Section 11250
SLUDGE CAKE PUMPING SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Material, design, fabrication and
installation requirements for progressing cavity pumps and related
equipment for pumping sludge cake (dewatered sludge) from dewatering
building to cake silos and from cake silos to loadout facilities.
B. Related Sections include but are
not necessarily limited to:
1. The requirements of the following
sections and divisions apply to the Work of this section. Other
sections and divisions of the Specifications, not referenced below,
shall also apply to the extent required for proper performance of
this Work.
a. Division 01, Additional General
Requirements b. Section 05500, Miscellaneous Metalwork
c. Section 09800, Protective Coating
d. Section 11005, Equipment: Basic
Requirements e. Section 11309, Progressing Cavity Pumps
f. Section 11210, Pumps and
Equipment, General g. Section 15101, Valve Operators
h. Section 15008, Steel Pipe
i. Section 15009, Fabricated
Specials j. Section 15106, Ball Valves
k. Section 16220, Electric Motors
l. Section 16418, Variable Frequency
Drives Below 100 HP
m. Section 16419, Variable Frequency
Drives 100 HP and Above n. Section 16442, Control Panels
o. Section 17300, Control Strategies
p. Section 17405, Process
Instrumentation and Controls
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. American Bearing Manufacturers
Association (ABMA)
2. American Iron and Steel Institute
(AISI):
a. Steel Products Manual
3. American National Standards
Institute (ANSI).
4. ASTM International (ASTM):
a. A48 Standard Specification for
Gray Iron Castings
5. Hydraulic Institute (HI)
1.3 WARRANTY
A. The pumping units shall be
warranted by the manufacturer for a minimum of three (3) year
period after beneficial occupancy of the Work pursuant to “Use
Prior to Final Completion” of the general conditions, against
defects in workmanship and materials. Wear items such as seals,
bearings, rotor, stator and motor. Rotors and stators may be
prorated during the three year period. The first year warranty shall
cover pump performance to comply with the design criteria stated in
Articles “2.3 Equipment and 2.4
Dewatered Cake and Cake Silo Transfer
Pump Accessories” and the pump manufacturer shall be responsible
for replacing the pumps with adequately sized pumps to meet the
criteria.
1.4 SYSTEM DESCRIPTION
A. All pumps specified in this
section shall be provided by the same manufacturer. B. Pump
manufacturer will also supply:
1. Inlet chutes (hoppers) with
flexible top connection.
2. Slide gates for cake transfer
pumps only (not required for the silo pumps because it is
furnished with the sliding frame equipment).
3. Load cell weighing system.
4. Flexible connection on pump
discharge.
5. Slip injection rings.
6. Slip injection pumps.
7. Slip injection control panels.
8. Cake piping and fittings.
9. Full port ball valves with
pneumatic actuators for the cake silo pumps.
10. Full port ball valves with
electric motor actuators for the cake pumps.
11. Pipe supports for the cake piping
and valves.
1.5 SUBMITTALS
A. The CONTRACTOR shall submit
complete shop drawings for acceptance in accordance with Shop
Drawing Submittals of the General Requirements and as specified
herein.
B. In addition to the submittal
requirements of Section 11210, Pumps, General, the following shall
be submitted:
1. Shop drawings showing complete
fabrication and construction details, materials, weights,
dimensions, clearances, anchorage locations and bolt detail, piping
and utility requirements, and step-by-step sequence of controls.
2. Pump manufacturer, type and
model, rpm at rated condition, size of suction and discharge
flanges, and maximum bhp requirement at maximum differential
pressure condition.
3. Certified Pump Curves showing
maximum and minimum speeds.
4. Shop drawings including
fabrication layout and construction details, materials, weights,
dimensions, clearances, connection locations and bolt detail, piping
and utility connections for the inlet chutes and or hoppers.
5. Shop drawings showing layout of
slip injection rings with piping, connection and support details and
catalog cuts for materials, weights, dimensions, configuration, and
installation instructions.
6. For pump control panels, complete
master wiring diagrams, elementary or control schematics,
interconnection drawings, loop drawings including required
coordination with other electrical control devices operating in
conjunction with the pumping system and acceptable outline Drawings
shall be furnished for acceptance before proceeding with
manufacture. Due to the complexity of the control functions, it is
imperative the above Drawings be clear and carefully prepared to
facilitate interconnections with other equipment. Standard
preprinted sheets or Drawings simply marked to indicate
applicability to this Contract will not be acceptable. Refer to
section 16442, Control Panels, for additional requirements.
7. Coordination letter stating that
the pump manufacturer has coordinated with the manufacturer of the
Variable Frequency Drives specified in Specification section
16418, Variable Frequency Drives below
100 hp and 16419, Variable Frequency
Drives 100 hp and Above, for complete
compatibility.
8. Bearing Life Calculations.
1.6 DELIVERY, STORAGE, AND
HANDLING
A. All materials and equipment shall
be shipped, stored, handled and installed in such a manner as not to
degrade quality, serviceability or appearance. The equipment shall
be stored in a clean, dry location free from construction dust,
precipitation and excess moisture. If stored for more than two
weeks, the equipment shall receive all maintenance considerations
required by the manufacturer for proper storage of the equipment.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the
Contract Documents, the following Manufacturers are acceptable:
1. Progressing cavity pumps for
Dewatered Cake Transfer Pumps:
a. Seepex, Model THE 300-27
2. Progressing cavity pumps for Silo
Cake Transfer Pumps:
a.
b. Seepex, Model -THE 240-24D
B. Submit request for substitution
in accordance with the General Requirements.
1. CONTRACTOR shall provide the
following additional information for substitution:
a. Five references for similar
operating installation with contact names and numbers.
b. Detailed Drawings in 3-D.
c. Ensure substitution fits within
the allocated space.
d. Substitution cannot encroach in
the open space around the cake pumps as indicated on the
construction Drawings.
2.2 MATERIALS
A. Cake Silo Transfer Pumps
(15JPMP810; 15JPMP830; 15JPMP850; 15JPMP870), and Dewatered Cake
Transfer Pumps (15MPMP580 and 15MPMP590):
1. Pump Body: Cast iron, ASTM A48
Class 35.
2. Rotor: D6 tool steel hardened to
Rockwell C57-60:
a. For abrasive service; a fissure
free non-porous coating diffusing deep into the base metal will be
provided. The coating shall be a minimum of .010 inch thickness and
1250 Vickers hardness minimum. Galvanic chrome plating in 633
Vickers hardness or 57hRc shall be acceptable if the pump
manufacturer furnished an extended warranty for the rotor for two
years after the contractors warranty for 12 month from beneficial
use of the facility expires.
3. Stator:
a. Buna-N 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 "O"
rings may not be used to form this seal. All stators must be
individually made and not cut to size. Each stator must have
elastomer cover the end of each stator tube. The stator tube shall
not be exposed to the product.
b. Joints: Each pump shall use two
flexible joints. The joints must be guaranteed for a minimum of
20,000 hours
4. Base plate: Fabricated steel.
5. Stuffing Box Gland: Ductile iron.
6. Lantern Ring: Teflon. B. Slip
Injection Rings
1. Body: Type 316 stainless steel.
C. Inlet Chutes/Hoppers: Type 304
stainless steel
2.3 EQUIPMENT
A. Performance and Configuration
Requirements:
1. Material Description:
a. Dewatered anaerobically digested
municipal sludge.
b. Maximum Sludge Density: 65
pounds/cubic foot. (1040 kg/m3). c. Minimum Sludge Density: 60
pounds/cubic foot (960 kg/m3).
d. Maximum Sludge Moisture: 75
percent. e. Minimum Sludge Moisture: 65 percent. f. Abrasive.
g. Corrosive.
h. Contains oil, grease, grit,
ferric chloride, and polymer. i. Maximum Lump Size: 1 inch
2. Dewatered Cake Transfer Pumps:
a. Tag Id’s: 15MPMP580 and
15MPMP590
b. Liquid Pumped: 25 – 35 percent
Centrifuge Dewatered Cake. c. Design conditions:
a) 130 gpm with 25 percent cake
solids. b) 120 gpm with 30 percent cake solids. c) 93 gpm with
35 percent cake solids.
d. Maximum condition:
a) 150 gpm at 400 pounds per inch
with 25 percent solids. e. Nameplate Driver hp: 200
f. Feed Mechanism: Provide
positive means of shearing cake to reduce apparent viscosity
and ensuring that cake feeds properly to pumping elements. Use one
of two methods:
1) Ribbon auger:
a) Ribbon auger attached to plate
fixed to pump drive shaft extending through oversized extension
tube.
b) Feed rate minimum of four times
rated pump capacity. c) Support with heavy duty urethane liner in
hopper.
g. Number of Stages: 8 minimum.
h. Pump Speed: 50 RPM at design
condition.
i. Pump Speed: <60 RPM at
Maximum condition.
j. Pressure per Stage: 60 pounds
per inch at maximum pressure. k. Drive Type: Variable frequency.
l. Drive Configuration: Inline
helical gear.
m. Discharge ANSI B16.5, 300 pounds;
14-inch diameter, minimum.
3. Silo Cake Transfer Pumps:
a. Tag Id’s: 15JPMP810; 15JPMP830;
15JPMP850; 15JPMP870
b. Liquid Pumped: 25-35 percent
Centrifuge Dewatered Cake Stored in the
Silo.
c. Design condition:
1) 145 gpm with 25 percent cake
solids.
2) 110 gpm with 30 percent cake
solids.
3) 85 gpm with 35 percent cake
solids. d. Maximum condition:
1) 145 gpm at 220 psig with 25
percent cake solids. e. Nameplate Driver hp: 150.
f. Feed Mechanism: Provide
positive means of shearing cake to reduce apparent viscosity
and ensuring that cake feeds properly to pumping elements. Use one
of two methods:
1) Ribbon auger:
a) Ribbon auger attached to plate
fixed to pump drive shaft extending through oversized extension
tube.
b) Feed rate minimum of four times
rated pump capacity. c) Support with heavy duty urethane liner in
hopper.
g. Number of Stages: 4 minimum.
h. Pump Speed: 50 RPM (At design
condition). i. Drive Type: Variable frequency.
j. Drive Configuration: Right angle
drive; vertical orientation.
k. Discharge ANSI B16.5, 300 pounds;
8-inch diameter, minimum.
2.4 DEWATERED CAKE AND CAKE SILO
TRANSFER PUMP ACCESSORIES A. Load cells:
1. Provide load cells and
transmitter where shown on the Drawings.
2. Provide four load cells per pump
on one controller to provide one weight signal to the control
system.
3. Load cells suitable for
installation in corrosive and humid environment.
4. Designed and installed so sensors
can be replaced without removing load cell.
5. Sealed, 316 stainless steel.
6. Fully potted in NEMA 6P enclosure
with watertight cable system.
7. Temperature range 50 – 100
degrees F.
8. Nonlinearity/Hysteresis Combined:
0.2 percent rated output.
9. Return to Zero: 0.05 percent
rated output.
10. Kistler Morse Model LD II with SVS
2000 controller, Hardy Model ADVANTAGE Series Load Point HI LPRA
with HI 4050 controller and associated junction box, Or Equal.
B. Provide run-dry protection for
each pump consisting of a temperature probe installed in the pump
stator for switching off the pump upon high temperature.
C. Boundary Layer Injection Rings:
1. Continuous annular ring to evenly
introduce fluid around inner wall of pipe.
2. Wafer style for installation
between ANSI B16.5 Class 400 flanges.
3. Provide multiple point fluid
connection, 1/2 inch NPT, minimum 2 points.
4. From connection, provide
injection rings at every 50 feet. D. Inlet Chutes (Hoppers):
1. Fabricate as indicated on the
Drawings.
2. Provide flex connection as
indicated on the Drawings.
3. Coordinate dimensions with
conveyor supplier.
4. Provide flanged nozzles as shown
for connection of rupture disk return line, as indicated on the
Drawings.
E. Electrically Actuated Slide Gate:
1. Provide AISI 316 stainless steel
frame.
2. Maximum vertical dimension of 4
inches excluding the electric motor operator.
3. Opening at least the full width
of the pump trough.
4. Stainless steel minimum thickness
is 1/4 inch and UHMW Polyethylene (PE) 3/16 inch minimum thickness.
5. The UHMW PE shall have a machined
groove to accept the gate blade and give a positive seal.
6. Actuators:
a. Electric actuators meeting the
requirements of Section 15101, Valve
Operators.
7. Control panels meeting the
requirements of Section 16442, Control Panels. F. Cake Forcemain:
1. Provide 14-inch diameter welded
steel pipe for conveying cake as shown on the
Drawings. Pipe shall be in accordance
with Section 15008, Steel Pipe.
2. For fabricated fittings, refer to
Drawings for size and location. Fittings shall be in accordance with
AWWA standards with flanged joints and a 4 feet minimum turning
radius.
G. Slip Injection Pumps:
1. Slip Injection Pumps:
a. For Dewatered Cake Transfer
Pumps:
1) Tag Id’s: 15MPMP600;
15MPMP605; 15MPMP610; 15MPMP615;
15MPMP620; 15MPMP625; 15MPMP630;
15MPMP635
2) Liquid Pumped: Water
3) Design conditions:
a) Maximum Condition: 0.5 gpm at 400
psig. b) Minimum Condition: 0.25 gpm at 400 psig.
4) Nameplate Driver hp: 1.5
b. For Silo Cake Transfer Pumps:
1) Tag Id’s: 15JPMP911;
15JPMP913; 15JPMP915; 15JPMP917;
15JPMP919; 15JPMP921; 15JPMP923;
15JPMP925; 15JPMP927;
15JPMP929; 15JPMP931; 15JPMP933;
15JPMP935; 15JPMP937;
15JPMP939; 15JPMP941
2) Liquid Pumped: Water
3) Design Conditions:
a) Maximum Condition: 0.5 gpm at 250
psig. b) Minimum Condition: 0.25 gpm at 250 psig.
4) Nameplate Driver hp: 1.5
2. Rotor and Stator: Each pump
shall be a minimum eight stage design for the dewatered cake slip
injection and four stage design for the silo cake transfer slip
injection employing a convoluted rotor operating in a similarly
convoluted stator. The convolutions shall be configured to form a
cavity between the rotor and stator, which shall progress from the
pump's inlet to discharge port with the operation of the rotor. 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 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 with clamp ring design can
be used to form this seal. Stators for
the pumps shall have EPDM elastomer. The pump rotors shall be
constructed of 316 stainless steel.
3. Rotor and Drive Train: Each
pump rotor shall be driven through a positively sealed and
lubricated pin joint. The joint shall be grease lubricated with a
high temperature (450 degrees F), PTFE filled synthetic grease,
covered with EPDM sleeve and positively sealed with hose clamps
constructed of 304 type stainless steel. The shaft under the
mechanical seal shall be constructed of 316 stainless steel.
4. Casing: NPT connections shall be
provided at both the inlet and discharge ports. Casings shall be
constructed of 316 type stainless steel. SHAFT SEALS AND
BEARINGS: Shaft shall be sealed using a single-acting mechanical
seal constructed of EPDM elastomer, carbon vs. silicon carbide
faces, and 316 stainless steel metal parts. The shaft shall be solid
through the mechanical seal area, but of a two part design which
allows the mechanical seal and all other wetted rotating parts to be
removed from the pump without disassembly of the pump or gear motor
(if required) bearings. Bearings shall be located in the motor or
gear motor as required and shall be designed to adequately withstand
all radial and thrust loads imposed by the pump at the service
conditions.
5. Motor and Drive Unit: Motor
shall be 1.5 hp, 600 to 20 rpm gear motor, meeting the requirements
of Section 16220, Electric Motors. TEFC High Efficiency, 480V 60
Hz with power cord. The controller
housing shall be NEMA 4X Type 316 stainless steel and meeting the
requirements of Section 16442, Control Panels. The control panel
shall have a main circuit breaker with external operating handle
interlocked with the door so that the door cannot be opened unless
the breakers are in the OFF positions. The main breakers shall be
pad-lockable in the OFF position. The control panel shall contain a
variable frequency drive, control power transformer and indicating
and control devices as shown on the Drawings.
H. Sludge Cake Pumping System Valves:
1. Ball Valves:
a) Valve Schedule:
(1) The following Valve Schedule
establishes the tagging convention for ball valves on the Drawings
related to the sludge cake pumping system. For valves indicated on
the Drawings that are not included in the Valve Schedule, CONTRACTOR
shall request confirmation of the tag number during the submittal
review. CONTRACTOR shall provide all valves shown on the Drawings
whether or not listed in the Valve Schedule.
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FULL
PORT BALL |
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FULL PORT
BALL |
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FULL
PORT BALL |
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FULL
PORT BALL |
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FULL
PORT BALL |
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FULL
PORT BALL |
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b) Ball Valves (6 inches and
larger):
(1) CONTRACTOR shall meet the
requirements as specified in Section
15106, Ball Valves.
2.5 FABRICATION FOR DEWATERED
CAKE TRANSFER AND SILO CAKE TRANSFER PUMPS
A. Pump Body:
1. Provide body containing two (2)
inspection ports 180 degrees apart.
2. Provide connections for seal
water, drainage, and gauge connections. B. Rotor:
1. Rotor shall have a minimum of
.010 inch thickness chromium nitride surface; Galvanic chrome
plating in 633 Vickers hardness or 57hRc shall be acceptable if the
pump manufacturer furnished an extended warranty for the rotor for
two years after the contractors warranty for 12 months from
beneficial use of the facility expires.
C. Stator:
1. Construct by bonding rubber-type
material to inside of a steel tube.
2. Minimum 65 durometer hardness
(Shore A). D. Drive Train:
1. Include crown gear-type or
Cardan-type universal joints, seals, connecting rod, driveshaft, and
shaft bearings.
2. Connect rotor drive shaft by a
connecting rod equipped with two (2) crowned gear-type or
Cardan-type factory grease/oil lubricated and positively sealed
universal joints.
a. Joint unconditionally
guaranteed by manufacturer to meet 10,000-hour operation at the
required performance conditions.
3. Use universal joints to transmit
thrust and torque while allowing the rotor to move through an
eccentric path.
4. Joint shall be positively sealed
and encased in a series 300 stainless steel cover to protect it from
tramp metal and glass.
5. Joints shall be designed to
withstand 60 pounds per inch in the suction casing.
6. Joints design shall allow for
filling of the oil so that no air pockets exist inside the
Buna-N Sleeve.
7. The pumps shall be with a
dedicated bearing frame and drive shaft that is solid and one-piece
through the (2) tapered roller bearings and sealing area up to the
concentrically rotating universal joint. Friction welded shafts are
not allowed due to the likelihood of increased shaft run-out with
high thrust loads. The gear reducer shall be sized for a minimum
service factor of 1.5, net of any factors for thermal loading
reductions.
8. Bearing ABMA L-10 Life: 50,000
hours at design operating conditions specified
9. Provide fittings for grease or
oil lubrication of bearings.
10. Stuffing box:
a. Design for either grease
lubrication or water seal.
b. Permit gland adjustment and
repacking without dismantling pump.
c. The drive shaft under the packing
shall have 0.010 inch thickness Chromium
Nitride coating for wear resistance.
E. Provide open throat suction
flange, 24 inches x 36 inches minimum.
F. Base Plate:
1. Provide common base plate for
pump, drive and motor.
2. Support discharge end of pump
body on pivoting support assembly that permits free movement of the
drive end to ensure that the load cells reflect the weight of
material
3. Pump system will provide full
restraint of axial loads imposed by the sweep elbows on the
discharge.
4. Baseplate shall be hot dipped
galvanized steel
5. All anchor bolts shall be 316
stainless steel.
PART 3 - EXECUTION
3.1 INSTALLATION
A. All materials and equipment shall
be installed in a neat, workmanlike manner.
B. All wiring of the equipment shall
be as specified under Division 16, Electrical, of these
Specifications.
C. All equipment specified
herein shall be installed in accordance with the
manufacturer's recommendations and the Drawings.
D. Where anchor bolts and other parts
to be embedded in concrete are required, such parts shall be
furnished to the site in advance of the equipment along with
templates and instructions for their installation.
E. Such installation shall be done
under Division 3, Concrete.
3.2 PAINTING
A. Shop painting and the surface
preparation is a part of the Work specified in this section and
shall be as specified in Section 09800, Protective Coatings.
Stainless steel shall not be painted.
3.3 CLEAN-UP
A. Prior to start-up and field
testing, all foreign matter shall be removed from the pumps,
interconnecting piping, and spillage of lubricants used in servicing
the equipment shall be cleaned from pumps, piping and concrete
surfaces.
3.4 LUBRICATION REQUIREMENTS
A. All lubricants required for the
first year of operation shall be provided for the system.
3.5 SPARE PARTS
A. The following spare parts shall
be provided:
1. One (1) shaft sleeve.
2. One (1) rotor.
3. One (1) stator.
4. One (1) connecting rod with
bushings.
5. One (1) set of connecting rod
joint assemblies.
3.6 MAINTENANCE OF INSTALLED
EQUIPMENT
1. Maintain the operability and
functionality of all installed equipment between the time of
installation and the commissioning period. See Specification
section 01660 for requirements.
3.7 MANUFACTURER’S FIELD
SERVICES
1. Furnish the services of authorized
technical representatives of the Manufacturer to assist/inspect the
installed equipment and to certify that the equipment has been
properly installed and is ready to operate, train OCSD personnel,
conduct pre-operational mechanical checkout of the equipment, place
equipment into operation, optimize the performances of the equipment
and perform the field performance testing.
2. Conduct multiple, separate site
visits as follows:
a. Inspection of equipment
installation – three visits
1) Cake Silos 1 and 3 (8 hours
minimum)
2) Cake Silos 2 and 4 (8 hours
minimum)
3) Thickening and Dewatering Facility
Dewatered Cake Pumps (8 hours minimum)
b. Training of OCSD personnel. See
Specification section 01820 for requirements. c. Commissioning.
See Specification section 01810 for requirements. Number of
trips and hours shall be as
required to meet all testing and commissioning
requirements, but shall not be less
than 48 hours.
3.8 PUMP TESTS
A. Pump tests shall be performed for
all equipment supplied under this section as outlined in Section
11210, Pumps and Equipment and Section 01810, Commissioning.
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