46 24 23 - Channel Sewage Grinders.pdf

46 24 23 – CHANNEL SEWAGE GRINDERS

Herbert, Rowland & Grubic, Inc. 46 24 23 - 1 000483.0450

SECTION 46 24 23 – CHANNEL SEWAGE GRINDERS

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes: Channel Sewage Grinders.

B. Related Requirements:

1. Section 05 50 00 – Metal Fabrications: Fasteners, brackets, and other miscellaneous metal fabrications as required by this Section.

2. Section 09 91 00 – Painting: Product and execution requirements for painting specified by this Section.

1.2 DEFINITIONS

A. FRP: Fiberglass-reinforced plastic.

B. Channel Sewage Grinder: A type of sewage grinder that uses hardened cutters to shred objects into smaller pieces, installed upstream of pumps and unit processes to protect equipment. A channel sewage grinder is installed in a wet well at the end of the influent pipe.

C. TEFC: Totally enclosed, fan cooled.

1.3 REFERENCE STANDARDS

A. American Bearing Manufacturers Association:

1. ABMA 9 - Load Ratings and Fatigue Life for Ball Bearings.

2. ABMA 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. ASTM International:

1. ASTM A536-84 – Standard Specifications for Cast Iron Castings.

2. ASTM A36 – Standard Specification for Carbon Steel Plate.

3. ASTM A48/A48M - Standard Specification for Gray Iron Castings.

4. ASTM B108/B108M - Standard Specification for Aluminum-Alloy Permanent Mold

Castings.

5. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs.

C. AISI:

1. AISI 4140 – Heat Treated Round Steel.

2. AISI 4130 – Heated Treated Alloy Steel.

D. National Electrical Manufacturers Association:

1. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum).

Herbert, Rowland & Grubic, Inc. 46 24 23 - 2 000483.0450

1.4 PREINSTALLATION MEETINGS

A. Section 01 31 19 – Project Meetings: Requirements for preinstallation meeting.

B. Convene minimum one week prior to commencing Work of this Section.

1.5 SUBMITTALS

A. Section 01 33 00 – Submittal Procedures: Requirements for submittals.

B. Product Data: Submit manufacturer information, including installation instructions, accessories, capacities and pressure differentials, power, rotational speed, electrical characteristics, and connection requirements.

C. Shop Drawings:

1. Furnish wiring diagrams.

2. Indicate size and configuration of assembly, mountings, weights, and accessory connections.

D. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.

E. Manufacturer Instructions: Submit detailed instructions on installation requirements, including storage and handling procedures.

F. Source Quality-Control Submittals: Indicate results of factory tests and inspections.

G. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections.

H. Manufacturer Reports: Certify that equipment has been installed according to manufacturer instructions.

I. Qualifications Statements:

1. Submit qualifications for manufacturer and installer.

2. Submit manufacturer's approval of installer.

1.6 CLOSEOUT SUBMITTALS

A. Section 01 77 00 – Closeout Requirements: Requirements for submittals.

B. Project Record Documents: Record actual locations of grinders.

1.7 MAINTENACE MATERIAL SUBMITTALS

A. Section 01 73 00 – Execution Requirements: Requirements for maintenance materials.

B. Spare Parts:

1. Furnish two sets of manufacturer’s recommended spare parts.

Herbert, Rowland & Grubic, Inc. 46 24 23 - 3 000483.0450

1.8 QUALITY ASSURANCE

A. Perform Work according to Northwestern Chester County Municipal Authority standards.

1.9 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' documented experience.

B. Installer: Company specializing in performing Work of this Section with minimum three years' documented experience and approved by manufacturer.

1.10 DELIVERY, STORAGE, AND HANDLING

A. Section 01 61 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products.

B. Deliver, handle and store equipment and materials in manufacturer’s packaging with tags and labels intact and legible, including application instructions.

C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage.

D. Store materials according to manufacturer instructions.

E. Protection:

1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.

2. Provide additional protection according to manufacturer instructions.

1.11 EXISTING CONDITIONS

A. Field Measurements:

1. Verify field measurements prior to fabrication.

2. Indicate field measurements on Shop Drawings.

1.12 WARRANTY

A. Section 01 78 36 – Warranty Requirements: Requirements for warranties.

B. Furnish five-year manufacturer's warranty for channel sewage grinders.

PART 2 - PRODUCTS

2.1 CHANNEL SEWAGE GRINDERS

A. Manufacturers:

1. Vogelsang USA, Ravenna, OH Model XRC136-560QD.

2. Or approved equal.

3. Substitutions: As specified in Section 01 61 00 – Product Requirements.

Herbert, Rowland & Grubic, Inc. 46 24 23 - 4 000483.0450

B. Description:

1. The sewage grinder shall be two-shaft design and be capable of continuous operation, processing wet or dry.

2. Two-shaft design shall consist of two parallel shafts equipped with monolithic cutter assemblies positioned on the shaft to form a helical pattern.

3. The two shafts shall counter-rotate with the driven shaft operating at different speed then the speed of the drive shaft.

C. Performance and Design Criteria:

1. Maximum Peak Instantaneous Flow Rate: 1,100 gpm.

2. Percent of Solids: Up to 1%.

3. Medium: Municipal Wastewater.

4. Maximum RPM: 47

5. Minimum blade width: 9.8 mm.

6. Mount style: Wall-mounted.

D. Housing:

1. Grinder gearbox housing: ASTM A48 cast iron.

2. Bottom end housing: Carbon steel bolted together to be field changeable on demand.

3. Grinder housing: 1018 mild steel, bolted together.

E. Cutting Elements:

1. Material: Monolithic assembly constructed from solid block of alloy steel.

2. Cutters shall be heat treated to produce hardness of 60-65 Rockwell C.

3. Cutters shall be nitrated for high corrosion resistance.

4. Size: nominal height of 22 inches minimum.

5. Blade thickness: .37 inches +.000/-.001

6. Cutters shall have 8 cam shaped teeth.

7. Cutter tooth height shall not be greater than 1/2inch above the root diameter of the cutter.

8. Cutter OD shall be 4.72 inches minimum.

9. Spacer shall be cut into monolithic cutter and shall have smooth outside diameter with no tooth profiles.

F. Upper End Bearings and seals:

1. Type: radial spherical roller.

2. L-10 Life: 100,000 hours under continuous operation.

3. Lubrication:

a. Oil or Grease according to manufacturer recommendations.

b. Provide sight glass for determining oil level.

4. Bearings shall be protected by a single cartridge mechanical seal.

5. Seal face materials must be a minimum of chrome oxide vs duronit, not requiring an external flush, but in a static bath of oil.

6. Mechanical seal shall be rated at 90 psi continuous duty by seal manufacturer.

7. Bearings and seals shall be housed in a replaceable cartridge that supports and aligns the bearings and seals, as well as protects the shafts and end housings.

8. Seal elements shall be independent of the stack height.

Herbert, Rowland & Grubic, Inc. 46 24 23 - 5 000483.0450

9. Seal shall meet required pressure rating regardless of cutter stack fit.

10. The seal and bearing cartridge shall provide protection against axial loading on shafts and bearings.

11. O-rings shall be made of Buna-N elastomers.

G. Lower End Bearings and seals:

1. Type: deep groove ball.

2. L-10 Life: 100,000 hours under continuous operation.

3. Lubrication:

a. Oil or Grease according to manufacturer recommendations.

b. Provide sight glass for determining oil level.

4. Bearings shall be protected by a single cartridge mechanical seal.

5. Seal face materials must be a minimum of chrome oxide vs duronit, not requiring an external flush, but in a static bath of oil.

6. Mechanical seal shall be rated at 90 psi continuous duty by seal manufacturer.

7. Bearings and seals shall be housed in a replaceable cartridge that supports and aligns the bearings and seals, as well as protects the shafts and end housings.

8. Seal elements shall be independent of the stack height.

9. Seal shall meet required pressure rating regardless of cutter stack fit.

10. The seal and bearing cartridge shall provide protection against axial loading on shafts and bearings.

11. O-rings shall be made of Buna-N elastomers.

H. Electrical Characteristics:

1. 3 hp.

2. Voltage: 460 V, three phase, 60 Hz.

3. Overcurrent Protection and short circuit protection is required

4. Motors:

a. Low speed, high-torque parallel shaft gearbox manufactured by Nord Gear or approved equal.

b. Maximum motor speed shall not exceed 1800 rpm and should provide a minimum of 10% reserve hp as evidenced by specific requirements at maximum design.

c. Motor shall be immersible, rated explosion-proof for operation in UL listed for Class I, Division I, Group D service; conform to latest NEMA, IEEE, ANSI and AFBMA standards where applicable.

d. Housing: ASTM A48, cast iron.

e. Motors supplied shall be specifically designed for inverter duty to allow for potential future variable frequency drives.

f. The gear speed reducer shall be Nord parallel shaft geared type of reducer with “Heavy Shock” load classification.

g. The drive shaft of the grinder shall be directly coupled with the reducer without use of a coupling.

5. Controls: Automatic drive motor reversal with time delay for jamming protection;

provide audible and visual alarm.

a. Controller shall be the supplier’s UL/cUL listed standard and shall provide independent control of the grinder.

Herbert, Rowland & Grubic, Inc. 46 24 23 - 6 000483.0450

6. Constant speed, inverter duty rated, explosion proof and immersible motor.

Control Panel:

a. Wall mounted.

b. Enclosure: Stainless steel.

c. NEMA Type 4x Stainless steel.

d. Doors shall have hinges and corrosion resistant latches.

e. Single-point power connection and grounding lug.

7. Controls:

a. Furnish audible and visual alarm for power failure and jamming.

b. Power Failure Protection: Automatic motor-starter reset.

c. Jamming Protection: Automatic drive motor reversal with time delay.

d. Lamps and the selector switch shall be heavy duty NEMA 4 type.

I. Finishes: Two factory-applied finish coats as specified in Section 09 91 00 - Painting.

J. Accessories:

1. Fasteners and Supports: As specified in Section 05 50 00 – Metal Fabrications.

2. Temporary, Stainless steel, rail mounted screening basket

3. Anchor Bolts and Nuts:

a. Material: Type stainless steel.

b. Comply with ASTM F593.

K. Rail mounting system and accessories as necessary to install grinder or temporary screening basket at end of pipe in wet well

2.2 SOURCE QUALITY CONTROL

A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis.

B. Provide shop inspection and testing of completed assembly.

C. Certificate of Compliance:

1. If manufacturer is approved by authorities having jurisdiction, submit certificate of compliance indicating Work performed at manufacturer's facility conforms to Contract Documents.

2. Specified shop tests are not required for Work performed by approved manufacturer.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Section 01 73 00 – Execution Requirements: Requirements for installation examination.

B. Verify that designated areas, clearances, structural requirements, piping, utility connections, and electronic signals are ready to receive equipment.

Herbert, Rowland & Grubic, Inc. 46 24 23 - 7 000483.0450

3.2 INSTALLATION

A. According to manufacturer instructions.

3.3 FIELD QUALITY CONTROL

A. Section 01 40 00 – Quality Requirements: Requirements for inspecting and testing.

B. Inspection:

1. Ensure that grinder has been installed correctly and that there is no objectionable heat or vibration.

2. Ensure that bearings are adequately lubricated.

C. Test for proper alignment.

D. Manufacturer Services: Furnish services of manufacturer's representative experienced in installation of products furnished under this Section for not less than eight (8) hours on Site for installation, inspection, startup, and field testing, and four (4) hours on site for instructing Owner's personnel in proper care and operation and maintenance of equipment.

E. Equipment Acceptance:

1. Adjust, repair, modify, or replace components failing to perform as specified and rerun tests.

2. Make final adjustments to equipment under direction of manufacturer's representative.

F. Furnish installation certificate from equipment manufacturer's representative attesting that equipment has been properly installed and is ready for startup and testing. Startup shall be performed in the presence of the Engineer and Owner.

G. Equipment shall be tested under both utility power and emergency power.

H. Contractor shall have an electrician present at startup to resolve any wiring issues.

3.4 DEMONSTRATION

A. Section 01 73 00 – Execution Requirements: Requirements for demonstration and training.

B. Demonstrate equipment startup, shutdown, routine maintenance, alarm condition responses, and emergency repair procedures to Owner's personnel.

END OF SECTION 46 24 23