46 31 24 - Spiral Screen Screening Equipment.pdf

46 31 24 - SPIRAL SCREEN SCREENING EQUIPMENT

Herbert, Rowland & Grubic, Inc. 46 31 24 - 1 005153.0436

SECTION 46 31 24 - SPIRAL SCREEN SCREENING EQUIPMENT

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes General, Products (Manufacturers, Spiral Screen and Motor Controller), Execution.

1.2 REFERENCE STANDARDS

A. Equipment shall, as applicable, meet the requirements of the following industry standards.

B. ASTM International (ASTM):

1. ASTM A36 - Carbon Steel Plate.

2. ASTM A536 - Ductile Iron Castings.

3. ASTM A48 - Gray Iron Castings.

4. ASTM A564 Grade 630 condition H1150 (17-4) stainless steel.

C. American Iron and Steel Institute (AISI):

1. AISI Type 1020 Steel.

2. AISI Type 1045 Steel.

3. AISI Type 4130 - Heat Treated Alloy Steel.

4. AISI Type 4140 Heat Treated Alloy Steel.

5. AISI Type 18-8 Stainless Steel.

6. AISI Type 303 Stainless Steel.

7. AISI Type 304 and 304L Stainless Steel.

8. AISI Type 316 and 316L Stainless Steel.

D. Society of Automotive Engineers (SAE):

1. SAE Type 660 Bearing Bronze.

E. Society of Protective Coatings (SSPC):

1. SSPC-SP 1 Solvent Cleaning.

2. SSPC-SP 6 Commercial Blast Cleaning.

F. National Electrical Manufacturer’s Association (NEMA) Standards.

G. National Electrical Code (NEC).

H. Underwriters Laboratory (UL and cUL).

I. International Electrotechnical Commission (IEC).

1.3 QUALITY ASSURANCE

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A. Qualifications:

1. Manufacturer is documented as being engaged in the sale of similar products for over fifty-years.

2. Manufacturer is single supplier for equipment listed in this section.

3. Manufacturer’s Service Center is located domestically for repairs and upgrades.

4. Manufacturer stocks all non-custom spare Parts.

B. Regulatory Requirements:

1. Manufacturer is U.L. listed for the construction of controller.

C. Certifications:

1. Manufacturer’s management system is ISO9001 certified.

1.4 SUBMITTALS

A. Submittal documentation provided for approval in “.pdf” format.

1. Product Data:

a. Product description text.

b. Performance curves or capacity tables.

c. Catalog data (Motor).

2. Drawings:

a. Product configuration and general arrangement of installation.

b. Main assembly and sub-assemblies.

c. Controller front panel layout and schematic.

1.5 OPERATION & MAINTENANCE MANUALS

A. Operation & Maintenance Manuals supplied as printed hard copy and in electronic “.pdf” format:

1. Sections:

a. Introduction.

b. Safety and Intended Use.

c. Receiving & Storage.

d. Installation.

e. Operation.

f. Maintenance.

g. Troubleshooting.

2. Drawings:

a. General arrangement of installation.

b. Main Assembly and Sub-Assemblies.

c. Electrical schematic.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Packaging, Shipping, Handling, and Unloading:

1. Packaged in containers or on skids suitable for normal shipping, handling, and storage.

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2. Protected from rain, snow, impact, and abrasion while in the possession of the carrier.

B. Acceptance at Site:

1. Contractor reviews the contents of the shipment at time of delivery and promptly notify the carrier and supplier of any discrepancies.

C. Storage and Protection:

1. Equipment to remain in the packaging provided by the supplier until it is installed.

2. Equipment to be stored in a dry environment between 40 and 100 degrees F.

D. Waste Management and Disposal:

1. Contractor responsible for discarding all packaging materials in an environmentally friendly manner and in accordance with local regulations.

1.7 WARRANTY

A. 12-month Limited Warranty:

1. Manufacturer submits a standard twelve-month limited warranty document clearly identifying the scope, terms, and exclusions from the coverage.

1.8 SERVICE

A. Supplier supports product with multiple programs options available:

1. Renew Program: Provides new factory-built replacements of selected products without requirement to return existing products.

2. Repairs and Upgrades: Provides factory inspection and replacement or upgrade of required parts.

3. Preventative Maintenance Program: Provides inspection, recommendation, and service of equipment by manufacturer’s technicians.

4. Spare Parts: Providing shipment of factory authorized parts.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. JWC Environmental Inc, 2850 S. Red Hill Ave. Suite 125, Santa Ana, CA 92705; Tel: 800- 331-2277; www.jwce.com:

B. Lakeside Equipment Corporation, 1022 E. Devon Ave., P.O. Box 8448, Bartlett, IL 60103, Tel: 630-837-5640.

C. Or Approved Equal.

2.2 SPIRAL SCREEN

A. Basis of Design: Model# ALT1835-200:

http://www.jwce.com/

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1. Manufactured and supplied by JWC Environmental Inc.

2. Spiral Diameter (screen section): 170mm (6-11/16-inch).

3. Spiral Diameter (transport section): 170mm (6-11/16-inch).

4. Inclination angle of Spiral Screen: 35-degrees.

5. Maximum Design Flow Capacity: 1,265 GPM (1.8 MGD).

B. Perforated Screen Trough and Wash Water Manifold:

1. Perforated Screen Trough:

a. Perforations: Nominal 2mm (5/64-inch diameter with 23% open area.)

b. Baffles mounted on both sides of trough with replaceable ¼-inch Buna-N channel seals.

c. Base plate sits flat on channel floor to position trough at 35-degree inclination.

d. Flange contains 1-inch diameter lifting hole.

2. Wash Water Manifold:

a. Spray nozzles provide flat spray and are rated to provide 1.5 GPM at 40 psi.

b. Manifold maximum water usage 4.5 GPM at 40 psi.

c. Manifold mounts to screen basket flange and can be removed for maintenance.

d. ¾-inch hose barb for attachment of water line from water control assembly.

3. Material: AISI 304L stainless steel.

C. Spiral and Brush:

1. Spiral:

a. Material: AISI 304L stainless-steel.

b. Screen section of brush includes brush mounting groove on its outside diameter to prevent catch or collection points for material. Spiral using face mounted brush shall not be allowed.

c. Knurled cup set screws used to secure brush into mounting groove.

d. Transport section of spiral with minimum outside bar thickness of 5/8-inch.

e. Drive shaft with material deflection paddles.

2. Brush configuration:

a. Two Section Segmented and Helical:

1) Segmented lower section with individual 180° brush segments and upper section with helical spiral brush. Segmented lower design allows for individual replacement of 180° brush segments.

2) Diameters specifically designed for proper fit into spiral’s mounting groove.

3) Nylon bristles secured in stainless steel backing with tie rod and epoxy fill.

D. Transport Segments

1. Casing:

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a. Cylindrical construction with flanged ends with 8-bolt pattern.

b. 2-inch NPT inspection ports.

c. Casing Material: AISI 304L stainless steel.

2. Wear Bars:

a. Wear bars 1-inch wide with minimum ½-inch thickness.

b. Wear bar material: 17-4 stainless steel with minimum hardness of 33 HRc.

E. Press Zone:

1. Screen Insert-Perforated:

a. 5mm diameter holes on 1-inch straight pattern.

b. Keyed into position and replaceable.

2. Casing:

a. 2-inch female NPT drain port.

b. Bolted cover for maintenance.

3. Spray Water Manifold:

a. ½-inch schedule 40 pipe.

b. Spray nozzles provide cone spray and are rated to provide 0.3 GPM at 40 psi.

c. Manifold maximum water usage 1.8 GPM at 40 psi.

4. Insert, Casing, and Spray Water Manifold Material: AISI 304 stainless steel.

F. Discharge

1. Casing:

a. Cylindrical construction with flanged ends with 8-bolt pattern.

b. Full diameter bottom opening configured for vertical discharge of material.

c. Inspection cover located over discharge outlet.

d. Casing Material: AISI 304L stainless steel.

2. Wear Bars:

a. Wear a bars 1-inch wide with minimum ½-inch thickness.

b. Wear bar material: 17-4 stainless steel with minimum hardness of 33 HRc.

G. Discharge Bagging Assembly

1. Adapter:

a. Mounts to discharge opening of Discharge Casing and mounts Cassette Bag Holder.

b. Material: AISI 304L stainless steel.

2. Cassette Bag Holder:

a. Three (3) piece assembly with flanged discharge cylinder for connection to adapter, continuous bag flare and clamp.

b. Material ABS plastic.

c. AISI 316 stainless steel ring clamp with retaining spring.

3. Continuous Bag:

a. Cassette bag 230 ft. long continuous non-porous three-ply, co-extruded polyethylene with a thickness not to exceed 1.8 mils.

H. Motor:

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1. 2 HP TEFC Motor:

a. Motor Service Factor: 1.15.

b. 3-Phase, 208VAC.

I. Speed Reducer:

1. Helical parallel shaft gear design.

2. 155.4:1 reduction ratio.

J. Pivot Assembly:

1. Pivot clamps to transport casing in manufacturer specified position to allow weight of spiral screw screen to hold the system within the channel by gravity.

Pivot uses tube in tube design to allow spiral screen to be removed from pivot without any disassembly of fasteners.

2. Mounting flanges with holes for anchoring.

3. Material: AISI 304L stainless steel.

K. Identification:

1. Corrosion resistant nameplate affixed to top cover of Spiral Screen.

2. Nameplate Information: Manufacturer’s name and address, Model No., Serial

No., Capacity, Max. psi, Weight, Manuf. Date.

L. Finishes:

1. Tnemec 1095 Polyurethane paint in the color Hunter Green.

2. Paint Coatings for Previously Coated Components (Motors, Speed Reducers, etc.):

Prepared to SSPC-SP1 (Solvent Cleaning).

3. Paint Coatings for Ferrous Materials: Prepared to SSPC-SP6 (Commercial blast

Cleaning) and coated with a minimum 3 to 5 mils TDFT (total dry film thickness).

4. Passivation for welded Stainless-Steel Components: (Casings) Clean stainless steel and full dip passivate to ASTM A967.

5. Electropolish for Perforated Components (Screen Trough): Electropolish to ASTM

B912.

M. Level Sensors Configuration:

1. Differential (Upstream & Downstream):

a. Uses two (2) level sensors to measure upstream water level and downstream water level and a percent differential to operate system.

b. Measuring principal: Radar.

c. Measuring Range: 66 feet.

d. Ingress protection: IP68/ NEMA 6P.

e. Output signal: 4 to 20Ma.

f. Mounting bracket with threaded connection for Level Sensor and flange for mounting to wall of channel.

g. Mounting bracket material will be AISI 304L stainless steel, clean welds and spot passivated to ASTM A380.

N. Water Control Assembly:

1. Mounting Bracket:

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a. Bracket supports assembly allows mounting.

b. Housing Material: AISI 304 stainless steel.

2. Basket Strainer:

a. Size 20 wire mesh screen.

3. Y-Strainer:

a. Size 80-100 wire mesh screen.

4. Solenoid Valve:

a. 120-volt AC coil, explosion proof.

5. Ball Valve:

a. Manual operation.

6. Material & Finishes:

a. Passivation for welded Stainless-Steel Components (Mounting Bracket):

Clean stainless-steel welds and spot passivate to ASTM A380.

b. Housing and Valve Body Material: Bronze and AISI 304 Stainless steel.

O. Weather Protection:

1. The Weather Protection System shall inhibit freezing of the conveyor contents.

The heat-tracing shall be automatically energized when the ambient temperature is equal to or less than 40°F (4.5°C) and will be automatically de-energized when the ambient temperature is greater than 40°F (4.5°C).

2. The auger transport and discharge sections shall be wrapped by weatherproofed heat-tracing covered by an insulation jacket. The auger spray wash system shall be wrapped with heat-tracing to prevent freezing.

3. Each Weather Protection System shall be installed by affixing the heat-tracing to the auger components and then wrapping the insulation jacket around the heat-traced auger transport and discharge sections. The insulation jacket shall use lacing and/or an optional buckling system to hold the insulation jacket in place so the insulation jacket can be easily removed from the auger.

4. Temperature control shall be self-regulating.

5. The sensor shall be fitted with a junction/terminal connection for customer/user

120/240V power connection. Power connection and control shall be provided and installed by the customer/user as defined by the National Electric Code.

6. Auger run sequence shall be set through the operator interface (OIT) of the controller and shall operate the auger regardless of the present condition (On or OFF) of the heating cycle of the weather protection system.

7. Components:

a. Temperature Sensors:

1) Temperature sensors shall not be provided by JWC Environmental since the heat tracing is self-regulating.

b. Heat Tracing:

1) Heat tracing shall provide 6-watts/foot of heating at 40°F (4.5°C) and shall be self-regulating.

2) The heat-tracing conductors shall be protected by a braided-metal sheathing and waterproof outer jacket.

c. Insulation Jacket:

1) The insulation jacket shall consist of a silicon-based, fabric shell encapsulating 1.5 inch (38 mm) thick fiberglass matting.

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2) The insulation jacket shall be held in place with lacing and/or an optional buckling system.

8. Power connection and control shall be provided and installed by the customer/user as defined by the National Electric Code.

2.3 MOTOR CONTROLLER (1 MOTOR) WITH OPERATOR INTERFACE TERMINAL

A. NEMA rated enclosure with programmable logic controller (PLC), operator interface terminal (OIT), operation indicator lamps, emergency stop pushbutton, reset pushbutton and selector switch.

B. Control Panel:

1. In addition to the requirements below, the Control Panel(s) shall be in accordance with Division 40 Specifications.

2. Motor Controller Power Supply:

a. 208 V/ 3 PH/ 60 Hz.

3. Enclosure, Selector Switches, Pushbuttons and Pilot Lights:

a. NEMA 4X fiberglass enclosure:

1) Fiberglass reinforced plastic with hinged lockable door and mounting flanges.

2) 22 mm, three-position, rated equal or better than the enclosure and indicate On-Off/Reset-Remote.

3) 22 mm, LED (pilot lamp), rated equal or better than the enclosure and indicate POWER ON, grinder RUN, grinder JAMMED and

MOTOR FAULT.

4. Programmable Logic Controller (PLC):

a. In addition to the requirements below, the PLC shall be in accordance with Section 40 94 43.

1) 10K program steps, 20KB data memory.

2) (14) 24 Vdc inputs, (10) relay outputs.

3) Ethernet/IP interface.

5. Operator Interface Terminal (OIT):

a. In addition to the requirements below, the OIT shall be in accordance with Section 40 94 43.

1) Touchscreen operation, 7 in. widescreen TFT (Thin Film

Transistor) display.

2) Ethernet/IP interface.

3) MicroSD card slot and USB port.

4) NEMA 4X suitable for indirect sunlight.

6. Motor Starters, Overload Relays and Control Power Transformer:

a. NEMA, full voltage, and reversing.

b. Maximum short circuit protective fault current 5 kA.

c. Adjustable and sized to full load amperes (FLA) of the motor.

d. Produce 120-volt AC power from the supply power. Sized and fused in accordance with code to accommodate the control power requirements.

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7. Current Transducers:

a. Discrete output type with an adjustable set point from 1-135A with

200ms or faster response time.

8. ON-OFF/RESET-REMOTE Switch Status Contact:

a. Provides indication of controller switch in REMOTE position

b. Normally open contact rated for 10A.

9. Main Circuit Breaker Disconnect Switch and Rotary Operating Handle

a. Provides integral disconnect switch using enclosure door mounted rotary operating handle.

b. Main Circuit Breaker Disconnect Switch:

1) Molded case circuit breaker.

2) Protection Type: Fixed thermal/ fixed magnetic.

3) Current Range: Sized to match motor horsepower and operating voltage.

c. Rotary Operating Handle:

1) NEMA Type 4X.

2) Padlockable.

C. Operation:

1. Auger Control: ON-OFF-LEVEL Selector Switch:

a. OFF Position (OFF): De-energizes Auger.

b. ON Position: Energizes Auger.

c. LEVEL Position: Auger operates based on the water level measured by the system’s level sensor(s):

1) Auger Run Cycle will be initiated and will continue until water level difference measured is more than setpoint. Auger Run Cycle fully programmable from OIT:

a) Auger Run Cycle with 5 setpoints: (1) Forward (2) Stop (3)

Reverse (4) Stop (5) Forward.

b) Auger Run Cycle runs setpoints 1-4 if run permission still active, the sequence will repeat. If run permission is no longer active, program will run setpoint 5 and stop operation.

c) Screen trough water spray solenoid will open and supply water to screen trough during Auger Run Cycle.

d) Press zone water spray solenoid valve will open after Auger Run Cycle is complete and the setpoint of accumulated runs has been achieved.

2) High Level Run setting will initiate run of auger regardless of differential setting to prevent overflow of channel.

3) Auger Run Cycle will be initiated and will continue running if level sensor fails.

4) Auger Start Time Interval Setpoint monitors time period from last Auger Run Cycle and initiates a single run cycle if time period exceeds the setpoint.

2. Emergency Stop: In accordance with EMERGENCY STOP pushbutton depressed:

a. Control circuit de-energizes the PLC outputs to motor starter causing the

Herbert, Rowland & Grubic, Inc. 46 31 24 - 10 005153.0436 coils of motor starter to be de-energized to stop auger motor.

b. Fail relay energizes.

c. Emergency Stop condition only cleared locally by resolving the issue, resetting the EMERGENCY STOP switch, and depressing the RESET pushbutton.

3. Auger Reverse Jog Soft Switch (OIT Display):

a. Energizes the auger reverse contactor while depressed. Only functional when auger selector switch is ON or LEVEL.

4. Auger Fail Conditions: (OIT Display):

a. JAMMED:

1) Controller will stop and reverse the Auger motor no more than two times in a 30 second period. OIT displays Auger JAMMED and FAIL indicator lamp will illuminate and Fail relay will be activated.

2) Auger will stop operation.

b. MOTOR OVERLOAD:

1) OIT displays AUGER MOTOR OVERLOAD and FAIL indicator lamp will illuminate and Fail relay will be activated.

2) Auger will stop operation.

c. MOTOR OVERTEMP (Only with applicable motors):

1) OIT displays AUGER MOTOR OVERTEMP and FAIL indicator lamp will illuminate and Fail relay will be activated.

2) Auger will stop operation.

d. UPSTREAM or DOWNSTREAM LEVEL PROBE FAILED:

1) OIT displays UPSTREAM (or DOWNSTREAM) LEVEL PROBE FAILED and FAIL indicator lamp will illuminate and fail relay will be activated.

2) Initiates continuous run cycles on loss of signal from any probe.

e. HIGH LEVEL ALARM:

1) OIT displays HIGH LEVEL ALARM and FAIL indicator lamp will illuminate when upstream water level reached the High Level setpoint.

2) Run the auger in forward only; return to normal operation when water level drops below High Level Setpoint.

f. EMERGENCY STOP:

1) OIT displays EMERGENCY STOP ACTIVATED, FAIL indicator lamp will illuminate and Fail relay will be activated,

2) Deenergizes motor starter and wash water solenoid valve.

5. Power Failure Condition:

a. While System is Operating: System shall return to normal operation when power is restored.

b. While System is in a Fail Condition: System shall return to a fail state when power is restored. The fail state shall not be cleared until reset.

c. Fail Condition Reset: Accomplished by depressing the RESET pushbutton.

6. Communications:

a. All panel indications noted above shall be communicated to 40-PLC-400 via Ethernet/IP over Ethernet for dedicated screen display on 40-PLC-400

OIT.

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PART 3 - EXECUTION

3.1 INSTALLATION

A. Coordinate installation of the equipment in accordance with the manufacturer’s installation instructions, approved submittals, and manuals, and in accordance with OSHA, local, state, and federal codes, and regulations.

3.2 FIELD QUALITY CONTROL

A. INSPECTION:

1. The manufacturer is required to provide the services of a factory or manufacturer’s representative for a minimum of one day to inspect the equipment for proper installation, apply power for the first time and check for proper motor rotation, oversee the initial introduction of material into the system and confirm the equipment operates as intended.

B. TRAINING:

1. Field training for operations, maintenance, and supervisory staff members is to be provided by a manufacturer or manufacturer’s representative. Field instruction shall cover key components of the equipment, operating and maintenance requirements and troubleshooting techniques.

END OF SECTION