3-SLCI27036 Attachment 2 Technical Specifications.pdf

SALT LAKE CITY REQUEST FOR BID NO. SLCI27036

ATTACHMENT 2 TECHNICAL SPECIFICATIONS

LANDFILL GAS BLOWER/FLARE SYSTEM EQUIPMENT

PART 1 GENERAL

1.1. SUMMARY

A. Section includes the complete design, manufacture, supply/delivery, installation, start-up, and initial operational testing of landfill gas blower/flare system intended for Salt

Lake Valley Solid Waste Management Facility, located at 6030 W. California Ave.

(1300 S.) Salt Lake City, Utah 84104. The supporting utilities and installation of the complete manufactured blower/flare system will be performed by a separate contractor.

B. Bidder of the blower/flare system shall be responsible for design, manufacture, and delivery of the complete and operational blower/flare system from the connection with the main landfill gas header from the landfill, to the end of the flare stack.

C. All equipment, products, and installations which are a sub-component of the complete landfill gas blower/flare system shall comply with the manufacturer’s recommendations.

D. All equipment, products, and installations that will be in direct contact with the landfill gas shall be compatible with the corrosive environment of the landfill gas.

E. The complete system and resulting destruction efficiency of the landfill gas shall comply with all applicable Federal, State and Local requirements.

F. The landfill gas blower/flare system shall include the following sub-systems:

1. Gas Handling System

2. Interconnecting Piping System

3. Enclosed Combustor Flare System

4. Control System

1.2. SUBMITTALS

A. Bidder 90% design review shop drawings for review by the Salt Lake City

Engineering Division (“City”) showing all proposed design layouts, dimensions, and components for the complete blower/flare system. City shall provide comments to

Bidder based on review of the shop drawings and subsequent discussions.

B. Bidder’s final shop drawings along with installation/assembly specifications, for completion of City design of the blower/flare pad, for soliciting bids from general contractors (“Contractor”) for construction of the pad, and for installation (assembly) of the blower/flare package provided by Bidder. The final design and specification package shall be approved by City and Owner (Salt Lake County and Salt Lake City jointly) prior to manufacture and delivery.

C. Bidder shall test all equipment and accessories for conformance with the final design and specified requirements prior to final acceptance and final payment by Owner.

One (1) electronic copy of the following shall be submitted:

1. Certified Shop Drawings showing all important details of the complete system for construction, including all dimensions.

2. Descriptive literature, bulletins, and/or catalog cuts of equipment used.

3. The total weight of the equipment, including the weight of the single largest item.

4. Complete performance data that will indicate full compliance with the

Specifications; performance curves for flow and pressure/vacuum capacity;

calculations showing the equipment gas flow and motor corrections required for operation at the elevation of the job site.

5. Complete control panel diagrams and elevations showing all components, wires, connections, and numbered terminals.

6. Complete electrical interconnect diagram showing all wires and terminals between the control panels and external devices.

7. Exceptions and modifications, if any, to approved Plans, Specifications, regulatory requirements, and applicable codes and standards.

8. Certification that the equipment furnished for this project does not exceed the sound pressure specified herein.

D. One (1) complete electronic copy of the draft operation and maintenance manual shall be required four (4) weeks prior to equipment delivery. The manual shall be prepared specifically for this installation and shall include all required catalog cuts, drawings, equipment lists, descriptions, definitions, procedures, peak load requirements, operational load requirements, and all information necessary to properly and fully instruct operating and maintenance personnel regarding proper operation and maintenance of the system. Bidder shall list all components requiring routine, frequent, and infrequent maintenance. The manual shall include a list of suppliers, with phone numbers and contact information, for equipment parts that may need servicing or replacement.

E. One (1) electronic copy of the final manual shall be submitted two (2) weeks after start-up that incorporate comments and revisions from City and field personnel, and adjustments made, resulting from start-up.

F. Test Procedures which shall include a step-by-step description of proposed tests, a list of all test equipment including calibration dates, and signoff sheets demonstrating conformance of the blower/flare system with specified and regulatory requirements.

G. Bidder shall provide a complete list of recommended spare parts that frequently need maintenance and/or replacement.

H. Calibration certificates for all meters, gauges, sensors, and other equipment incorporated in the blower/flare system that requires calibration.

1.3. QUALIFICATION

A. The Landfill Gas Blower/Flare System, including all ancillary equipment, shall be designed, furnished, and manufactured by a flare manufacturer who is fully experienced, reputable, and qualified in the manufacture of the equipment for destruction of landfill gases. The equipment shall be designed and fabricated in accordance with the best practices and methods. Bidder shall provide references showing experience in the design and manufacture of this type of equipment, and have examples demonstrating successful design and operation of such systems in the U.S.

1.4. DESIGN CRITERIA

A. All equipment shall be designed for elevation, seismic, wind, and other climatic, physical, and environmental conditions local to the site.

1. Elevation: 4,230 feet above msl

2. Wind: 113 mph

3. Seismic: Seismic Zone Classification D

B. Equipment specified herein shall be a Flare System and blower skid intended to be standard equipment for use in a landfill gas handling system.

1. Contact Information: Avery Holyoak, P.E., City Project Engineer avery.holyoak@slc.gov

(801) 913 - 4946

Leon Ford, SLVSWMF Operations Manager lford@saltlakecounty.gov

(801) 381 – 8670

2. Expected deadlines for Bidder:

a. Ninety (90) percent design Submittal Schedule: six (6) weeks after bid award.

b. Final Submittal Schedule: two (2) weeks after receipt of City and Owner comments.

c. Production Schedule: 32-36 weeks after receiving approved submittal.

mailto:avery.holyoak@slc.gov mailto:lford@saltlakecounty.gov

d. Delivery Schedule: up to four (4) weeks after fabrication is complete.

e. Flare delivery is expected to be completed no later than October 2027, with earlier design, fabrication and delivery strongly preferred.

C. Landfill Gas Blowers

1. The blowers shall be designed for continuous operation in an outdoor environment and shall conform to the following:

Number required 3 blowers, (2 for full capacity with 1 matching backup)

Rated capacity ≥2,000 scfm maximum flow capacity for each blower at site elevation

Minimum capacity ≥500 scfm, but not more than 1,000 scfm, each at site elevation

Site elevation Approximately 4,230 feet above MSL

Vacuum at blower station connection to main header pipe

25-48 inches of water column at 500-

4,000 SCFM

Blower outlet pressure, inches of water column

Flame Arrester Inlet Pressure, inches of water column

As required for proper flare operation and combustion, after calculation of flame arrester head loss at 4,000

SCFM with a minimum safety factor of two (2).

As required

Landfill Gas Composition

Methane 30 - 60 percent

Carbon Dioxide 30 - 50 percent

Oxygen

Nitrogen

0 - 5 percent

5 - 25 percent

Trace gases (e.g., VOCs, H2S) 0 - 1 percent

LFG moisture content 0-100% saturated

Site elevation 4,230 feet above MSL

See Attachment 4 for lab results from Spring 2026 gas composition samples.

The blower design point shall be based on 50% methane concentration and at

100% saturated at 100°F. The blowers must be able to safely operate at the maximum of 145.4 MMBtu/hr.

Landfill gas inlet temperature

Maximum, degrees 140 F

Minimum, degrees 40 F

Motor

480V, three phase Fully enclosed fan cooled

Shaft speed

Motor speed control rpm 3,600, normal

Each blower equipped with variable frequency drives for soft start-up and variable flow operation.

Minimum motor efficiency 85%

Noise limit 85 dbA at 3 feet

1. When rated volumetric capacity is reduced to 35 percent of design, blowers under the specified inlet condition shall not surge or overload the motor.

2. Each blower equipment rating shall be based upon data previously established by tests in accordance with the ASME Power Test Code for Centrifugal Blowers.

D. Enclosed Combustor Flare System:

1. The landfill gas flare system shall be designed to operate continuously and sustain stable combustion while maintaining the operating temperature, and shall operate free of pulsation and vibration with at most 5% oxygen concentration in the landfill gas stream, without requiring any burner adjustment, at the following service conditions:

Landfill gas flow rate, scfm 1,000 to 4000

Btu heat release, MM Btu/hour About 18.2 (low) to 145.4 (high)

Inlet temperature, degrees F 40 to 140

LFG moisture content 100% saturated

Landfill Gas Composition Range:

Methane 30 - 60 percent

Carbon Dioxide 30 – 50 percent

Oxygen

Nitrogen

0 - 5 percent

5 - 25 percent

Traces gases (e.g., VOCs, H2S) 0 - 1 percent

LFG moisture content 0-100% saturated

Site elevation 4,230 feet above MSL

See Attachment A for lab results from Spring 2026 gas composition samples.

The flare design point shall be based on 50% methane concentration and at

100% saturated at 100°F. The flare must be able to safely operate at the maximum of 145.4 MMBtu/hr.

2. The landfill gas flare system shall consist of the following at minimum:

Enclosed ground flare.

(3) Belt drive blowers.

Isolation butterfly valves at the intake and outlet sides of each blower.

Pressure gauges before and after each blower.

Pressure sensor at the header connection to the blower/flare system to provide the option for vacuum control of blower speeds.

Propane supply with a spark igniter for flame ignition.

Thermocouples for flame temperature confirmation and monitoring (With the option for both automatic and manual selection).

Ultraviolet flame scanner or thermocouple for flame presence confirmation and monitoring.

Flare control panel.

Automatic re-start. (3 attempts)

Automatic notification system for failure to restart (local, visual, and remote notifications).

Pneumatically operated emergency shut-off valve (block valve).

Purge air blower motor starter.

Flow meter capable of measuring 500 scfm minimum to 4,000 scfm maximum. Flow meter shall provide the option for flow control of blower speeds.

Digital data recorder.

Paper data recorder.

Flame arrester with gauge(s) to measure pressure drop across the flame arrester.

Flare stack condensate drain.

Condensate drains at all low points in the system, including blowers.

Knockout Pot.

Canopy.

Air compressor.

Intermittent Pilot.

Capability to automatically restart following facility power outage (backup generator and automatic transfer switch is not included in the scope of this specification)

Current (up to date) PLC to monitor all operational data and provide controls over all aspects of operation.

Current (up-to-date) Internet connectivity with facility internet provider for remote monitoring, notification, and control.

3. The flare, including all parts and components, shall be designed to withstand the stresses that could occur during delivery, installation, operation, wind loads, snow loads, and seismic loads without permanent strain.

4. All vacuum and pressure requirements through the blower/flare system operation shall be part of the system design and shall provide a minimum vacuum of 25 inches of water column to a maximum vacuum of 48 inches of water column at a range of 1,000 scfm to 4,000 scfm at the connection of the main header pipe to the blower/flare station. Bidder shall determine additional pressure requirements from the header connection to the end of the flare stack (over the range of flows) for proper blower selection and system operation.

5. Bidder shall provide equipment and materials for all connections and piping within or on the flare skid and blower station. This includes but is not limited to connections and piping for gas, compressed air, condensate, and propane.

6. The landfill gas flare shall comply with all requirements of 40 CFR 62 Subpart

OOO and 40 CFR 63 Subparts AAAA. The landfill gas flare shall reduce NMOC by 98 percent weight or reduce the outlet NMOC concentration to less than 20 parts per million by volume, dry basis, as hexane at 3% oxygen or less. The landfill gas flare shall not produce visible emissions, except for no more than 5 minutes per 2 hour period.

7. The landfill gas flare shall not exceed the following emission rates: 0.06 lb./MMBtu of NOx and 0.2 lb./MMBtu of CO compliant with Approval Order

DAQE-AN113620004-26 and UAC R307-401-4(3).

8. The enclosed flare system shall sustain stable combustion at the specified flow rates (1,000-4,000 SCFM), while maintaining the operating temperature, without requiring any burner adjustment or flare modification, at the range of methane concentration specified.

1.5. APPLICABLE CODES AND STANDARDS

A. All equipment editions shall be manufactured in accordance with codes and guidelines, including but not limited to as specifically detailed herein and in accordance with applicable portions of the following (latest):

1. Local laws and ordinances.

2. State and Federal laws.

3. National Electrical Code.

4. National Electrical Manufacturers Association (NEMA).

5. Underwriters Laboratories (UL).

6. Uniform Building Code (UBC).

7. American National Standards Institute (ANSI).

8. American Society of Mechanical Engineers (ASME).

9. American Gas Association (AGA).

10. Institute of Electrical and Electronic Engineers (IEEE).

11. Instrument Society of America (ISA).

12. Industrial Risk Insurance (IRI).

13. Factory Mutual (FM).

14. National Fire Protection Agency (NFPA).

15. Environmental Protection Agency (EPA).

16. Occupational Safety and Health Administration (OSHA).

17. American Society for Testing and Materials (ASTM).

1.6. PRODUCT DELIVERY, STORAGE, AND HANDLING

A. All parts shall be properly protected so that no damage or deterioration will occur during delivery, storage, handling, or a prolonged delay from the time of shipment until installation is complete and the units and equipment are ready for operation.

B. The equipment shall be delivered on site as fully assembled as transportation will allow. Factory-assembled parts and components, that can be transported as units, shall not be dismantled for shipment unless approved by City.

C. Equipment shall be placed at Owner designated final location on the landfill property by Contractor.

D. Finished surfaces of all exposed openings shall be protected by wooden blanks, strongly built, and securely bolted thereto.

E. Each box, assembled unit, or package shall be properly marked to show its net weight in addition to its contents.

1.7. WARRANTY AND GUARANTEES

A. Bidder shall warrant the units being supplied to Owner against defects in workmanship and material for a minimum period of two (2) years from February 1, 2028, which is the date equipment is expected to be installed, operational, and accepted by Owner. In the event that the equipment fails to perform as specified, Bidder shall promptly repair or replace the defective equipment without any cost to

Owner (including handling and shipment costs). Should delivery be delayed, then the dates will be adjusted accordingly. If delivery is on schedule and Contractor delays startup beyond January 31, 2028, Owner will negotiate a resolution with Bidder.

Bidder shall provide list of warranties which apply to coatings.

1.8. SERVICE AND MAINTANENCE

A. Bidder shall provide five (5) years of blower/flare system equipment maintenance and testing. Maintenance shall be a minimum of once per year and will depend on equipment manufacturer’s standards and schedule to be performed.

PART 2 PRODUCTS

2.1. GENERAL

A. These Specifications are intended to give a general description of what is required, but do not cover all equipment or requirements for a complete and properly functioning blower/flare system. They are, however, intended to cover the furnishing, delivery, and field testing of materials, equipment, and apparatus to verify that the system is fully operational as required. Auxiliary equipment necessary for proper operation of the proposed Landfill Gas Blower/Flare System not mentioned in these

Specifications shall be furnished.

B. All equipment included shall be designed specifically for use in landfill gas service.

Bidder may propose alternative products or components, compatible with the corrosive environment of landfill gas. Proposed alternatives shall only be used as approved by City during the design phase.

C. Bidder is responsible to provide a single 24-inch connection just before the flare system knockout pot, and is responsible for detailed design and manufacture of all piping and systems thereafter until the end of the flare.

D. No previously used (except for shop testing and calibration), returned, or refurbished equipment shall be used. The equipment shall be factory-assembled to the extent possible for shipping and handling, and installation at the project site.

E. Equipment shall be designed with sufficient strength, stability, and stiffness to accommodate fabrication, shipping, handling, installation, and for its intended service.

Ample room around the blower/flare system shall be provided for inspections, repairs, general maintenance, and adjustments.

F. Bidder shall supply City with both electrical operational (normal) load and electrical peak (startup) load requirements for the future installation of a generator by

Contractor. These load requirements shall be included in the design drawings and in the operation and maintenance manual.

G. At all levels of performance of the gas system, under normal conditions for well-maintained equipment, the sound pressure shall not exceed 85 dbA. Measurement shall be made a distance of 3 feet from the outer face of the equipment. Bidder shall certify that the equipment furnished for this project does not exceed the specified sound pressure under normal conditions for well-maintained equipment. This written certification shall be submitted with the Shop Drawings.

H. Bidder shall include with the design, detailed information regarding electrical components of the system including: thermocouple types (manufacturer, model, and options), a list of all programmable logic controller hardware (manufacturer, model, memory, ports, input/output card type/size/number, racks, power supplies), uninterruptible power supply (manufacturer, model, type, rating), copy of

Programmable Logic Controller (“PLC”) program in the native format of the programming software, and control panel layout (schematics and data sheets).

I. A mounting template shall be delivered to the site with the flare. The mounting template shall correspond to the flare’s stack base bolt pattern.

J. A brass or stainless-steel nameplate shall be attached to each piece of equipment in a conspicuous place. The following information shall be plainly marked on the nameplate: name and address of the manufacturer, serial number, model number, pertinent information regarding electrical requirements, size and capacity and any other information necessary for complete identification.

K. If necessary, modifications shall be made to part manufacturer’s standard products to meet Specification and regulatory requirements for enclosed landfill gas flares. Such modifications shall be noted in Shop Drawings submittals.

2.2. GAS HANDLING SYSTEM

A. Blower and Motor:

1. Blower. The blower / motor assemblies shall be belt driven, multistage centrifugal type blowers with motors of sufficient size to drive the blowers to full design capacity at normal operation.

a. A total of three (3) blowers (2 blowers to meet capacity requirements and 1 identical blower as a backup) shall be provided and installed on the skid.

b. The blowers and motors shall be designed for, and include, variable frequency drive (VFD) control to provide the full design range of flow and vacuum to the system, and pressure through the system to the flare (500 scfm for a single blower to 4,000 scfm for two combined blowers).

c. Blower housings, impellers, and bearings shall be compatible with the corrosive nature of landfill gas and condensate generated therefrom. Factory applied protective coatings shall be provided on interior and exterior surfaces to protect the blowers and motors from landfill gases and condensate, and from atmospheric conditions. Internal surfaces shall receive ceramic, fluoropolymer, phenolic coating, or approved equal, minimum 10 mils thick to provide resistance to corrosion by landfill gas and condensate. The coating shall be applied to all parts of the blower which come in contact with the landfill gas stream. Proposed materials and linings shall be submitted for approval by City.

2. Automatic Greasers. Each blower shall be provided with automatic greasers for lubrication of all regularly greased components. A reservoir of grease shall be provided, equipped with sensors that alert the operator when the reservoir needs replacement. A suggested replacement timeline for the grease reservoir shall be included in the O&M manual.

3. Blower Housings. The blower housings shall consist of tested, airtight sections held securely between the inlet and outlet heads. City approved alternatives are acceptable.

a. No contact shall be made between the shaft rotor and the housing, other than through the bearings. Stuffing boxes shall be used as seals to ensure no leakage of gas to the atmosphere or atmospheric air into the landfill gas, and to ensure that no condensate liquids contact the bearings.

b. The inlet and outlet connections shall be drilled and tapped flange pattern per

ANSI 1316.1, 125-pound, and shall be an integral part of the heads.

4. Belt Guard. Totally enclosed, safety yellow coating.

5. Impellers. The following requirements apply:

a. Impellers shall be one piece heavy duty cast aluminum alloy, or heavy duty riveted aluminum construction with wheel type spark resistant construction or equal with a protective coating compatible with landfill gas and condensate, or stainless steel.

b. Cast aluminum impellers shall receive a coating of internal ceramic, fluoropolymer, phenolic coating, or approved equal, minimum 10 mils thick to provide resistance to corrosion by landfill gas and condensate.. The impellers shall be keyed to the shaft and held by a locknut.

c. Impellers shall be precisely machine balanced. Vibration shall not exceed 2 mils in the vertical plane measured at the blower bearing housings.

6. Diffusers. Diffuser sections which deliver landfill gas from one impeller stage to the next impeller shall be provided. The diffusing vanes shall be an integral part of the sections and shall consist of material that is compatible with the corrosive nature of landfill gas and condensate.

7. Shaft. Each shaft shall be made of high-grade metals compatible with the impeller materials, bearings, and with landfill gas and condensate. Each shaft shall also be of sufficient diameter to operate at all required design speeds.

8. Bearing Housings. Each blower shall be provided with two (2) antifriction bearings. It shall be possible to replace bearings without disconnecting piping or disassembling the blower casing. Both inlet and outlet bearings shall be designed for a minimum expected life of 10 years of continuous operation.

9. Casing Drains. Each blower stage shall be provided with a ¾-inch NPT casing drain for condensate removal, manifolded into a single manual shut-off valve.

10. Motor. Each blower shall be belt drive-coupled to a horizontal 480V, 3-phase, 60-hertz motor. The blower manufacturer shall be responsible for selecting the proper motor size to suit the equipment and performance requirements noted herein, and the site condition. The motor shall be totally enclosed fan-cooled

(TEFC) suitable for Class 1, Division 2, Group D, classified location, and UL-approved. Motor shall be rated at 105 degrees F ambient with not more than 131 degrees F rise. Bearings shall be of the antifriction type with an AFBMA L-10 life rating of not less than 25,000 hours.

11. Bases. Hot dip galvanized, epoxy-coated, or equal steel bedplates of suitable size for mounting blowers and drivers shall be furnished by the blower manufacturer. The blowers shall be carefully and properly aligned with the motors. Suitable vibration isolation pads shall be provided for each unit.

12. Expansion Joints. Expansion joints between the blower inlets and outlets and connected piping shall be flanged to match the blower flanges to the connecting piping or valves. Flexible concentric reducers appropriately sized for blower and pipe flanges may be used.

13. Valves. The following requirements apply to the various valve types:

a. Butterfly valves located at the inlet and outlet of each blower shall be bubble-tight, wafer-type with 316 stainless steel disc and stem, Acetal stem bushing, and Teflon or Viton replaceable resilient seat, or other approved material with coatings to provide equivalent compatibility with landfill gas and condensate.

Interior of valve body and valve disc, except for valve seat, shall be stainless-steel, or other approved material with landfill gas and condensate compatible coating. The valve seat ring shall be coated with a fusion bonded thermosetting epoxy coating or equal, with compatible primer. Coating shall be uniformly applied with a minimum thickness of 12 mils. The valve shall be equipped with worm gear operator, position indicator, and handwheel for operation. Valves shall be rated for full vacuum service. Bolts, nuts, and washers shall be 304 stainless steel and shall be assembled with an anti-seize compound as recommended by the blower Manufacturer. All flanged connections shall be complete with a flat ring Viton gasket.

b. Actuator valves, otherwise known as automated block valves, shall be provided to automatically seal the landfill gas collection system from releases into the atmosphere during periods of flare shutdown. The actuator valves shall consist of butterfly valves with fail-closed pneumatic actuators. The actuator valve(s) are not the underground header valves.

c. Manual operators shall be gear or lever type. Operators shall have adjustable stop limiting devices to prevent overtravel of disc. Should an adjustment of the disc be required to maintain a bubble-tight seal, this adjustment shall be made externally without removing the operator housing cover.

d. Butterfly valves shall be manufactured by Centerline, Dezurik, Apollo Valves, Valamatic, ABZ, Clow Valve Company, or approved equal.

e. Flanged check valves shall be provided on each blower outlet to prevent backflow through the blowers should blower failure occur. The body, flappers, and interior components of the valves’ shell shall be of materials and coatings compatible with landfill gas and condensate.

14. Variable Frequency Drive. Bidder shall supply a VFD for control of each blower/motor assembly. The VFDs shall be compatible with the motors and capable of controlling the blower motor by both a manually selected speed control signal and an automatically selected speed control signal provided by the flow rate or vacuum monitoring system. The operator shall be able to select a desired flow rate or vacuum at the operator interface console, and the VFD shall automatically control the blower speed to maintain the selected flow rate and/or vacuum. VFD’s shall be mounted in enclosures suitable for use in outdoor environment.

15. Blower Controls: Starters and controls shall be commonly available parts. Bidder shall provide Owner with a list of known suppliers for all parts, including parts not commonly available that are expected to need servicing or replacement. Blower controls shall be located on the gas handling system skid.

16. Spare Parts. Bidder shall provide the following spare parts:

a. Replacement grease cartridges for each automatic lubricator.

b. One (1) each vacuum and one (1) pressure gauge.

c. Two (2) shaft couplings.

d. Thermal couplers.

e. Other as recommended by Bidder for routine type maintenance and approved by City.

17. Experience:

a. Blower shall be manufactured in the United States. Blower manufacturers shall demonstrate suitable experience in the design and manufacture of this type of equipment and shall provide a list of successful installations, with references, at landfills in the U.S.

b. Acceptable Manufacturers include:

1) Gardner Denver, Inc. (Hoffman & Lamson Corporation)

2) Houston Services Industries, Inc.

3) City approved equal.

B. Moisture Separator Assembly (knock-out pot):

1. The moisture separator shall have a minimum upper flow capacity of 4,000 scfm.

At the design flow rates, temperatures and pressures, the moisture separator shall be capable of withstanding a minimum of 4.0 pounds per square inch gauge vacuum.

2. The knock-out pot shall have a minimum volume of 100 gallons while maintaining liquid removal performance at full LFG design flow. It shall be of a vertical, cylindrical design with element removal from the top. A 24-inch flanged, covered, inspection port shall be provided in the side near the bottom for manual clean out of accumulated debris. Flanges shall meet ANSI 125-pound specifications.

3. Demister Pad. The demister pad shall be made from stainless steel mesh and shall be supported on, and held down by, a high open area stainless steel grid. It shall be mounted flush against the inside of the knock-out pot and have no gaps present. The moisture separator shall be able to remove 100 percent of droplets greater than 6 micron and shall also remove particulates having a density equal to or greater than water which are greater than 6 micron in size. Routine inspection and possible cleaning, or replacement, of the demister pad shall be included in the O&M manual. Sufficient access shall provided for inspection and cleaning of the demister pad.

4. Condensate Removal. There shall be a 2-inch IPS pipe coupling in the bottom of the assembly for condensate removal.

5. Pressure Drop Monitoring. There shall be two (2) ½-inch NPT ports in the side of the assembly, one upstream and one downstream of the demister element material, with a gauge, for the purpose of monitoring pressure drop across the demister element.

6. High Level Sensor. A high condensate level sensor shall be installed through a

¾-inch penetration below the inlet pipe. Sensors shall be manufactured by

Omega, Endress+Hauser, or City approved equal.

7. Liquid Level Sight Glass. There shall be two (2) ¾-inch penetrations spaced at 8-inches apart on the side of the unit, below the inlet pipe, and a site glass furnished, for the purpose of monitoring condensate liquid levels. Sight glass shall be manufactured by Schott Duran, Kenco or City approved equal.

8. The moisture separator assembly shall be manufactured in the United States.

Manufacturers shall have experience in the design and manufacture of this type of equipment, and shall provide documentation verifying successful installations on similar landfill gas installations in the U.S.

9. The moisture separator assembly shall be located, installed, and pre-plumbed on the gas handling system skid.

C. Fasteners. Bolts, nuts, and washers shall be stainless steel or City approved equal.

D. All condensate removed in the blower/flare station system (blowers, knock-out pot, all low points, etc.) shall be directed to a vacuum tight condensate sump equipped with an automatic pneumatic pump. The pump will operate from the compressed air-line and will discharge to the condensate line that extends to the landfill.

2.3. INTERCONNECTING PIPING SYSTEM

A. Butterfly Valves:

1. All valve shafts shall be connected to operators by use of keys and keyways. The use of compression or friction connection will not be accepted.

2. The butterfly valves, for low-pressure/vacuum landfill gas services, shall have cast-iron wafer-style valve body with contoured 316 stainless steel disc

3. Valves shall include type 316 stainless steel stem, Acetal stem bushing, and

Viton replaceable resilient seat, or City approved equal. Valves shall be bubble-tight at 150 pounds per square inch differential pressure and shall be suitable for installation between ANSI 125-pound flanges.

4. All butterfly valves shall open left or counterclockwise when viewed from the stem. Manual valve operators shall be worm gear. Valves installed greater than 6 feet in height from the ground or skid platform shall be provided with chain wheel operators. All operators shall have adjustable mechanical stop limiting devices to prevent overtravel of disc. Should an adjustment of the disc be required to maintain a bubble-tight seal, this adjustment shall be made externally without removing the operator housing cover. The operator shall be designed such that adjustments can be made under pressure and without the possibility of dirt getting into the operator lubricant. Adjustments through the lower shaft will not be acceptable. Operator components shall, at the extreme operator positions, withstand without damage a pull of 200 lb. for handwheel or a torque of 300 ft-lb for operating nuts.

5. Interior of valve body and valve disc except for valve seat and stainless-steel valve seat ring shall be coated with a fusion bonded, thermosetting epoxy coating or equal, with compatible primer. Coating shall be holiday-free with a minimum thickness of 12 mils. Surfaces shall be clean, dry, and free from rust and grease before coating.

6. All butterfly valves shall be manufactured by Centerline, Dezurik, Apollo Valves, Valamatic, ABZ, Clow Valve Company, or approved equal. Replacement parts and valves shall be commonly available.

7. All exterior surfaces of butterfly valves shall be clean, dry and free from rust and grease before coating. The exterior ferrous parts of all valves shall be 12 mils minimum dry film thickness of fusion bonded thermo-setting epoxy coating or equal. The color of the coating shall correspond with the color of other components of the skid and shall be approved by Owner. Coating shall be reapplied per the manufacturer’s recommendation to any surface damaged during installation or transport.

B. Gas Handling Piping:

1. Piping on the gas handling system skid shall be ASTM A-249 304L/316L stainless steel, HDPE DR11, or City approved equal. Stainless steel piping, if any, shall be primed and painted, color to correspond with other components on the skid and shall be approved by Owner. Stainless steel flanges, if any, shall be painted cast iron or galvanized steel conforming to ANSI 125-pound specifications, or City approved equal. HDPE flanges shall include HDPE flange adapters with stainless steel backup rings. The same specification applies to stainless steel tees, elbows, wyes, flanges, and other pipe fittings. HDPE fittings shall be used with HDPE pipe.

2. Inlet pipe flow capacity of at least 4,000 scfm.

3. Stainless steel flanges, and stainless steel (and other metals) to HDPE transition flanges shall include gaskets. The gaskets shall be full-face rubber or equal, 1/16 inch to 1/8 inch in thickness, and shall meet the requirements of ANSI

Specification A21.11.

4. HDPE flanges shall be designed and fabricated to not require gaskets.

5. As specified or as required, pipes and fittings shall be drilled and tapped to receive drainage or other piping or plugs. All holes shall be drilled at right angles to the axis of pipes and fittings. Any localized low point shall have a condensate drain port capable of tying into the common line for easy connection by others.

6. Piping and fittings shall be supported to prevent any strain being transmitted between sections and connected equipment and appurtenances. Release of any joint shall result in no transverse piping movement and shall allow easy removal and replacement of any piping component. Flanged flexible fittings shall be used where necessary for easy removal and replacement of components.

7. Sampling Ports. Gas and pressure sampling ports shall be ¼-inch barbed fittings with rubber dust caps to match the monitoring ports on the wellheads. Parts shall be commonly available. Sampling ports shall be installed in the following locations:

a. Upstream and downstream of the flame arrestor.

b. Upstream and downstream of the moisture separator at the knock-out pot.

c. Inlet and outlet pipe of the knock-out pot.

d. Inlet pipe to blower.

e. Outlet pipe from blower.

f. Upstream of the mass flow meter.

g. At least one of the previously described sampling ports shall be located in a straight reach of pipe which is:

1) after the moisture separator at the knock-out pot,

2) at an accessible location between the blower system and the flame arrester,

3) located at 8 or more pipe diameters downstream from the nearest upstream flow disturbance and at 2 or more pipe diameters upstream from the nearest downstream flow disturbance.

C. Drain Line Piping:

1. The blower drain lines shall tie into a common line for easy connection by others.

D. Fasteners. Bolts, nuts, and washers shall be stainless steel or equal.

E. Bidder shall assume the length of piping from the last blower to the flare is 45ft. This pipe length may be shortened during the design depending on the location of gauges, meters, and other fittings.

F. Bidder will provide a single 24-inch connection to landfill gas piping just before the flare system knockout pot.

2.4. ENCLOSED COMBUSTOR FLARE SYSTEM

A. The landfill gas flare system shall be a unitized, modular system including all components for a complete and operational system.

B. The landfill gas flare system shall be pre-piped and pre-wired to the extent possible, requiring minimal field assembly.

C. The landfill gas flare system shall include, but not be limited to, the following components:

1. Automatic Shut-Off Valve. The valve shall open when prompted by the flare control panel and be closed by loss of electrical power, flame failure, or blower failure. It shall be a pneumatically operated butterfly valve, bubble-tight, wafer-style, equipped with a stainless-steel disk and Viton seat, or equal. The interior of the body shall receive a fusion bonded thermosetting epoxy coating or equal, with compatible primer, 12 mil dft. The operator shall have a manual override and be equipped as a spring fail close device. It shall close when directed in less than

5 seconds. The compressed gas necessary to operate the valve shall be supplied by an air compressor.

2. Flame Arrester. The following requirements apply:

a. Flame arrester shall have 125-pound ANSI flanged connections and shall be drain plug equipped.

b. The inlet/outlet housing construction shall be stainless steel or CITY approved equal. The bank assembly shall be stainless steel or equal and shall be arranged for easy removal from the housing to facilitate inspection and cleaning. The piping and inlet/outlet arrestor housing shall be fully supported when arrestor element is removed. The net free area through the bank assembly shall not be less than four (4) times that of the corresponding size pipe.

c. A second, spare bank assembly shall be provided as a backup to the one installed.

d. Maximum head loss through the flame arrester shall be calculated by Bidder with a safety factor of two (2) at 4,000 scfm.

e. The flame arrestor assembly shall be equipped with inlet and outlet differential pressure gauge.

3. Flare Stack. The following requirements apply:

a. The flare stack shall be constructed from carbon steel, or equal, and shall be sufficient length to provide an overall flare system height of approximately 40-

50 feet. Flare construction shall consist of welds conforming to AWS D1.1 standards.

b. The internal portion of the stack requires insulation with a 2200 °F temperature rating minimum. Sufficient insulation shall be installed to ensure the outer skin of the flare shall not exceed 250 °F. Bidder shall consider potential for up to 5% thermal shrinkage.

c. The stack shall contain a burner manifold with ANSI 150-lb, flat-faced flanged inlet connection, and individual flanged burner connections, allowing proper gas distribution.

d. The stack shall contain an insulated burner floor with burner passages. This floor shall be designed to reduce radiation exposure to the burners, burner manifold, and dampers.

e. The flare stack shall be furnished primed and finished by Bidder. All exterior surfaces, including mounting and mating surfaces, shall be primed and finished. Surface preparation and primer application shall be in strict accordance with the more stringent of the written instructions of the primer

Manufacturer and the following:

1) Round all edges and prominences to duplicate, to the greatest extent feasible, a wheelbrator finished flat plate product. Remove all weld spatter prior to sandblasting. Sandblast all surfaces to be primed in strict accordance with SSPC- SP-6 Near-White Blast Cleaning. Apply primer as soon as feasible, but in no case more than 24 hours after sandblasting.

2) Exterior finish application includes one (1) prime/one (1) finish. Prime application shall be inorganic zinc rich primer coating system, 4-mils DFT, for superior corrosion protection at shell temperatures to 750°F. Finish coats shall be silver, coated 1 to 2-mils DFT to provide enhanced finish with protection up to 750°F. Furnish 1 gallon of finish coat for field touch up.

3) Finish shall be capable of withstanding peak flare surface temperatures under the conditions stated in this Section without blistering, cracking, discoloring, or otherwise degrading for a minimum period of 5 years.

Rated for anticipated high temperatures.

f. Two (2) 4-inch diameter FNPT sample ports and plugs, minimum, shall be located 90 degrees apart and one-half stack diameter from the stack top for emissions testing. Each of the 4-inch diameter plugs shall be insulated with ceramic fiber refractory.

g. A view port, at least 4-inches in diameter, shall be provided and positioned for convenient inspection of the pilot and the flame from at least one (1) burner tip. Two (2) view ports shall be provided if it is not feasible to provide a view of the pilot and burner tip using one (1) viewport. For view ports higher than

5-feet above grade, Bidder shall provide a step or rung welded to the flare for access to the view port(s). Bidder shall provide appropriate hand-holds or rails if a step or rung is provided.

h. Quench air dampers shall be heavy duty, multi-opposed-interlocking blade, low leakage manual dampers. Full-closed leakage rate shall be 7.5% or less of the full open flow rate at the same differential pressure. Design shall allow for removal of blades for access to the flare interior. Frame, blades, and seals shall be suitable for at least 400°F operating temperature. Nonmetallic seals shall not be allowed. Operator handles shall be indexed, lever-type handles.

Provide 1-inch by 1-inch stainless steel mesh bird screen. Actuator for the automatic damper shall be electrical type with a position modulating motor and a NEMA enclosure rated for outdoor installations. A connection for the purge air blower shall be supplied on the stack.

i. At least three (3) Type K thermocouple probes spaced evenly throughout the stack. One connection shall be located in the lower one-third of the stack for installing the high temperature thermocouple. Thermocouples shall be affixed to the stack in wells designed to house and protect the thermocouple probes.

Conduit mounting brackets affixed to the stack for conduit routing to the thermocouples shall be provided. The probes shall be equipped with a continuous recorder and have a minimum accuracy of ±1 percent of the temperature being measured expressed in degrees Celsius, or ±0.5 degrees

Celsius, whichever is greater. The device must be able to record at least one

(1) measurement per 15 minutes, and the rate of measurement shall be adjustable.

j. A stainless steel rain guard shall be provided at the stack top, covering the exposed edge of refractory, to prevent water damage. This rain guard shall consist of overlapping segments and not a continuous ring, to minimize thermal expansion effects.

k. The flare base and pedestal shall be designed to secure the stack firmly on the concrete pad with bolt holes and anchor bolts.

l. Permanently attached, two (2) trunnion-type lifting lugs located 180 degrees apart at or near the flare top for use during installation.

m. At minimum, the following components shall be mounted or installed to the flare stack:

1) One (1) weatherproof (NEMA 4X) ignition panel with a transformer sized to provide appropriate spark voltage for intermittent pilot ignition.

2) One (1) self-checking ultraviolet flame scanner to monitor both the pilot flame and presence of the main flame.

3) One (1) purge air blower sized for the flare model provided.

4) One (1) pressure switch to verify purge air flow.

n. Yellow signs meeting OSHA standards stating “CAUTION: HOT” (or equivalent) to be placed every 120 degrees around the stack at approximately 6 feet in elevation.

4. Antiflashback Burner. The burner unit, within 12 inches of the burner flame zone, shall be constructed of 304 stainless steel or equal. The burner unit shall be antiflashback type, with an internal stainless steel flame arresting seal, a stainless steel diverter plate, and no adjustable or moving parts. All burners shall be individually flanged for easy removal through the damper opening. The burner unit shall be designed such that the full range of flow rates, as specified herein, shall combust without causing either flame yellowing, flame lift-off, or flashback, and shall perform according to the destruction and reduction efficiency requirements listed in this specification.

5. Propane Pilot System. The propane pilot system shall be assembled to the greatest extent possible prior to delivery. Bidder shall include any necessary transformers, igniters, and other electrical components mounted in appropriately rated electrical enclosures. Pipe shall be plain black steel per ASTM A53 or City approved equal. The externally removable pilot assembly shall include pressure regulator, pressure indicator, fail-closed shutdown valve, solenoid valve, strainer, manual shutoff valve and pilot gas pressure manometer port. Bidder shall provide one (1) horizontal L.P. tank sized for 6 months of operation without refill and equipped with fuel gauges and regulators arranged to provide warnings or indicators for the need to refill the tank, so system operation is not interrupted.

The pilot shall be capable of firing on the propane from the designated propane tank at 3 to 15 psig.

6. Electronic Spark Ignition. An electronic igniter assembly, removable from outside the flare without disconnecting conduit or wiring shall be provided. Igniter assembly shall be commonly available parts and a spare shall be provided.

Bidder shall provide a list of parts not commonly available including known suppliers.

7. Flare Mounting System. This system shall be manufactured of ASTM A36 carbon steel members or equal, which shall be welded to the structure using AWS D1.1 methods. Flare mounting shall provide anchorage to a concrete foundation, constructed by others, to prevent overturning and provide resistance against seismic forces “Seismic Site Classification D” and minimum 113 MPH wind forces. Bidder shall provide to City, licensed Professional Engineer sealed design calculations and drawings for the flare mounting system and anchorage.

8. Finish. The base of the flare stack shall be sand-blast prepared and primed.

Sand blasting shall be to SP-6 guidelines. Prime application shall be inorganic zinc rich primer coating system, 4-mils DFT. Finish coats shall be silver, coated 1 to 2-mils DFT. Acceptable coating supplies include Ameron Protective Coatings, DuPont Chemical Company, Glidden Company, Koppers Company, or City approved equal.

9. Fasteners. Bolts, nuts, and washers shall be stainless steel, hot-dipped galvanized, or equal.

10. Condensate Drains. Flare stack and flame arrester shall be equipped with drain ports for easy connection by others.

2.5. CONTROL SYSTEM

A. The control system shall be designed and manufactured as an outdoor system. A weather/heat shield (including but not limited to canopy) shall be provided to protect the control panel against radiated heat (solar and/or flare) and rain or snow.

B. Bidder shall provide all materials and equipment, and shall fabricate and pre-wire the

Control Panels complete. Bidder shall be responsible for providing all instrumentation integral to the construction of the panels and other instrumentation for the system.

The Blower Control Panel and Flare Control Panel can be provided either as a common panel or as separate but integrated panels. Bidder shall provide all labor, materials, and equipment to shop test the entire blower/flare station system with control panels connected before delivery to the site.

C. Control panel. The control panel for the landfill gas blower/flare system shall be compliant with NEMA 4X specifications at a minimum. The main control panel shall be sized to accommodate the required controls and shall be provided with a swing out panel, and with a NEMA 4X compliant window in the door through which status annunciators, recorder, controller, etc. may be viewed. The panel shall include, but not be limited to, the following components:

1. Electrical connections and controls for 3 motors, outlets, fixtures, controls, and devices, etc., included with the system. The panels shall be pre-wired to receive incoming power from the electrical service equipment, and with suitable junction boxes for all outgoing conduit and cables to equipment.

2. A control center shall receive all the signals from the…