Section 11341 GRINDERS

Section 11341

GRINDERS

PART 1 - GENERAL

1.1 THE REQUIREMENT

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

1.2 RELATED WORK SPECIFIED ELSEWHERE

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

1. Division 01, Additional General Requirements

2. Section 01783, Operation and Maintenance Manuals

3. Section 01810, Commissioning

4. Section 01820, Training of OCSD Personnel

5. Section 05500, Miscellaneous Metalwork

6. Section 09800, Protective Coating

7. Section 11005, Equipment Basic Requirement

8. Section 11309, Progressive Cavity Pumps

9. Section 16220, Electric Motors

10. Section 16442, Control Panels

11. Section 17300, Control Strategies

12. Section 17405, Process Instrumentation and Controls

1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

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

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

1. American Bearing Manufacturers Association (ABMA):

2. American Iron and Steel Institute (AISI)

3. ASTM International (ASTM)

4. American Welding Society Publication (AWS)

5. Institute of Electrical and Electronics Engineers (IEEE)

6. National Electrical Manufacturers Association Standards

7. Occupational Safety and Health Act

8. Electrical Manufacturers Association

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

Requirements and Additional General Requirements.

1.4 CONTRACTOR SUBMITTALS

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

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

2. Grinder head loss curves.

3. Brochures and catalogue cuts.

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

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

16480, Low Voltage Motor Control.

6. Manufacturer’s list of recommended spare parts.

7. Manufacturer’s recommended field test procedures.

8. Operation and Maintenance Manuals.

1.5 QUALITY ASSURANCE A. General:

1. Comply with the requirements specified herein and the applicable reference

Specifications of the General Requirements and Additional General Requirements.

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

B. Manufacturer’s Qualifications:

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

1.6 WARRANTY

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

1.7 TOOLS

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

PART 2 - PRODUCTS

2.1 MANUFACTURER

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

2.2 GENERAL

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

B. Construction:

1. Each sludge grinder shall be of the in-line configuration with flanged-end connections of the size shown in Table 1. The flanges shall be 150 pound drilled to conform to ASME B16.1 standard. A cleanout shall be provided on the inlet side of the body. The grinder body shall be constructed of ASTM A48 gray iron top end housing, with ASTM A36 steel bottom covers, and ASTM A536-84 ductile iron side rails. The grinder shall have two counter-rotating shafts with mechanical seals, spacers, and intermeshing cutters. Grinder drive and driven shafts shall hexagonal, measuring 2-1/2 inches across the flats, and be made of AISI 4140 heat treated hexagon steel with a minimum tensile strength rating of not less than 149,000 pounds per inch, and hardened to 38-42 Rockwell C. One shaft shall not exceed a speed of 40 rpm and the other shaft shall not exceed a speed of 80 rpm. The spacers shall be constructed of AISI 8620 alloy steel, surface ground to a thickness of 0.446 inches and hardened to 34-38 Rockwell C. The cutters shall be constructed of AISI

8620 alloy steel, surface ground to a thickness of 0.438 inches and hardened to 60-

65 Rockwell C. . Cutters shall have 11 cam shaped teeth, with a tooth height not greater than 11/16 inch above the root diameter of the cutter; the OD of the cam cutter shall be 7.50 inches. . Seals shall be mechanical face-type that operate on a reverse pressure principal with a design pressure rating of 90 psig. The dynamic and

rotating seal faces shall be tungsten carbide wit 6 percent nickel binder. The radial

and axial loads shall be borne by sealed, oversized, deep-groove ball bearings. The sludge grinders shall be capable of running dry and shall not require an external water source.

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

3. All motors shall be heavy-duty, constant-speed type with a maximum speed of

1800 rpm, acceptable for a wet and corrosive Class I, Division 2, Group D hazardous

location and shall conform to the requirements shown in Table 1. Motors shall be furnished by the grinder manufacturer and shall be coordinated to the requirements of the grinders. Motors shall conform to the requirements of Section 16220, Electric Motors.

2.3 LUBRICATION

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

2.4 PROTECTIVE COATING

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

PART 3 - EXECUTION

3.1 GENERAL

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

3.2 MAINTENANCE OF INSTALLED EQUIPMENT

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

3.3 MANUFACTURER’S FIELD SERVICES

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

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

1. Inspection of equipment installation (8 hours minimum)

2. Training of OCSD Personnel: See Specification section 01820, Training of

OCSD Personnel, for requirements.

3. Commissioning: See Specification section 01810, Commissioning, for requirements. Number of hours shall be as required to meet all testing and commissioning requirements, but shall not be less than 8 hours.

3.4 FIELD TESTING

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

SEE FOLLOWING TABLE 1

TABLE 1

SPECIFIC CONDITIONS AND REQUIREMENTS GRINDERS

A. Design Conditions

Tag #	System	Location	Feed Liquid	Quantity	Minimum Inlet Diameter (in.)	Maximum Flow (gpm)	Solids Concentration (% TS)	Maximum Headloss (psig)	Minimum Speed (rpm)	Maximum Motor Size (hp)	Power Type
15LGDR080	Thickening Centrifuge Feed Pump	Centrifuge Building Basement	WAS/Primary Sludge/Trickling Filter Sludge	1	12	1600	0.5-5	3.0	1,725	10	480V, 3 PH, 60 Hz, Class I, Division 2
15LGDR083	Thickening Centrifuge Feed Pump	Centrifuge Building Basement	WAS/Primary Sludge/Trickling Filter Sludge	1	12	1600	0.5-5	3.0	1,725	10	480V, 3 PH, 60 Hz, Class I, Division 2
15LGDR086	Thickening Centrifuge Feed Pump	Centrifuge Building Basement	WAS/Primary Sludge/Trickling Filter Sludge	1	12	1600	0.5-5	3.0	1,725	10	480V, 3 PH, 60 Hz, Class I, Division 2
15MGDR010	Dewatering Centrifuge Feed Pumps	Centrifuge Building Basement	Digested Sludge	1	12	2000	2-4	3.0	1,725	10	480V, 3 PH, 60 Hz, Class I, Division 2
15MGDR020	Dewatering Centrifuge Feed Pumps	Centrifuge Building Basement	Digested Sludge	1	12	2000	2-4	3.0	1,725	10	480V, 3 PH, 60 Hz, Class I, Division 2

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

1. Gasket kit

2. Full cutter and spacer assembly