1-Specifications_-_AccuBrine_Brine_Maker_7.15.2024.pdf

CARGILL AccuBrine® BRINE MAKER EQUIPMENT

V7.15.2024

GENERAL DESCRIPTION - BRINE MAKING System Specifications

This specification covers system models:

BRINE MAKER

• 100 & 200 GPM Models

• 30 Amp Single/Three Phase

• RTF, ABS, ABS2 Truck Filling add on modules

SALT HOPPER

CARGILL ACCUBRINE® BRINE MAKING EQUIPMENT

It is the intent of this document to provide specifications for a downward flow automatic brine production system(s) where the salt acts as a filter bed as the water moves down through to sump area and filter screen. The automatic brine production system(s) shall be capable of producing up to

6,000/6100 (Model dependent) gallons of brine per hour, (based on available water pressures and volume and bulk salt quality). The brine maker when purchased with other equipment and options is capable of producing a blended product by injecting up to three additives each with a ratio between 0 and 100%. Depending on the model(s) purchased, it is capable of remotely filling trucks with brine, blend or additive liquids, and recording truck fill data via a numerical password entry system. The system is capable of flushing all waste sediment collected in the bottom of the salt tank. Complete automation of brine production without the intervention of an operator after initial system start and automatically monitor and control brine concentration during production.

A full parts and labor warranty shall be provided for the first year starting upon delivery.

1. Salt Hopper

1.1 The salt hopper shall have a minimum capacity of 5 cubic yards.

1.2 The salt hopper shall hold approximately .75 cubic yards of sediment without interfering with brine outlet.

1.3 Minimum inside dumping width shall be no less than 120” inches.

1.4 The hopper shall be constructed of 16,000 lb tensile strength fiberglass and isophthalic resin.

1.5 All inside surfaces shall be coated with a ceramic resin .050” thick.

1.6 Vessel shall have structural integral ribs to limit flex to within 1” from full to empty.

1.7 Overall thickness of fiberglass and resin in the salt tank shall be .35” thick, structural areas such as ribs, corners and floor shall have additional layers of woven fiberglass matt for an overall thickness of .50”

1.8 Sediment collection area shall have a 15 degree slope towards a 12”X 12” sump to promote debris clean out.

1.9 For ease and expediency of cleaning accumulated sediment, the system shall be capable of being cleaned with the salt hopper full of salt by a process of opening sump outlet cap. Any salt tanks that require dumping of the hopper or trap doors for clean out shall be deemed unacceptable.

1.10 There shall be a 4” stainless steel bulkhead fitting and 4" ball valve for cleanout purposes.

1.11 All Valves, bulkhead fittings, etc. 1” and larger shall be bolted manifold type fittings.

1.12 There shall be a pressure transducer connected to the PLC to manage water flow into salt tank.

These levels shall be adjustable from the HMI Interface and be adjustable to within 1 Gallon increments.

1.13 Transducer shall have an air capillary to the inside of salt hopper.

1.14 Vessel shall have 2” male cam-lock type fittings and on/off ball valves for hose connections

(fresh water, brine return, brine outlet to pump).

1.15 All metallic items shall be 304 stainless steel.

1.16 Flow meter shall protect the pump from running without liquid

1.17 A 4” valve, male cam lever and cam lever cap shall be supplied to drain the salt tank of liquid and sediment.

1.18 Salt tank shall have a stainless steel debris screen located above the sump and sediment collection area

1.19 The screen shall have 3/16” diameter perforations.

1.20 To allow for maximum flow, the debris screen shall have 60 square feet of surface area.

1.21 Debris screen shall be capable of supporting 10,000 lb of salt evenly distributed across the total area.

1.22 Screen frame shall have six 3/8” diameter stainless steel eyebolts connected to a poly sling to allow removal of the screen from the tank for cleaning or maintenance purposes.

1.23 Accubrine brine maker machine will come complete with two 100 ft rolls of 2” EPDM rubber corrugated suction hose and appropriate fittings to connect the fresh water to the brine maker skid, and the brine maker skid to the salt mixing tank. Based on the number of storage tanks or the distance between the skid and the storage tanks, additional hose may be required for proper plumbing. Consult your Accubrine Sales or Technical Representative for more information and quotation.

2. Control System

2.2 The control system shall be a continuous brine production system to be located inside a climate controlled building with above freezing temperatures.

2.2 For customer’s safety the main control panel shall be made up of two separate enclosures. The power enclosure has high voltage and is segregated from the control enclosure which has low voltage to allow the system to remain powered and safe while troubleshooting.

2.2.1 Single phase power option: The single phase power enclosure will require a customer supplied minimum 30A, 240VAC single phase electrical service with applicable junction box. Machine will be equipped with single-to-three phase variable frequency drive, receptacle, receptacle housing and plug along with disconnecting means. Customer will install Cargill supplied receptacle, receptacle housing and disconnecting means. The control panel will be equipped with 10 feet of

SOOW type cord with matching plug.

2.2.2 Three phase power option: The three phase power enclosure will require a customer supplied

30A, 208VAC three phase electrical service and junction box. Machine will be equipped with receptacle, receptacle housing, plug and disconnecting means. Customer will install Cargill supplied receptacle, receptacle housing and disconnecting means. The control panel will be equipped with 10 feet of SOOW type cord with matching plug.

2.2.3 The PLC control panel shall be powered by a 24VDC power supply and shall house all low-voltage control components.

2.3 The brine maker frame will be constructed of either 304 SS 1/8” sheet thickness or fiberglass 1-

3/4” square tubing with 3/16” wall thickness. 1-1/2” x 1-1/2” x ¼” SS angle supports the 1” thick x 1-1/2” square fiberglass grating that the components are anchored to and fitted with a

304 brushed stainless-steel covers on the front, top and sides of the unit.

2.3.1 The brine maker dimensions are 72” H x 34” W x 20” D

2.4 The Brine concentration sensor shall be equipped with an external temperature sensor for “real time” temperature compensation. It shall monitor the brine for temperature and automatically compensate brine concentration accordingly.

2.5 The brine concentration controller shall have the internal feature to be calibrated using a single point zero and saturated calibration method and setup using a 21-point concentration curve.

2.6 Brine concentration sensor shall be a toroidal type conductivity sensor and must be mounted in the supplied arrangement for it to work properly.

2.7 All brine exiting the salt tank shall pass over the brine concentration sensor that measures the conductivity of the sodium chloride brine where it is then equated to a concentration by weight.

2.8 System shall include an HMI with a color LCD touch screen display (7” diagonal 16:9 wide screen). Information on the display screen shall include, but not be limited to:

2.8.1 Login screen that can be setup up for multiple individual users at different “access” levels.

2.8.2 HMI screen will have a central “Home” screen for access to multiple functional screens depending on the model and options purchased.

2.8.3 HMI will show graphic illustration of liquid flow during brine production process.

2.8.4 The HMI has programming to allow the customer to input 20 ingredient blending recipes for the truck fill process and associate numbers with the blend.

2.8.5 For system security the HMI programming has the ability to store 99 customer truck identification PIN’s to prevent theft.

2.8.6 For system and customer security the system is designed so that the customer admin can setup and manage operator access to the system.

2.9 Pressure transducer calibration shall be performed from the HMI interface located on the face of the machine. Programming parameters shall be password protected.

2.10 The programmable logic controller (PLC) shall have a non-volatile memory with SD Flashcard back up of programming and all custom user settings.

2.11 As the brine concentration is pumped from the salt tank, the brine shall be monitored for the desired concentration. Systems requiring an operator to manually test brine concentration will be deemed unacceptable.

2.12 If the brine concentration is above the target brine concentration, the brine shall be automatically corrected via an automatic proportional dilute valve that is PID controlled to add the proper volume of fresh water to achieve the target concentration as it is being sent to the brine storage tank.

2.13 When brine is at the desired concentration the brine will automatically be diverted to pre-designated storage tank.

2.14 In the event that the concentration is below the minimum desired concentration, the system shall automatically divert brine to the salt tank for subsequent passes through the salt bed to achieve the desired concentration.

2.15 The control system shall be configured to accept a signal from a pressure transducer located in a storage tank to automatically stop brine production when tank is full, or by flowmeter when production batch is complete.

2.16 Control system shall use a flowmeter to measure total gallons of brine produced and calculate the approximate quantity of water used and salt used daily and seasonally for record keeping purposes.

2.17 The control system will allow the customer to set a customized recirculation schedule based on wall clock timing for 15 minute intervals. The pump “on” and “off” times shall be programmable to desired parameters via the HMI. This feature may only be available with certain options.

2.18 Electrical power panels shall be UL listed.

2.19 The system shall be completely self-diagnostic to include the pump, electrical valves and input signals from other electrical components.

2.20 All electric valves and sensors shall communicate with the PLC controller to confirm the current state and operation.

2.21 In the event of a component failure, the system shall automatically shut down and inform the operator of the specific failure via event driven indication.

2.22 All wetted parts shall be of manifold type polypropylene rated for 150 psi.

2.23 All cables from each electrical component housed on the brine maker will be IP69 High water pressure rate or housed in flexible seal tight and non-corrosive PVC conduit from the component to the either the power or control enclosures mounted on the brine maker support frame.

3. Mechanical Components

3.1 Pump shall be constructed of cast 304 stainless steel with a stainless steel shaft and impeller.

3.2 Electric pump motor shall be thermally protected 5 hp close-coupled pump.

3.3 Pump seals shall be constructed of carbon/ceramic faces, Viton elastomers and stainless metals.

3.4 Pump shall be rated for 100/200gpm (model dependent) @ approximately 60 ft of head

3.5 Dilute circuit shall have a 1-1/4” analog control valve for controlling brine concentration proportional to the conductivity output via PID instruction.

3.6 Pump shall be “close-coupled” connection to the motor

3.7 All fittings and valves shall be manifold type polypropylene.

3.8 Wetted components shall be kept to a minimum; all steel components shall be constructed of

304-grade stainless steel.

3.9 All fasteners shall be constructed of stainless steel.

4. RTF, ABS, ABS2 Truck Fill Add On Modules

4.1 RTF is for truck filling brine only or 1 product, ABS,.

4.2 ABS is for truck filling with 2 products in a stacking method. Such as brine and 1 additive.

4.3 ABS2 is for truck filling with 3 products in a stacking method. Such as Brine, additive 1 and additive 2.

4.4 RTF, ABS and ABS2 will utilize the level sensor in the brine tank and fill based on flow meter rate

4.5 The AccuBrine PLC shall control the RTF, ABS, and ABS2 options.

4.6 RTF, ABS and ABS2 will use AccuBrine pump and controls

4.7 All fittings and valves shall be manifold type polypropylene.

4.8 Wetted components shall be kept to a minimum; all steel components shall be constructed of

304-grade stainless steel.

4.9 All fasteners shall be constructed of stainless steel.