service.
3.04 SPARE PARTS
Refer to individual equipment specification sections for spare parts applicable to
mechanical equipment. Spare parts for electrical equipment shall be provided in
accordance with Division 40.
END OF SECTION
February 2019 Project#17.01107 141150-Page 10

SECTION 145200 SHAFTLESS SCREW CONVEYOR
PART 1: GENERAL
1.01 - RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. The Contractor shall furnish, install, and place in satisfactory operation
shaftless screw conveyors complete with all supports, spare parts,
accessories and appurtenances as specified herein and shown on the
Drawings, and as required for a complete and operable system.
B. The equipment shall be of the latest design and shall be fabricated of
materials and in a fashion, which will fully perform the functions described
herein.
C. The Shaftless Screw Conveyors shall be furnished in the complete scope
of supply by the System Manufacturer in Section 141150 (Solids
Conveying System). The Shaftless Screw Conveyors shall be capable of
conveying dewatered sludge, and as shown on the Contract Drawings.
The Shaftless Screw Conveyors shall be compatible with all other new
components listed in Section 141150 (Solids Conveying).
D. Dimensions shall be verified by the Contractor and coordinated with the
manufacturer. Any modifications to the existing concrete supports, steel
supports, concrete pads, or concrete structures by the manufacturer to
adequately install the system shall be included in the Contractor's bid, and
must be approved by the Engineer.
E. The Contractor 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.
F. Refer to Section 141150 for performance and design requirements.
1.03 QUALITY ASSURANCE
A. MANUFACTURER
All equipment shall be supplied by a reputable manufacturer, with at least
ten (10) years of experience in the manufacture of Shaftless Screw
February 2019 Project#17.01107 145200-Page 1

Conveyors. The manufacturer shall have supplied a minimum of ten (10)
installations of similar units in the United States.
Any manufacturer wishing to supply equipment under this section shall
submit for prequalification in accordance Article 1.04 below and Section
141150. Any approved exceptions or deviations will be addressed by
Addendum only.
1.04 SUBMITTALS
A. Refer to Section 141150 for requirements for prequalification, shop
drawing and operation and maintenance manual submittals.
B. Shop Drawings
1. If materials manufactured for this specification section are not
manufactured by the "system supplier" a written statement shall be
provided from the manufacturer stating that the manufacturer has
reviewed the proposed application as detailed in the Contract
drawings and specifications, and that all equipment, materials, and
systems proposed to be supplied are compatible with this specific
application. This statement shall be submitted with the complete
shop drawing submittal per Section 141150.
1.05 DELIVERY, STORAGE AND HANDLING
All equipment shall be delivered, stored and handled in strict accordance with the
manufacturer's recommendations.
1.06 WARRANTY
A. Refer to Section 141150 for requirements for system warranty. Equipment
supplied under this section shall be warrantied by the Solids Conveying
System manufacturer under a single warranty to the Owner.
1.07 MANUFACTURER AND SUPPLIER INFORMATION
A. MANUFACTURER NAMEPLATE
A manufacturer's nameplate shall be securely and permanently mounted
to each individual piece of equipment furnished under this Section. The
nameplate shall be constructed of a durable, non-corrosive material.
Critical information shall be clearly engraved or otherwise permanently
stamped on the nameplate, and shall be fully legible. The information
contained on the manufacturer nameplate shall include at least the
following:
February 2019 Project#17.01107 145200-Page 2

• Manufacturer's Serial Number
• Name, address and telephone number of equipment manufacturer
• Model and/or Part Number, including pump impeller sizes, when
applicable
• Performance Criteria (i.e., capacity, design point, etc.)
• Motor size, speed and voltage
• Enclosure Type or Rating
• Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
- B. SUPPLIER AND SERVICE INFORMATION
A durable nameplate, stamp or sticker shall be adhered to each individual
piece of equipment containing the name, address, and telephone number
of the local business that supplied the equipment, and the name, address
and telephone number of the local business that can provide service and
replacement parts for the equipment. A 24-hour emergency service
telephone number should also be included.
PART 2: PRODUCTS
2.01 GENERAL
A. All parts furnished shall be amply designed and constructed for the maximum
stresses occurring during fabrication, transportation, erection and continuous
operation. All materials for the conveyors shall be new and shall be of the
very best quality, entirely suitable for the service to which the units are to be
subjected and shall conform to all applicable sections of these specifications.
B. The screw conveyor equipment shall be factory pre-assembled, factory pre-
wired, and factory tested to the greatest extent practical.
C. The following screw conveyors and motors shall be provided by the system
Manufacturer:
February 2019 Project#17.01107 145200-Page 3

t Material - Y;,
No. Type,' Length* Angle* Specific - Max otor
tM
= Gravity n Capacity ,Size
Horizontal w/Splash
SC-1 Guard&Inlet Chute; 11'-4" 0° 1.048 84.0 ft3/hr 2 HP
Uncovered; Shaftless
SC-2 Inclined; Covered; 30'41" 22° 1.048 84.0 ft3/hr 5 HP
Shaftless •
SC-3 Inclined; Covered; 41'-0" 18° 1.048 84.0 ft3/hr 5 HP
Shaftless
SC-4 Inclined; Covered; 27'-0" 10° 1.048 84.0 ft3/hr 3 HP
Shaftless
SC-5 Horizontal; Covered; 12'-0" 0° 1.048 61.6 ft3/hr 2 HP
Shaftless
SC-6 Vertical; Enclosed; 24'-5" 180° 1.048 61.6 ft3/hr 5 HP
Shaftless
SC-7 Horizontal; Covered; 23'-7" 0° 1.048 61.6 ft3/hr 2 HP
Shaftless
SC-8 Horizontal; Covered; 16'-0" 0° 1.28 8.8 ft3/hr 1 HP
Shaftless
*Dimensions are approximations only
2.02 EQUIPMENT
A. SPIRAL FLIGHTING
1. Spiral shall be manufactured from chromium nickel alloy steel with a
brinnel hardness of 220, and maximum yield strength of 80,000 psi.
2. Spiral flighting shall be designed to convey material without a center shaft.
3. The spiral flights shall be designed with the stability to prevent distortion
and jumping in the trough. The torsional rating of the spiral shall be such
that, at 150% of the motor nameplate horsepower, the drive unit cannot
produce more torque than the torsional rating of the flighting. Sectional
flighting, formed from plate, shall not be permitted. Dual ribbon spirals may
be provided when recommended by the manufacturer.
4. Connect spiral flighting to drive shaft by welding spirals to minimum 3/4
inch circular torque plate reinforced with curved gusset plate for 180
degrees. Drive shaft shall have a mating flange for bolting to the spiral
flighting.
February 2019 Project#17.01107 145200-Page 4

5. A gland packing ring consisting of two Teflon fiber packing rings shall seal
the drive shaft at its penetration through the end plate, along with a
greased labyrinth sealing system.
6. Compression and/or elongation: Less than 0.08 inch per 1 foot at
maximum loading
7. Edges: Smooth in the as-rolled condition
B. TROUGHS
•
1. Trough shall conform to CEMA Standards and be manufactured from T-
304 stainless steel.
2. Minimum trough thickness (inch): 3/16 in.
3. A neoprene or rubber gasket shall be provided at each trough flange and
between trough top and covers
4. 12 gage T-304 stainless steel covers shall be provided over the top of
trough to enclose unit.
5. Covers shall not exceed 48" each in length.
6. CEMA standard trough end plates shall be provided with a split gland
packing ring consisting of two Teflon coated packing rings shall seal the
drive shaft at its penetration through the end plate.
7. UHMW-PE Liner: 1/2" thick, in four (4) foot sections, held in place without
penetrations or fasteners through trough, and replaceable
8. Stiffeners shall be placed across the top of the trough and fastened to
both sides of the trough to maintain trough shape.
9. Drain: 3 inches from driven-end trough flange, bottom mounted, and
welded perpendicular to the trough
10.Each trough shall be equipped with filling and/or discharge spouts at the
location shown on the drawings. If required, each filling and discharge
spout shall be flanged suitable for interconnection to other devices.
C. SUPPORTS
1. Provide T-304 stainless steel supports suitable for mounting as shown on
the drawings and as required by supplier's design. The supports shall be
capable of supporting the equipment weight when fully loaded. The
supports shall be fabricated from structural steel shapes and plates.
Supports shall be match marked and shipped to the job site for installation
in the field.
2. At a minimum, each conveyor shall be provided with supports at the inlet
and discharge end, with intermediate supports at 10 feet-0 inches on
center.
February 2019 Project#17.01107 145200-Page 5

3. Provide base plates at each support leg for anchor bolting
4. Height of support legs as indicated on Drawings
5. The supports shall be designed to avoid interference with other equipment
or equipment supports.
6. All structural supporting members shall be designed such that the ratio of
the unbraced length to least radius of gyration (slenderness ratio) shall not
exceed 120 for any compression member and shall not exceed 240 for
any tension member. In addition, all structural members and connections
shall be designed so that the unit stresses will not exceed the American
Institute of Steel Construction allowable stresses by more than 1/3 when
subject to loading of twice the maximum design operating torque of the
spiral conveyor drive motors.
D. DRIVE SYSTEM
1. Drive assembly shall consist of an integral gearmotor, mounted directly to
the screw shaft. Gearmotor housing shall be cast iron, furnishing complete
protection under all conditions of service. Gears shall be manufactured
and rated for continuous duty in accordance with AGMA Standards, of
heat-treated alloy steel. Provide splash type gear lubrication. Gear
reducer shall be Class II speed reducer.
2. The gear reducer and drive shall be designed to provide an applied torque
adequate to start a full loaded conveyor.
3. Drive shall have a minimum AGMA service factor of 1.4 and shall operate
on 460V/3 phase/60 Hz power.
4. The drive system shall be provided with an instantaneous trip current relay
for torque overload protection. The relay shall be provided with a time
delay (adjustable) to short the relay on start-up and initial motor amp draw.
5. 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 at 2 times the design load.
6. Gearboxes and motors shall be factory-assembled on the conveyor,
factory-tested and shipped fully assembled with the conveyors.
E. SAFETY DEVICES
1. Each conveyor shall be furnished with a pull cord emergency stop switch.
The cord shall run the full length of each conveyor. The trip switch shall
immediately stop all conveyors when the switch is actuated. This device
shall be in NEMA 4 enclosure.
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2. A zero speed switch shall be provided. The switch shall be housed in a
NEMA 4 enclosure, mounted on the side of the conveyor U-trough with a
stainless steel bracket.
F. HARDWARE
1. All fasteners shall be hot dip galvanized or stainless steel. Zinc plated
fasteners shall not be used.
2. All stainless steel bolts shall be assembled using an anti-seize compound.
3. All structural bolts shall be A-325, hot-dip galvanized.
4. Contractor shall coordinate bolt sizes and lengths with equipment
manufacturer.
G. FABRICATION.
1. All parts and components shall be factory-assembled in sections
convenient for field handling and installation but requiring the minimum
amount of work for field assembly. Field welds at the jobsite by the
Contractor for installation may be necessary when any overall conveyor
length presents shipping or handling constraints.
2. Gears and gear drives as part of an equipment assembly shall be shipped
fully assembled for field installation.
3. All assembled parts and components ready for shipment shall be securely
bundled, coiled, or crated and adequately protected from damage and
corrosion during shipment and storage. -
H. SURFACE PREPARATION
1. Fabricated carbon steel components shall be shop blasted & hot dipped
galvanized.
2. Drive unit shall include manufacturer's standard wash down duty paint
system.
2.03 SPLASH GUARD
A. The screw conveyor manufacturer shall provide a stainless steel splash
guard and inlet chute to connect discharge of belt press to the horizontal
screw conveyor (SC-1). The screw conveyor manufacturer shall
coordinate the dimensions and elevations of the hopper and chute with the
belt press manufacturer. Stainless steel splash guard and chute shall
prevent dewatered cake spillage and shall be designed to provide
consistent feed of dewatered cake to the horizontal screw conveyor.
February 2019 Project#17.01107 145200-Page 7

2.04 CONTROLS
A. SEQUENCE OF OPERATION:
1. HAND OPERATION: When the H-O-A switch is in the hand mode
then the equipment shall run continuously.
2. AUTOMATIC OPERATION: The unit shall be operated by the Main
Control Panel.
3. EMERGENCY STOP: The unit can be deactivated at any time by
pressing either the control panel or unit mounted Emergency Stop
push buttons.
4. FAULT CONDITIONS: Motor overload or high current will stop the
drive motor and illuminate the fault light.
5. Refer to Division 40 sections for full.descriptions.
B. CONTROL PANEL: Refer to Section 141150 (Solids Conveying System)
and Section 409513 (Process Control Panels and Hardware) and
electrical sheets for control requirements.
C. REMOTE MONITORING AND CONTROL: Refer to Division 40 sections.
D. INSTRUMENTATION: Refer to Section 409100 (Primary Process
Measurement Devices)
February 2019 Project#17.01107 145200-Page 8

PART 3: EXECUTION
3.01 INSTALLATION
The system shall be installed in strict accordance with the drawings,
specifications, and manufacturer's recommendations.
3.02 QUALITY CONTROL AND FIELD TESTING
A. QUALITY CONTROL: The installation, alignment, and testing of
equipment shall be checked and approved by a factory representative
before acceptance. Perform these services prior to and in conjunction with
those for the system in Section 141150.
B. FIELD TESTING: The manufacturer shall demonstrate to the Owner and
Engineer that the system works effectively and that all electrical and
mechanical equipment functions as intended.
3.03 OPERATOR TRAINING
A. Provide operator training for owner's personnel after the system is
operational. Training shall take place while manufacturer's representative
is at the job site for equipment inspection.
3.04 SPARE PARTS
The Contractor shall furnish one (1) complete set of recommended spare parts
for all equipment and conveying system. Spare parts shall include a minimum of
the following for each shaftless screw conveyor: One (1) Packing Gland Set, One
(1) full set of liners, and One (1) loss of rotation sensor. All spare parts are to be
conveyed to the Owner.
END OF SECTION
February 2019 Project#17.01107 145200-Page 9

SECTION 147000 LIVE BOTTOM HOPPER
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. The Contractor shall furnish and install Live Bottom Hoppers complete and
operable, in accordance with this section of the Contract Documents.
B. The equipment shall be of the latest design and shall be fabricated of
materials and in a fashion, which will fully perform the functions described
herein.
C. The Live Bottom Hoppers shall be furnished in the complete scope of
supply by a common System Manufacturer of the Live Bottom Hoppers,
Screw Conveyors, and Bucket Conveyor.
D. Live Bottom Hoppers shall be capable of conveying dewatered sludge and
as shown on the Contract Drawings. The Live Bottom Hoppers shall be
compatible with all other new components included in the project.
E. Dimensions shall be verified by the Contractor and coordinated with the
manufacturer. Any modifications to the existing concrete supports, steel
supports, concrete pads, or concrete structures by the manufacturer to
adequately install the system shall be included in the Contractor's bid, and
must be approved by the Engineer.
F. The hopper will be provided complete with mounting and support frame,
load cells, live bottom with shaftless screw conveyors, VFDs for the live
bottom screws, discharge chute, motor reducer, electrical controls, control
panel, access ladder, safety accessories and all appurtenances specified
or required for a complete and operable system. The equipment and all
appurtenances will be installed as shown on the plans, as recommended
by the Manufacturer, and in compliance with all OSHA, local, state and
federal codes and regulation.
G. All necessary safety equipment and guards to meet OSHA requirements
shall be provided.
February 2019 Project#17.01107 147000-Page 1

H. All equipment included in this section shall be furnished by a single
supplier who shall be responsible for the design, coordination, and
satisfactory operation of the system.
I. PERFORMANCE AND DESIGN REQUIREMENTS
1. Wet Cake Hoppers shall be sized and selected to meet the following:
a) Number of Wet Cake Hoppers: Base Bid:1, Alternate Bid: 1,
See drawings.
b) Type of Wet Cake: Dewatered Waste Activated Sludge,
c) Approximate Percent Solids (%): 15 - 20
d) Minimum Volume Per Hopper: See drawings
e) Maximum Total Height Per Hopper: See drawings
f) Maximum Width Per Hopper: See drawings
g) Minimum Length: See drawings
h) Number of Load Cells: One per support (Min. 6 per hopper)
2. Live Bottom shall be sized and selected to meet the following:
a) Number of Screws Per Hopper: 2 or 3
b) Screw Length: Full length
c) Maximum Live Bottom Width: 54"
d) Minimum Screw Diameter: 15"
1.03 QUALITY ASSURANCE
A. MANUFACTURER
All equipment shall be supplied by a reputable manufacturer, with at least
ten (10) years experience in the manufacture of Live Bottom Hoppers.
The manufacturer shall have supplied a minimum of ten (10) installations
of similar units in the United States.
Any manufacturer wishing to supply equipment under this section shall
submit for prequalification in accordance Article 1.04 below and Section
141150. Any approved exceptions or deviations will be addressed by
Addendum only.
February 2019 Project#17.01107 147000-Page 2

1.04 SUBMITTALS
A. Refer to Section 141150 for requirements for prequalification, shop
drawing and operation and maintenance manual submittals.
B. Shop Drawings
1. If materials manufactured for this specification section are not
manufactured by the "system supplier" a written statement shall be
provided from the manufacturer stating that the manufacturer has
reviewed the proposed application as detailed in the Contract
drawings and specifications, and that all equipment, materials, and
systems proposed to be supplied are compatible with this specific
application. This statement shall be submitted with the complete
shop drawing submittal per Section 141150.
1.05 DELIVERY, STORAGE AND HANDLING
All equipment shall be delivered, stored and handled in strict accordance with the
manufacturer's recommendations.
1.06 WARRANTY
A. Refer to Section 141150 for requirements for system warranty. Equipment
supplied under this section shall be warrantied by the Solids Conveying
System manufacturer under a single warranty to the Owner.
1.07 MANUFACTURER AND SUPPLIER INFORMATION
A. MANUFACTURER NAMEPLATE
A manufacturer's nameplate shall be securely and permanently mounted
to each individual piece of equipment furnished under this Section. The
nameplate shall ,be constructed of a durable, non-corrosive material.
Critical information shall be clearly engraved or otherwise permanently
stamped on the nameplate, and shall be fully legible. The information
contained on the manufacturer nameplate shall include at least the
following:
• Manufacturer's Serial Number
• Name, address and telephone number of equipment manufacturer
• Model and/or Part Number, including pump impeller sizes, when
applicable
• Performance Criteria (i.e., capacity, design point, etc.)
• Motor size, speed and voltage
• Enclosure Type or Rating
February 2019 Project#17.01107 147000-Page 3

• Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. SUPPLIER AND SERVICE INFORMATION
A durable nameplate, stamp or sticker shall be adhered to each individual
piece of equipment containing the name, address, and telephone number
of the local business that supplied the equipment, and the name, address
and telephone number of the local business that can provide service and
replacement parts for the equipment. A 24-hour emergency service
telephone number should also be included.
PART 2: PRODUCTS
2.01 GENERAL
A. Wet cake hopper shall be self-supporting with structural steel support legs
and framing complete with base plates drilled for mounting on concrete base.
All necessary cross bracing and reinforcing members shall be fabricated
within the support system. A 4-inch Class 150 flanged connection shall be
provided at the bottom of the hopper to drain the hopper during maintenance
activities. Intermediate supports within the hopper will not be acceptable.
Support system to be designed and stamped by a Professionally Licensed
Engineer.
B. Unless otherwise specified, the materials used in the fabrication of the
equipment under this section shall conform to the following:
1. Hopper: A53 Carbon Steel (coated)
2. Inlet/Outlet Chutes: T-304 stainless steel
3. Supports: A53 Carbon Steel (coated)
4. Discharge Gate (if required): T-304 stainless steel
5. Shafted Live Bottom Screws: Abrasion resistant Alloy Steel
6. Live Bottom Pan/Trough: A53 Carbon Steel (coated)
7. Bolts, Nuts, and Washers: 18-8 Stainless Steel
C. Welds: All welds shall be sealed watertight by continuous welds, unless
otherwise specified. Edge Grinding: Sharp corners of all cut and sheared
edges shall be made smooth by a power grinder.
February 2019 Project#17.01107 147000-Page 4

D. Hopper: Wet cake hopper shall be constructed of welded steel plate of a
thickness determined by the manufacturer. It shall be designed to limit
maximum deflection of no more than 1/270. Minimum plate thickness shall be
1/4-inch. Interior surfaces of hopper shall be smooth to allow unobstructed
flow. All stiffening of hopper shall be welded to the exterior surface.
E. Top Cover: Each wet cake hopper shall be supplied with a steel grizzley
grating cover to allow sludge to fall through but prevent personnel from falling
in.
F. Access Ladder:
1. Manufacturer shall provide aluminum access ladders with aluminum safety
cage and top grab rails complying with OSHA standards per wet cake
hopper to top cover and inspection door.
2.02 EQUIPMENT
A. BIOSOLIDS HOPPERS:
1. Function: The hoppers store biosolids and feed stored biosolids to the
Solids Conveying process. The biosolids will be conveyed to the hoppers
through sludge piping from a progressive cavity pump or directly loaded
from a truck or front loader.
2. Equipment Components:
a. Hoppers:
1. Provide flanges for connecting hopper to screw conveyor hopper.
2. Side slope angles of not less than 75 degrees from the horizontal.
3. Design stiffening members to limit deflection of hopper to 1/270 of
span.
4. Design hopper to rest on the support structure as shown on the
Drawings.
5. Provide continuous welds at all welded hopper joints. Stiffeners do
not require continuous welds.
6. Provide connections for level elements as shown on the Drawings.
7. Hoppers shall have integral support structure and anchors suitable
for mounting to steel structure designed and constructed by others.
8. Design integral hopper supports for dead loads and live loads
assuming hoppers completely full of biosolids of 65 lb/ft3 density.
Live loads are as specified on Drawings.
_ 9. Design the hoppers to have the minimum vertical clearance as
specified on the Drawings.
February 2019 Project#17.01107 147000-Page 5

10.Provide anchor bolts for support structure.
11.Make provision in structure for equipment and piping loads
specified on Drawings.
3. Option 1 - Bottom Shafted Screw Conveyors:
a. Provide a live bottom consisting of nonreversible shafted screw
conveyors.
b. Screw flights to be minimum 15-inch diameter.
c. Single flights with standard pitch or variable pitch shall be
provided. Flight outside diameter shall be CEMA standardized
sizes. Flights shall be of the required diameter and thickness to
convey the specified material at the specified rate.
d. Sectional flights shall have a constant cross section. Flights shall
be butt welded into a continuous helix, continuous throughout its
entire section.
e. Pipe shaft shall be minimum schedule 80 pipe and shall deflect
no more than '/4".
f. Coupling shafts shall be used to join screw augers. Coupling
shaft shall fit inside the screw shaft with minimal play. Coupling
shaft shall have matching bolt holes with screw shaft. Bolt holes
shall be jig-drilled. Bolts shall secure coupling shaft and screw
shaft together with a lock nut. Bolts shall be sized to adequately
carry all loads generated by the conveyor. Screw coupling shafts
shall be of sufficient length to allow rotation within the intermediate
bearings without the bearing and its housing being in contact with
. any part of the screw. Drive, coupling, and tail shafts shall be
manufactured from 1045 alloy steel. Coupling shafts shall be
heat treated through induction hardening.
g. Flights shall be manufactured from abrasion resistant alloy steel
with a brinnel hardness of 220, and maximum yield strength of
80,000 psi. Pipe shafts shall be manufactured from carbon
steel.
h. Conveyor pitch design shall permit even distribution of biosolids
across hopper during biosolids discharge.
i. Provide radial and thrust bearings for screw flight drive and end
shafts.
j. Provide externally mounted bearings, double tapered, grease
lubricated roller bearings having an AFBMA C-10 rating life of
100,000 hours.
k. Provide grease fittings at each bearing and brought to an -
accessible location.
February 2019 Project#17.01107 147000-Page 6

I. Provide packing glands on outboard hopper wall to prevent
contamination of bearings.
m. Designs incorporating inboard bearings, intermediate supports,
or bearings located inside the hopper are not acceptable.
n. Fabricate screws to CEMA 300 Standards.
o. Hanger bearings shall be provided as needed to prevent shaft
deflection from exceeding %". Hanger bearings shall not be
located in the hopper area.
p. Bearings shall be CEMA Style 226 with UHMW-PE bearing
insert.
4. Option 2 Bottom Shaftless Screw Conveyors
a. Spiral shall be manufactured from chromium nickel alloy steel
with a brinnel hardness of 220, and maximum yield strength of
80,000 psi.
b. Spiral flighting shall be designed to convey material without a
center shaft.
c. The spiral flights shall be designed with the stability to prevent
distortion and jumping in the trough. The torsional rating of the
spiral shall be such that, at 150% of the motor nameplate
horsepower, the drive unit cannot produce more torque than the
torsional rating of the flighting. Sectional flighting, formed from
plate, shall not be permitted.
d. Connect spiral flighting to drive shaft by welding spirals to
minimum 3/4 inch circular torque plate reinforced with curved
gusset plate for 180 degrees. Drive shaft shall have a mating
flange for bolting to the spiral flighting.
e. A gland packing ring consisting of two Teflon fiber packing rings
shall seal the drive shaft at its penetration through the end plate,
along with a greased labyrinth sealing system.
f. Compression and/or elongation: Less than 0.08 inch per 1 foot
at maximum loading.
g. UHMW-PE Liner: Min. 5/8" thick, in four (4) foot sections, held
in place without penetrations or fasteners through trough, and
replaceable. Liner shall be fully warrantied for a period of five (5)
years from Owner's acceptance. If liner requires replacement
during the warranty period, manufacturer shall provide all
materials and labor for liner replacement.
February 2019 Project#17.01107 147000-Page 7

4. Conveyor Drive Units: .
a. Provide live bottom direct drive unit with perpendicular motor
orientation for each live bottom screw.
b. Provide adjustable drive supports as part of the hopper
structure.
c. Provide severe duty variable speed inverter duty rated motors.
Live bottom screw conveyor motors shall have space heaters
and temperature sensing and protection.
d. Ensure output speed of bottom screw conveyor secondary gear
reducer is as required for specified discharge rate.
e. Provide 1,800 rpm, 460 volt, 60 Hz, 3 phase motors with a 1.15
services factor, with Class F insulation. Motors shall be inverter
duty rated. Furnish motors with TEFC enclosure and Design B
speed/torque characteristics.
f. Provide all gear reducers with AGMA Class II, single or double
reduction, helical gear units with high capacity roller bearings.
Design bearings for thrust loads from the fully loaded startup
condition with an AFBMA B10 life of 30,000 hours. Provide
standard air-cooled reducer units with no auxiliary cooling. Size
the gear reducer with a torque service factor of 1.5 times the
absorbed power or 1.1 times the motor nameplate, at the driven
shaft speed, whichever is greater.
g. Maximum continuous operating torque shall be determined by
hopper manufacturer for worst combination of service
conditions, feed or discharge rate, and biosolids consistency.
5. Retractable Cover (Hopper#2 only -Alternate Bid)
a. The cover shall match the receiving bin material and be
adequately stiffened and supported to prevent the deflection of
the roof from exceeding U360.
b. A section of the cover shall be retractable to allow receiving of
dewatered sludge from a truck. Covers shall be designed for a
100 psf live load.
c. The retracting cover mechanism shall utilize a minimum 2"
diameter, triple lead, ACME threaded rod. The rod shall be
supported at each end with roller bearings.
d. The cover shall ride on phenolic V-groove wheels, with a track
manufactured from the same material as the receiving bin.
e. The cover will operate by means of an electric actuator, sized as
required to operate the cover. Electric actuators shall be as
manufactured by Rotork, Limitorque, or equal.
February 2019 Project#17.01107 147000-Page 8

2.03 ELECTRICAL DEVICES AND CONTROLS
A. SEQUENCE OF OPERATION:
1. HAND OPERATION: When the H-O-A switch is in the hand mode
then the equipment shall run continuously.
2. AUTOMATIC OPERATION: The unit shall be operated by the Main
Control Panel, which will receive a start/stop signal from the belt
press or sludge drying system.
3. EMERGENCY STOP: The unit can be deactivated at any time by
pressing either the control panel or unit mounted Emergency Stop
push buttons.
4. FAULT CONDITIONS: Motor overload or high current will stop the
drive motor and illuminate the fault light.
5. Refer to Division 40 sections for full descriptions.
B. CONTROL PANEL: Refer to Section 141150 (Solids Conveying System)
and Section 409513 (Process Control Panels and Hardware) and
electrical sheets for control requirements.
C. REMOTE MONITORING AND CONTROL: Refer to Division 40 sections.
D. INSTRUMENTATION: Refer to Section 141150 Solids Conveying System
and Section 409100 (Primary Process Measurement Devices)
PART 3: EXECUTION
3.01 INSTALLATION
The system shall be installed in strict accordance with the drawings,
specifications, and manufacturer's recommendations.
3.02 QUALITY CONTROL AND FIELD TESTING
A. QUALITY CONTROL: The installation, alignment, and testing of
equipment shall be checked and approved by a factory representative
before acceptance. Perform these services prior to and in conjunction with
those for the system in Section 141150.
B. FIELD TESTING: The manufacturer shall demonstrate to the Owner and
Engineer that the system works effectively and that all electrical and
mechanical equipment functions as intended.
3.03 OPERATOR TRAINING
February 2019 Project#17.01107 147000-Page 9

A. Provide operator training for owner's personnel after the system is
operational. Training shall take place while manufacturer's representative
is at the job site for equipment inspection. Perform these services in
conjunction with those for the overall system in Section 141150.
3.04 SPARE PARTS
The Contractor shall furnish one (1) complete set of recommended spare parts
for all equipment and conveying system. Spare parts shall include a minimum of
the following for each Live Bottom Hopper: packing gland set, loss of rotation
sensor. All spare parts are to be conveyed to the Owner.
END OF SECTION
February 2019 Project#17.01107 147000-Page 10

SECTION 148000 BUCKET ELEVATOR
PART 1: GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General
Conditions and Division 01 Specification Sections, apply to this Section.
1.02 SUMMARY
A. The Contractor shall furnish, install, and place in satisfactory operation the
Bucket Elevator complete with all supports, spare parts, accessories and
appurtenances as specified herein and shown on the Drawings, and as
required for a complete and operable system.
B. The equipment shall be of the latest design and shall be fabricated of
materials and in a fashion, which will fully perform the functions described
herein.
C. The Bucket Elevator shall be furnished in the complete scope of supply by
the System Manufacturer in Section 141150 (Solids Conveying System).
The Bucket Elevator shall be capable of conveying dewatered sludge, and
as shown on the Contract Drawings. The Bucket Elevator shall be
compatible with all other new components listed in Section 141150 (Solids
Conveying).
D. Dimensions shall be verified by the Contractor and coordinated with the
manufacturer. Any modifications to the existing concrete supports, steel
supports, concrete pads, or concrete structures by the manufacturer to
adequately install the system shall be included in the Contractor's bid, and
must be approved by the Engineer.
E. The Contractor 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.
F. Refer to Section 141150 for performance and design requirements.
1.03 QUALITY ASSURANCE
A. MANUFACTURER
All equipment shall be supplied by a reputable manufacturer, with at least
ten (10) years of experience in the manufacture of Bucket Elevators. The
February 2019 Project#17.01107 148000-Page 1

manufacturer shall have supplied a minimum of ten (10) installations of
similar units in the United States.
Any manufacturer wishing to supply equipment under this section shall
submit for prequalification in accordance Article 1.04 below and Section
141150. Any approved exceptions or deviations will be addressed by
Addendum only.
1.04 SUBMITTALS
A. Refer to Section 141150 for requirements for prequalification, shop
drawing and operation and maintenance manual submittals.
B. Shop Drawings
1. If materials manufactured for this specification section are not
manufactured by the "system supplier" a written statement shall be
provided from the manufacturer stating that the manufacturer has
reviewed the proposed application as detailed in the Contract
drawings and specifications, and that all equipment, materials, and
systems proposed to be supplied are compatible with this specific
application. This statement shall be submitted with the complete
shop drawing submittal per Section 141150.
1.05 DELIVERY, STORAGE AND HANDLING
All equipment shall be delivered, stored and handled in strict accordance with the
manufacturer's recommendations.
1.06 WARRANTY
A. Refer to Section 141150 for requirements for system warranty. Equipment
supplied under this section shall be warrantied by the Solids Conveying
- System manufacturer under a single warranty to the Owner.
1.07 MANUFACTURER AND SUPPLIER INFORMATION
A. MANUFACTURER NAMEPLATE
A manufacturer's nameplate shall be securely and permanently mounted
to each individual piece of equipment furnished under this Section. The
nameplate shall be constructed of a durable, non-corrosive material.
Critical information shall be clearly engraved or otherwise permanently
stamped on the nameplate, and shall be fully legible. The information
contained on the manufacturer nameplate shall include at least the
following:
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• Manufacturer's Serial Number
• Name, address and telephone number of equipment manufacturer
• Model and/or Part Number, including pump impeller sizes, when
applicable
• Performance Criteria (i.e., capacity, design point, etc.)
• Motor size, speed and voltage
• Enclosure Type or Rating
• Any other pertinent information
Note: All equipment shall include a nameplate with a manufacturer serial
number validating the equipment as new. Failure to meet these
requirements will be cause for rejection of the equipment.
B. SUPPLIER AND SERVICE INFORMATION
A durable nameplate, stamp or sticker shall be adhered to each individual
piece of equipment containing the name, address, and telephone number
of the local business that supplied the equipment, and the name, address
and telephone number of the local business that can provide service and
replacement parts for the equipment. A 24-hour emergency service
telephone number should also be included.
PART 2: PRODUCTS
2.01 PERFORMANCE AND DESIGN CRITERIA
A. The bucket elevator system shall be designed to meet the following minimum
performance and design standards. The standards for elevator selection shall
be based on the operational experience of the manufacturer of single casing
bucket elevators and not standards developed for dual casing bucket
elevators.
B. Standard bucket elevators with chains and sprockets will not be considered
as an acceptable alternate to this bucket elevator.
C. Each elevator shall be designed and constructed for both continuous and
intermittent operation. The elevator shall operate smoothly and without undue
vibration and shall convey the Dried Sludge without jamming, spilling or
clogging.
D. The supplier shall demonstrate by submission of calculations that at 100% of
the motor nameplate horsepower, the drive unit cannot produce more torque
than the calculated torque rating of the bucket elevator bolts in shear, the
bolts & pipe in bearing, the pipe, and drive shaft using a minimum 5:1 yield
stress to safe stress ratio for the material selected.
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2.02 GENERAL , "
1
A. All parts furnished shall be amply designed and constructed for the maximum
stresses occurring during fabrication, transportation, erection and continuous
operation. All materials for the elevators 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.
B. The bucket elevator equipment shall be factory pre-assembled, factory pre-
wired, and factory tested to the greatest extent practical.
C. Fasteners:
All fasteners and grease fittings shall be Imperial sizing. Metric
fasteners and fittings shall not be used.
D. Welding:
Except as otherwise indicated, welding shall comply with ANSI/AWWA
D100 and AWWA C206, and the following:
1. Welding shall be by the metal-arc method or gas-shielded arc
method described in the American Welding Society's "Welding ,
Handbook" as supplemented by other AWS standards.
Qualification of welders shall comply with AWS Standard AWS
D1.198. Manufacturer must be an Affiliate Company Member of
the AWS and the equipment must be welded ASME and AWS
certified welders. The equipment must be inspected by AWS
certified welding inspectors and instructors.
2. In assembly and during welding, the component parts shall be
clamped, supported and restrained to minimize distortion and for
control of dimensions. Weld reinforcement shall comply with the
AWS code. Upon completion of welding, weld splatter, flux, slag
and burrs left by attachments shall be removed. Welds shall be
repaired to produce a workmanlike appearance with uniform weld
contours and dimensions. Sharp corners of material which is to be
painted or coated shall be ground to a minimum of 1/32" on the flat.
E. Safety Devices:
The completed work shall include all necessary permanent safety
devices, such as machinery guards and similar items as required by
OSHA and other federal, state and local health and safety regulations.
F. Flanges and Pipe Threads:
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Flanges on equipment shall comply with ANSI B16.1, Class 125 or
B16.5, Class 150, unless otherwise indicated. Threaded flanges and
fittings shall have standard taper pipe threads complying with
ANSI/ASME B1.20.1. Metric flanges, piping and threads shall not be
used.
G. Nameplates:
Equipment nameplates shall be fastened to the equipment in accessible.
Nameplates shall contain the Manufacturer's name and telephone
number for service.
H. Bearings:
1. Bearings shall conform to the standards of the Anti-Friction Bearing
Manufacturers Association, Inc. (AFBMA).
2. Except where otherwise indicated, bearings of process equipment
shall have a minimum B-10 life expectancy of 50,000 hours.
2.03 SERVICE CONDITIONS
A. Material:
1. Type of material: Dried Sludge
2. Material density - max: 15 lbs/ft3
3. Material density - min: 25 lbs/ft3
4. Capacity (design): 0.125 tons/hour
5. Capacity (design): 10 ft3/hr
6. Ambient temperature: 120 °F maximum,
7. Ambient temperature: 32 °F minimum
8. Max belt speed (elevator): 130 fpm
9. Hazardous Location Classification Unclassified
B. Physical Requirements:
1. Bucket elevator:
Elevator Minimum Nominal Casing Size
Tag No. Pulley (inches) Discharge
Height (feet)
BE-1 To be 15 To be
determined by determined by
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C. Service Duty:
1. Number of hours per day: 24
2. Number of days per week: 7
3. Number starts per hour (max): 4
2.04 EQUIPMENT
A. MATERIALS:
1. Head, boot, and intermediate casings: ASTM A-36 Low Carbon Steel
2. Inlets/outlets: Low Carbon Steel
3. Pulleys: Low carbon steel
4. Buckets: Nylon
5. Drive and end shafts: C 1045 steel with hardening, stainless steel not
acceptable.
6. Gaskets: Black Closed Cell Sponge Gasket PVC / Nitrile Blend
7. Bolts and All other hardware: Grade 5 Zinc Plated Carbon Steel
B. CASINGS
1. The casing shall be completely self-supporting and made of minimum 12
GA thick steel.
2. Vendor shall recommend the location and spacing of sway-bracing to be
provided by Others.
3. The upper head section shall be split. The upper head section shall have
dust-tight gaskets. Integral headshaft bearing supports shall be provided.
4. Inspection doors shall be provided in the stub discharge spout and boot
sections.
5. The boot section shall be provided with front and rear access panels for
cleanout and repair.
6. The head section, boot section, and intermediate casing sections shall be
dust tight.
7. Vendor to provide their standard inlet and outlet flanges for connection to
feed and discharge equipment.
8. Vendor shall fully describe their standard inlet and outlet flanges with
proposal.
9. Tail section to include a screw-type takeup to tension the belt with 6" of
travel.
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C. BUCKETS:
1. Buckets to be 4" X 3" "ME" (medium-front) style. Buckets to be spaced on
6" centers on belt.
D. BELTING:
1. Belting to be heavy-duty, abrasion resistant black Styrene Butadiene
Rubber (SBR) belt with covers on both sides. Belts to be 5" wide 2 ply
220 PIW with P1 punching.
E. PULLEYS:
1. Fabricated from carbon steel welded construction, 6" wide. Head pulley to
be crown-faced and 3/8" thick heavy duty neoprene lagging. Tail pulley to
be a heavy duty slatted wing pulley.
2. All pulleys to have XT or QD hubs and bushings.
3. Pulleys to be made by Dodge, or equal.
F. DRIVE ASSEMBLY, END SHAFT ASSEMBLY:
1. Drive and end shaft assemblies to consist of the following separate
components:
a. Drive assembly for drives up to 20 hp:
i. drive shaft;
ii. split gland seals;
iii. hollow shaft gear reducer with backstop;
iv. taper bushing kit
v. torque arm kit
vi. sheaves
vii. v-belt package with sheaves
viii. belt guard
b. End shaft assembly:
i. end shaft;
ii. split gland seals;
iii. bearings;
iv. motion-sensing ring.
2. Adjustable packing gland seal shall be provided if Manufacturer
determines they are needed where shafts project through elevator end
plate.
3. Outside support bearings to be SKF or Dodge ball bearings, mounted in
pillow block bearing houses. Mount bearing outboard of the packing gland
assembly with sufficient clearance to permit removal of bolts, cover and
repacking without having to remove the bearing housing or bearing from
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the housing. Fit each bearing housing with a grease nipple, with escape
release provisions.
4. Except where shaft-mounted gear reducers are being used, flexible
couplings shall separate drive shaft from gear reducer. Coupling to
consist of two cast iron hub rings separated by synthetic elastomer bushes
that absorb the misalignment that may occur between the bucket elevator
drive shaft and the gear reducer shaft, as well as absorb shock loads.
5. Gear reducers to be parallel helical or bevel helical, 2, 3 or 4-stage gear
reducers for shaft-mounted or foot-mounted, with flexible coupling.
6. Size gear reducers and flexible couplings based on the input power to
each gear reducer, with the resulting torque calculated at the output shaft
rpm, with a safety factor of 1.5 times this calculated torque. The nominal
rated output torque (AGMA 2) to be greater than or equal to the calculated
output torque and its safety factors. A second criteria to be met is that the
nominal rated output torque must exceed the electric motor nameplate
horsepower equivalent torque at the gear reducer output shaft rpm.
7. Oil level indicator and drain locations shall be readily accessible.
8. Belt drive connections between motor and gearbox shall be sized based
on the electric motor drive horsepower at the sheave rpm, with a safety
factor of 1.5 times the horsepower of the electric motor drive. V-belts or
notched V-belts may be used on all drives.
9. Gearboxes, motors and V-belt drives shall be factory-assembled on the
elevator, factory-tested and shipped fully assembled with the elevators.
G. MOTORS AND DRIVES:
1. Provide squirrel-cage AC induction motors that meet all applicable
requirements of NEMA standards. Load on motor shall not exceed
nameplate horsepower rating under any anticipated load condition.
2. In addition, the motors shall meet the following specific requirements:
a. Voltage rating: 460 volts (or 230/460), 3 ph, 60 Hz;
b. Efficiency: premium;
c. Service factor: 1.15;
d. Speed: 1800 rpm, constant;
e. Enclosure: TEFC;
f. Mounting: integral
H. CHUTES:
1. Provide chutes for connections between elevator and conveyors. Chutes
shall be fabricated from minimum 10 GA thick, A-36 plate. Flanged
connections shall be provided on the underside of the elevator troughs at
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the drop point. Flanges shall be located approximately 3" below the
bottom of the elevator trough.
2. Drop chutes longer than 2 feet between connection flanges shall include
gasketed flanges and at least four handles shall be provided on each
chute section to facilitate removal. Handles shall be 1/2" diameter rod, of
the same material as the chute, formed and welded to the sides of the
section.
3. Furnish 1/8" thick, full-face neoprene gasket for installation between each
flanged connection and transition chute.
2.05 ACCESSORIES
A. MOTION SWITCHES:
1. Provide non-contacting, proximity-type speed switch to point to the tail
shaft for detecting zero speed condition on monitored equipment.
2. Zero speed switch shall be 4B Components M100 or equal.
3. All motion switches shall have NEMA 4 enclosures.
2.06 CONTROLS
A. CONTROLS SYSTEM TO BE SUPPLIED BY CONTRACTOR
1. FACTORY-APPLIED PROTECTIVE COATINGS
2. Exterior Surface Preparation and Protective Coating:
3. Factory apply one coat of water-based enamel to bucket elevator casing
exterior.
4. Stainless Steel Surfaces:
5. Glassblast all exterior stainless steel surfaces only to a uniform finish.
6. Gearboxes, motors, bearings, etc. are to be supplied in Manufacturer's
standard enamel finish.
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PART 3: EXECUTION
3.01 INSTALLATION
The system shall be installed in strict accordance with the drawings,
specifications, and manufacturer's recommendations.
3.02 QUALITY CONTROL AND FIELD TESTING
A. QUALITY CONTROL: The installation, alignment, and testing of
equipment shall be checked and approved by a factory representative
before acceptance. Perform these services prior to and in conjunction with
those for the system in Section 141150.
B. FIELD TESTING: The manufacturer shall demonstrate to the Owner and
Engineer that the system works effectively and that all electrical and
mechanical equipment functions as intended.
C. Shop-assemble head section with drive prior to shipment and run under
no load for a minimum of 15 minutes to ensure proper operation. Provide
a signed shop test certificate and record amperage on motor. Shop
testing must be done at the same facility where the engineering staff is
located. Shop assemble tail section as much as conceivable.
D. Inspect equipment and test for proper alignment, quiet operation, proper
connection and satisfactory performance of components. Match-mark any
sections which have to be disassembled for the purposes of shipping,
individual casing sections to ship loose for field assembly and erection.
•
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3.03 OPERATOR TRAINING
A. Provide operator training for owner's personnel after the system is
operational. Training shall take place while manufacturer's representative
is at the job site for equipment inspection.
3.04 SPARE PARTS
The Contractor shall furnish one (1) complete set of recommended spare parts
for all equipment and conveying system. Spare parts shall include a minimum of
the following for each bucket elevator: One (1) drive and tail end bearing set,
One (1) gearmotor for each type used, and One (1) set of packing materials for
each elevator seal. All spare parts are to be conveyed to the Owner.
Manufacturer to provide the following site services, using a licensed and factory-
trained service technician that is a bachelor-degreed mechanical engineer with a
current professional engineer license. Contractor to make reasonable effort to
attempt to have supervision, commissioning, and training occur on a single trip, if
possible. A minimum of two weeks' notice shall be provided to manufacturer for
desired on-site date.
Supervision of installation 1 trips of 1 days
Commissioning and operator training 1 trips of 1 days
END OF SECTION
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