Specs_Sheet.pdf

Specs Sheet- Manure Liquid/Solid Separation System

Overview:

The Manure Liquid/Solid Separation System shall include a name brand or equal to Boerger PL200 Rotary Lobe Pump, a Boerger Macerator, and a Boerger RC40 HP liquid/solid separator.

This separation system shall all be mounted on a single skid, shall be capable of operating at a minimum capacity of 100 gallons per minute, and shall include all necessary plumbing, electrical, and control panels such that it operates as a single unit. It shall also include two 14-foot rotating conveyor belts to carry solids away from the skid.

Detailed Specifications:

Solids Separation Skid

1.00 General

a. The unit shall be a screw press for separating fibrous material from the liquid fraction as manufactured by Boerger.

b. Skid layout drawings must be submitted with proposal.

c. Two 14-foot conveyors shall be included to transport fibrous material away from separator.

d. Skid shall consist of a solid separator, rotary lobe feeding pump and macerator. It must be a robust and compact skidded design complete with electric motors, controls and all specified appurtenances.

e. The complete skid shall be delivered as one-piece. Designed to be installed via a single feed pipe, a single liquid discharge pipe, and incoming power.

f. There shall always be simple unblocked access to any wear components.

g. The equipment furnished shall be designed, constructed, and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed according to manufactures provided drawings.

h. All equipment shall be designed and built for 24-hour continuous service at any and all points within the specified range of operation, without overheating, without cavitation, and without excessive vibration or strain.

i. All working parts of the pump or screw press and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed to templates, such that parts will be interchangeable between like units and such that the OWNER may, at any time in the future, obtain replacement and repair parts for those furnished in the original machines.

j. Separator must be fed via direct feed line. No return or bypass line may be present.

k. Separator must be fed with direct positive pressure created via pump.

l. System must be closed loop. Venting of gasses prior or during separation process is not to be accepted.

m. No chemistry or additives of any form shall be required for separation process.

1.01 Motors and Controls

A. All units shall be manufactured with a gear reducers and 1800 rpm electric motors.

B. The motors shall be 3-phase, 60 Hz, 460 V with 1.15 SF and Class F Insulation.

C. All motors shall be built in accordance with latest NEMA, IEEE, ANSI and AFBMA standards where applicable.

D. Control Panel (460VAC, 3PH, 60HZ) to include

a. NEMA 4X stainless steel SS 304 enclosure. Main Control Power Disconnect for incoming power.

b. Easy Relay PLC controller

c. Control power transformer

d. Power, Stop and Fault LED Indicators

e. Emergency Stop push button.

Section 2 Screw Press Construction

1. The unit shall consist of 1 auger, 1 main dewatering filter, 1 high pressure filter and 1 rotating counter pressure plate.

2. The rotating counter plate shall retain solids to form and maintain fibrous plug. The counter plate shall be designed with blades to control the fibrous plug by stripping or shaving off the solid fraction.

3. The counter force shall be generated via a single adjustable spring tension mechanism. Units requiring pneumatic or hydraulic pressure for adjustment shall not be considered.

4. Rotating counter plate shall have adequate travel tolerances to prevent loss of fibrous plug.

5. Easy access to all wear components without removal of drive or pipe system.

6. Auger or “screw” must be fully supported via bearings located on both ends.

7. Mechanical seal to prevent loss of slurry or contamination of gearbox. Lip style seals or grease pack not to be considered.

Section 3 Boerger Rotary Lobe Feed Pump

3.00 GENERAL

A. The equipment covered by these Specifications shall be of standard units of proven ability as manufactured by reputable concerns having long experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown on the Drawings.

B. All equipment shall be designed and built for 24-hour continuous service at any and all points within the specified range of operation, without overheating, without cavitation, and without excessive vibration or strain.

C. The pumping units required under this section shall be complete. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the service to be performed. Ample room for inspection, repairs and adjustment shall be provided.

D. Stainless steel nameplates giving the name of the MANUFACTURER, the pump serial number and material code and all other pertinent data shall be attached to each pump, motor, and control panel.

E. All working parts of the pumps and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed to templates, such that parts will be interchangeable between like units and such that the OWNER may, at any time in the future, obtain replacement and repair parts for those furnished in the original machines.

F. The nameplate ratings of the motors shall not be exceeded, nor shall the design service factor be reduced when the pump is operating at any point on its characteristic curve at maximum speed.

G. Mechanical equipment, including drives and electric motors shall be supplied and installed in accordance with applicable OSHA regulations. The noise level of motors, unless otherwise noted, shall not exceed 85 dBA measured 3 meters from the unit under free field conditions while operating on utility power.

H. All lubrication fitting shall be brought to the outside of all equipment so that they are readily accessible from the outside without the necessity of removing covers, plates, housings, or guards.

I. Warranty: Rotary Lobe Pumps supplied under this section shall be warranted to be free from defects in workmanship, design and materials for a period of two (2) years from shipment. If any part of the equipment should prove to be defective during the warranty period, the MANUFACTURER at no expense to the OWNER shall replace the part.

3.01 PUMPS

A. General

a. The Rotary Lobe Pumps shall be designed to be abrasion resistant for applications in slurry treatment. The pump shall have a minimum displacement of 47.3 gal / 100 rev.

The ratio of the axial length of the lobe as compared to the lobe diameter (length/diameter) shall not exceed 1.0.

b. The pumps shall be of the positive displacement, rotary lobe type, designed to pump Dairy Slurry as manufactured by Boerger.

c. All fluid-wetted parts including the mechanical seal shall be replaceable through the quick release front cover without disassembly of coupling, drive unit or the pipe system.

d. The pumps shall be designed to temporarily run dry and to operate in either direction. Oil-quench for protection of the mechanical seal is mandatory. Seal water flush systems are not acceptable.

e. The pumps shall be constructed with an oil-filled intermediate chamber between the pump casing and the gearbox with the following functions:

1. Oil-Quench (Lubrication and cooling) of the mechanical seals

2. Visual Detection of seal failures

3. Buffer zone to the sealed timing gear

f. Oil drain of gearbox and intermediate chamber shall be easily accessible with side mounted drain screw. Oil drain under the pump is not acceptable.

g. The rotor/shaft connection shall be oil-lubricated fed by an intermediate chamber and shall not come in contact with the pumped fluid.

B. Pump Construction

a. The pump casing shall be manufactured in a single block construction (Cast iron ASTM A48 grade 40, Brinell hardness 264 Brinell). Multiple Piece Design Pump Casings held together by screw connections are not acceptable.

b. The rear of the pump casing and the front cover shall be protected with replaceable wear plates with a hardness of 550 Brinell. The front cover protection plate shall be reversible.

The pump casing shall be equipped with radial pump casing protection plates, which are less expensive and will eliminate the pump casing as a spare part for reduction of the Life Cycle Costs of the pump unit. Pump casings without radial liners are not acceptable.

c. The quick release cover shall be held in place by four eye nuts. The stationary threaded studs shall keep the front cover on the same level as the pump casing in the process of opening the pump for easy handling.

d. Rotors shall be tri-lobe screw rotor, design and shall consist of a non-sludge-wetted cast iron core entirely coated with abrasion-resistant Buna-N. Stacking of lobes is not acceptable. Rotors shall be keyed to the shaft and secured with one central screw to a cylindrical thread inside the shaft. The cast iron core of the rotor shall be equipped with a female thread to enable the removal of the rotor from the shaft with ease. Rotor/shaft designs with a cover disc and/or spring washers are not acceptable.

e. The shafts shall be non-sludge-wetted. The rotor/shaft connection shall be lubricated with quench fluid of the intermediate chamber. The shafts shall be timed in their rotation by straight cut timing gears running in a separate oil chamber, which also contains the ball and roller bearings for each shaft. Sludge wetted rotor/shaft connections are not acceptable. The shafts shall be constructed from AISI 4140 carbon steel.

f. The pumps shall be fitted with maintenance free, quenched mechanical seals with duronit seal faces. The seals shall be operating in a common oil-filled intermediate chamber (Quench for lubrication and cooling). Purge systems for the seals are not acceptable. The rotating holding bush shall be locked in a fixed radial position by a keyway that also holds the rotor in place. Seal designs that open during rotor replacement are not acceptable. No sleeves shall be necessary for the mechanical seal set up. Design of the pump shall allow removal and replacement of the seal via the front cover.

g. Bearings and timing gear shall be located in a common oil-filled cast iron gearbox, fitted with a built-in sight glass to monitor oil level. The timing gear shall maintain non-contact between the rotors. Bearing life to be designed for L-10 bearing life rating of 100,000 hours at design conditions.

h. Suction and discharge connections from galvanized steel shall be ANSI 150-lb flanges.

i. Pump and drive fitted on common base, made from galvanized steel.

Section 4 Boerger Rotorrake – Pre-Conditioner

4.00 GENERAL

A. The equipment covered by these Specifications shall be of standard units of proven ability as manufactured by reputable concerns having long experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown on the Drawings.

B. All equipment shall be designed and built for 24-hour continuous service at any and all points within the specified range of operation, without overheating and without excessive vibration or strain.

C. The macerator units required under this section shall be complete. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the service to be performed. Ample room for inspection, repairs and adjustment shall be provided.

D. Stainless steel nameplates giving the name of the MANUFACTURER, the macerator serial number and material code shall be attached to each macerator unit.

E. All working parts of the macerators and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed to templates, such that parts will be interchangeable between like units and such that the OWNER may, at any time in the future, obtain replacement and repair parts for those furnished in the original machines.

F. The nameplate ratings of the motors shall not be exceeded, nor shall the design service factor be reduced when the macerator is operating at any point on its characteristic curve at maximum speed.

G. Mechanical equipment, including drives and electric motors shall be supplied and installed in accordance with applicable OSHA regulations. The noise level of motors, unless otherwise noted, shall not exceed 85 dBA measured 3 meters from the unit under free field conditions while operating on utility power.

H. All lubrication fitting shall be brought to the outside of all equipment so that they are readily accessible from the outside without the necessity of removing covers, plates, housings, or guards.

I. Warranty: Macerators supplied under this section shall be warranted to be free from defects in workmanship: design and materials for a period of two (2) years shipment. If any part of the equipment should prove to be defective during the warranty period, the MANUFACTURER at no expense to the OWNER will replace the part.

4.01 Single Shaft Grinder

A. General

a. The unit shall be a solid grinder for chopping long fibrous materials as manufactured by Boerger. It shall be installed as tough material grinder with integrated solid separator in a robust and compact design complete with electric motor and all specified appurtenances. The casing shall be delivered as one-piece block casing to be installed on suction or pressure side. There shall always be a simple and quick access to the cutting unit and solid separator via the quick-release cover. The mechanical seal with oil quench shall be easily replaced through the front cover, without having to dismantle the pipe connections. The rotating shear knives as well as the firmly mounted counter blades have to work without touching each other, to avoid abrasion. The oil filling for initial commissioning should be part of the scope of delivery.

B. Grinder Construction

a. The casing shall be pressure-resistant, one-piece block casing made from ASTM A48-40- B gray cast iron.

b. The quick release front cover shall be painted steel, ASTM A570-36, with four ring nuts for easy access and shall be opened without removal of drive or pipe system. Grinders with the cutting assembly mounted to the cover, needing hydraulic support for opening, shall not be acceptable.

c. The unit shall consist of a hexagonal shaft, which is pushed onto the driving shaft, with 18 rotating blades on the hexagonal shaft. Nine stationary counter blades are mounted by means of locking rails. The counter blades capture solids (“rake”) and the solids are stripped off and macerated by rotating blades. The stationary blades shall also function as a bar screen to knock large, hard solids down toward the debris collector. Rotating and counter blades shall be constructed of AISI 4140 hardened steel.

d. The Rotorrake shall be fitted with a maintenance free Duronit mechanical seal quenched by an oil-filled intermediate chamber (Quench for lubrication and cooling). The intermediate chamber shall also indicate when a seal failure occurs and fluid penetrates through the seal. The geared motor shall be sealed from the intermediate chamber with a lip seal.

e. Suction and discharge connections shall be ANSI 150-pound flanges. Other flange sizes shall be available.

4.02 Helical Shaft Mounting Gear Unit

A. Each unit shall consist of a horizontally mounted macerator / hollow shaft geared motor configuration and shall be supplied complete with 1800 rpm electric motor, 3-phase, 60 Hz, 460 Volt, TEFC, 1.15 SF, Class F Insulation. Operating speed shall be approximately 250 rpm.

B. All motors shall be built in accordance with latest NEMA, IEEE, ANSI and AFBMA standards where applicable.