Section 15122 POLYMER HIGH ENERGY MAKE-DOWN UNITS

Section 15122

POLYMER HIGH ENERGY MAKE-DOWN UNITS

PART 1 - GENERAL

1.1 THE REQUIREMENT

A. Furnish polymer blending make-down unit with progressive cavity pump, mixing chamber, motors and controls, including all integral piping, valves, fitting, pipe supports, special equipment and appurtenances in accordance with these Specifications, including all incidental work necessary to make it complete, satisfactory and ready for operation and integration with the polymer feed and dilution system. The equipment shall be modified as necessary to meet these Specifications in full. The naming of manufacturers and models does not relieve those manufacturers from meeting the specifications in full.

B. The polymer dilution and feed system shall be capable of effectively activating and fully blending with water a homogenous polymer solution ranging from 0.1 percent to 1 percent concentration of emulsion polymers with active contents up to 75 percent.

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 01820, Training of OCSD Personnel

3. Section 11005, Equipment: Basic Requirements

4. Section 11210, Pumps, General

5. Section 11309, Progressive Cavity Pumps

6. Section 15000, Piping, General

7. Section 15100, Valves, General

8. Division 16, Electrical

9. Division 17, Instrumentation and Control

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.

OSHA Occupational Safety and Health Act Standards for Safety

CBC California Building Code

1.4 CONTRACTOR SUBMITTALS

A. Submittals shall be made in accordance with the General Requirements, Supplemental General Requirements and as specified herein.

B. Product Data:

1. Submit data completely describing product, including detailed scope of supply, detailed bill of materials and annotated specification sheets of all components.

2. Submit complete data sheets with material of construction for each component of the unit including but not limited to pumps, mixers, valves, pipes and appurtenances.

C. Shop Drawings:

1. Submit detailed specifications and shop drawings for the units, including dimensions and weights.

2. Submit wiring, control schematics, and control logic diagrams for all electrical and control components furnished.

D. Provide detailed Operations and Maintenance Manuals including storage, installation start-up, operating and troubleshooting instructions. Provide safety precautions and warnings of all hazards operating equipment.

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. The polymer blending technology on this project must have a minimum track record of five (5) years and 100 installations. A list of references testifying to the system’s ability to meet the above requirements must be provided.

3. Factory Testing: Prior to shipment the system shall be inspected for quality of construction verifying all fasteners and fittings are tight, all wires are secure and connections whisker-free. The system shall be tested under pressure for a minimum of three hours at 100 pounds per inch. If leaks are found they shall be fixed and a new test shall be conducted for three hours at 100 pounds per inch until the plumbing system is verified to be leak free.

1.6 WARRANTY

A. The polymer make-down units 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.

PART 2 - PRODUCTS

2.1 GENERAL

A. The polymer blending system is a critical part of the process and must be designed to provide optimal performance and reliability under all operating conditions.

B. The high energy make-down units shall be of the dynamic mixing type provided by mixing chamber with mixing energy provided by a dedicated motor with variable input intensity for effective mixing. The dynamic mixer shall be single or multi-stage. Units with static mixing chambers shall not be acceptable.

C. Acceptable manufacturers and model, Or Equal:

1. Siemens Water Technologies, Model M series.

2. Velodyne LLC, Model VeloBlend VM series.

3. SNF Inc., FloQuip EA Series.

2.2 DESIGN CRITERIA

A. Thickening Polymer Feed System:

1. Number of Units: Two.

2. Polymer Type: Emulsion.

3. Neat Polymer Activity (percent active) Range: 30 percent to 75 percent.

4. Diluted Polymer Concentration Range: 0.25 percent to 0.5 percent.

5. Neat Polymer Feed Rate: 1.5 to 3.5 gpm.

6. Dilution Water Rate: 200 to 500 gpm.

7. Dilution Water Control Valve Type: Motor-modulated valve.

8. Dilution Water Pressure Range: 75 – 90 pounds per inch. B. Dewatering Polymer Feed System:

1. Number of Units: Two (2).

2. Polymer Type: Emulsion.

3. Neat Polymer Activity (percent active) Range: 30 percent to 75 percent.

4. Diluted Polymer Concentration Range: 0.25 percent to 0.5 percent.

5. Neat Polymer Feed Rate: 1.5 to 3.5 gpm.

6. Dilution Water Rate: 200 to 500 gpm.

7. Dilution Water Control Valve Type: Motor-modulated valve.

8. Dilution Water Pressure Range: 75 – 90 pounds per inch.

2.3 MIXING CHAMBER

A. Polymer and water shall be mixed in a chamber designed to create sufficient mixing energy. This design shall include a motor driven impeller that will create high fluid sheer. The dynamic mixer shall be single or multi-stage. The mixer connections shall be flanged or threaded. Solution shall undergo a tapered mixing intensity slope as it exits the initial sheer zone and passes through a second zone.

B. The system shall be capable of producing high, non-damaging mixing energy at all flow rates without damage to the polymer’s molecular structure. Polymer activation efficiency shall be consistent over the dilution water range.

C. Impeller shall be 316 stainless steel mechanical mixer driven by a totally enclosed non-ventilated (TENV) wash-down duty motor. Motor shall be direct-coupled to impeller shaft. Plastic or brass impellers are not acceptable.

D. The mixing impeller shall be variable to allow for variation in mixing intensity. The mixer drive shaft shall be sealed by a mechanical seal. The mechanical seal assembly shall include an automatic seal flush. The seal shall be easily accessible for replacement.

E. A drain port shall be provided in the mixing chamber to drain the polymer solution.

F. The mixing chamber shall have a maximum rated pressure of 100 pounds per inch. All holes tapped in plastic shall have helicoil inserts for increased strength. Provide an adjustable pressure relief on the mixing chamber. The valve shall have stainless steel with stainless steel, Viton and Teflon internals.

2.4 NEAT POLYMER METERING PUMP

A. Unit shall have a polymer metering pump integrally mounted on the systems skid.

1. Pump shall be progressing cavity type.

2. The metering pump shall have a range as specified under paragraph 2.2 above. The polymer feed range shall be encompassed within 20 percent to 80 percent of the pump capacity.

3. Rotor shall be 316 stainless steel. Stator shall be Viton.

4. Pump shall have a packed gland.

5. Pump shall be driven 460 VAC, 3-phase, 60 Hz. AC motors with the following:

a. Variable speed shall be provided by a VFD controller. b. Motor shall be washdown, TENV duty.

c. Motor shall be direct-coupled to a gear reducer. A right angle gear reducer may be used.

d. Maximum pump shaft speed of not more than 500 RPM. e. Pump shall be direct-coupled to gear reducer.

B. Polymer Metering Pump Accessories: Pump shall be provided with the following:

1. Calibration column with two full port PVC ball valves having Viton O-rings. The column shall be calibrated for a one minute draw-down and read in GPH and milliliters. Calibration column shall be mounted to frame with PVC isolation ball valves. Cylinder shall be constructed of clear PVC with NPT threaded connections and provided with slip cap.

2. Pressure relief valve on the discharge of the metering pump, adjustable between

25 and 150 pounds per inch. The valve shall be factory plumbed to the suction of the pump. The valve shall have a stainless steel or PVC body with stainless steel, Viton and Teflon internals. Brass pressure relief valves shall not be acceptable.

3. Pressure gauge with diaphragm isolator to monitor polymer line pressure.

4. Pressure switch with diaphragm isolator to alarm on high polymer line pressure.

5. Metering pump priming assembly including vacuum device and valve.

6. Thermal type loss of polymer flow sensor.

2.5 DILUTION WATER ASSEMBLY

A. The dilution water flow rate shall be monitored by a magnetic type flow meter having the range as specified under paragraph 2.2 above. Unions or flanges shall be provided on the flow meter to allow easy removal for maintenance.

1. Dilution Water Flow Meter:

a. The water flow meter shall be the magnetic, inductive type. The piping parameters of the flow meter shall be in accordance with the manufacture’s recommendations. The appropriate earth rings and earth bonding shall be included. The connection and tube material shall be stainless steel. The flow meter liner shall be fluorocarbon PFA. The electrodes shall be the insertion type and be stainless steel. The meter casing shall be made from an aluminum alloy. The meter display shall be the integral mount type. The overall rating of the flow meter shall be NEMA 4X. The flow meter shall have a 4-20 mA (600 ohm) output signal and a configurable alarm output contact.

b. The flow meter shall have a range as specified under paragraph 2.2 above. Unions or flanges shall be provided on the flow meter to allow easy removal for maintenance.

B. The unit shall have a linear actuated variable rate control valve to automatically proportion water flow to polymer flow for polymer/water ratio control.

C. The unit will connect with the sensor on the dilution water to alarm for low water flow and unit shut-down.

D. Provide a 3-1/2-inch stainless steel liquid filled pressure gauge with diaphragm isolator to monitor dilution water inlet pressure.

E. Pressure Reducing Valve: If needed, a suitably sized pressure reducing valve shall be supplied for installation in the dilution water line. Pressure reducing valve shall be constructed of stainless steel with Teflon diaphragm. Valve shall be of the adjustable output type to reduce incoming line pressure variations.

2.6 SOLUTION DISCHARGE ASSEMBLY

A. Unit shall be provided with the following:

1. Pressure gauge 3-1/2-inch stainless steel liquid filled pressure gauge with diaphragm isolator to monitor system discharge pressure.

2. Pressure switch with diaphragm isolator to alarm on high polymer line pressure.

2.7 SYSTEM PIPE ASSEMBLY

A. The pipe assembly shall be 316 stainless steel. Flange and threaded fittings shall be used to connect all system components. All stainless steel welds shall be passivated.

2.8 SYSTEM SKID

A. The system's frame shall be of rugged 316 stainless steel construction. No mild steel shall be used. All piping shall be rigidly supported.

B. All fabrication welds should be continuous and free from warping and distortion. All stainless steel welds shall be passivated.

2.9 CONTROLS

A. A control panel integral to the systems frame shall be provided. The enclosure shall be rated NEMA 4X and constructed of 316 stainless steel. The control panel shall consist of all digital displays, potentiometers, switches, lights, relays, and other control devices required for a complete operable system. The control panel and all components shall be industrial duty. The control panel shall be positioned such that there are no obstructions in front of the control panel per related NFPA requirements. See Divisions 16 and 17 for other controls requirements.

PART 3 - EXECUTION

3.1 SHIPPING, STORAGE AND HANDLING

A. Delivery, Storage, and Handling: Equipment shall be protected from damage during shipping and delivery. The equipment shall be shipped in a new, high quality completely enclosed weather proof wooden crate. Crate skid shall be constructed to allow fork-lifting. The crate shall include a shock sensor to warn of equipment mishandling during shipment.

B. Each box, crate or package shall be properly marked to show its contents and net weight.

C. All parts shall be properly protected so that no damage or deterioration will occur in transit or during prolonged storage at the site.

D. All openings in equipment shall be protected against entry of foreign objects.

3.2 INSTALLATION

A. Installation: The equipment shall be installed per the Contract Documents and manufacturer’s recommendations.

3.3 FIELD TESTING

A. The equipment shall be tested in the field for functional operation and integration with control system for the full range of operation parameters.

B. All start-up and testing chemicals shall be provided by the CONTRACTOR. Top off all polymer tanks after testing and start-up is completed.

3.4 IDENTIFICATION

A. Provide a name plate securely affixed to the unit with Manufacturer’s phone number, model number, and serial number.

B. The equipment shall be identified with the health, flammability and reactivity of hazardous materials as required by codes.

3.5 MAINTENANCE OF INSTALLED EQUIPMENT, GATES AND VALVES

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

01660 for requirements.

3.6 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 24 hours.