46 43 21 Packaged Wastewater Treatment Plant Equipment.pdf

46 43 21 – PACKAGED WASTEWATER TREATMENT PLANT EQUIPMENT

Herbert, Rowland & Grubic, Inc. 46 43 21- 1 005153.0436

SECTION 46 43 21 – PACKAGED WASTEWATER TREATMENT PLANT EQUIPMENT

PART 1 – GENERAL

1.1 SCOPE

A. This Section includes the furnishing and installation of the following, including all labor, materials, equipment and incidentals required to install and place into operation the following as shown on the Drawings and specified herein:

1. Aerated Equalization Tank Piping.

2. Secondary Clarifiers.

3. Post Aeration Tank.

4. Post Aeration Blower/Motor Unit.

5. Equalization Tank Blower/Motor Unit.

6. Blower/Motor Assemblies.

7. Electrical Control System.

B. The Secondary Clarifier supplier shall supply a complete control system that integrates the operation of the two (2) new Secondary Clarifier units and one (1) post aeration unit, one (1) new Equalization Tank, and new Recirculation Wet Well equipment as a single unit process.

C. The Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank supplier shall provide installation and start- up assistance training, and guarantee the hydraulic and process performance of the system.

1.2 RELATED DOCUMENTS

A. Contract Drawings and general provisions of the Contract Documents including, but not limited to, General Conditions, Supplementary Conditions, Division 01, Division 26 and Division 40 specifications apply to this Section.

1.3 SUBMITTALS

A. Product Data and Shop Drawings:

1. Submit under provisions of Section 01 33 00.

2. The manufacturer shall furnish mechanical drawings, electrical drawings and catalog cuts of equipment.

3. Submittals shall include, but not be limited to:

a. General arrangement / assembly drawings.

b. Control panel power and control wiring diagrams.

c. Control panel equipment.

d. Manufacturer's catalog information consisting of descriptive literature, specifications and materials of construction for all components.

B. Installation Certificate:

1. After successful startup, Manufacturer or authorized representative shall provide certification that the equipment is commissioned and ready for service.

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C. Operation and Maintenance Manuals:

1. Submit under provisions of Section 01 78 23.

2. As a minimum, the manuals shall include the following:

a. Equipment operating and maintenance instructions.

b. Parts lists.

c. Assembly and disassembly instructions.

d. Equipment specifications and guaranteed performance data.

e. Recommendations for preventive maintenance.

f. Step-by-step operating and start-up procedures.

g. Lists of spare parts, tools, and supplies.

h. Wiring diagrams of all control circuits.

i. Troubleshooting instructions.

1.4 QUALITY ASSURANCE

A. The products furnished under this section shall be supplied by a single manufacturer who has been regularly engaged in the design and manufacturer of Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank Equipment.

B. Manufacturer shall be successful in the experience of manufacture, operation, and servicing of Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank Equipment of type, size, quality, performance, and reliability equal to that specified for a period of not less than 5 years. The manufacturer shall submit evidence of experience having supplied a minimum of 5 installations within the United States of similar size to the proposed system upon request of Engineer.

C. In the absence of verifiable experience, the manufacturer shall be required to provide an extended warranty and subsequent Performance Bond for the same number of years that the manufacturer was found lacking in experience from the specified 5-year period. The performance bond shall commence with acceptance of the equipment and time described herein and beyond the standard warranty period.

D. Data on performance testing, service history and operation of existing installations using the submitted equipment shall be made available to the Engineer, upon request.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, protect, and handle products to site under provisions of Section 01 61 00.

1.6 WARRANTY

A. Provide in accordance with Section 01 78 36.

B. The Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank Equipment

Supplier shall submit a written guarantee to the Engineer for all materials and workmanship of equipment furnished and installed under this specification for a period of eighteen months (18) from the date of Substantial Completion. Any defects due to the

Herbert, Rowland & Grubic, Inc. 46 43 21- 3 005153.0436 use of improper materials or workmanship occurring within that time shall be promptly rectified by the manufacturer, as approved by the Engineer, without cost to the Owner.

C. The Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank Equipment Supplier shall also submit a Process Performance Guarantee, which shall guarantee that the process will meet the effluent requirements specified. After successful start-up and operation of the Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank equipment and process when the treatment facility is deemed to be operating under equilibrium conditions and at a time selected by the Owner, there will commence a Two-week test period to evaluate the performance of the Secondary Clarifier Units, Post Aeration Unit, and Equalization Tank processes.

D. In addition to the process evaluation at Design Flow, a second testing procedure assessing performance of Peak Flow Rates shall be performed using simulated peak flows to assure conformance with Process Cycling and Maximum Decant Rates by the Contractor and the equipment supplier.

E. Blowers shall be covered by a warranty for 24 months from the date of Final Acceptance.

PART 2 – PRODUCTS

2.1 AERATED EQUALIZATION TANK

A. Piping/Diffusers:

1. A surge tank aeration piping package shall be provided as specified and shown on the plans.

2. An air header with pipe supports and diffuser drop piping assemblies shall be provided surge compartment as shown on plans.

3. Non-clog plastic diffusers shall be so spaced to ensure proper mixing of the tank contents and located parallel to and near the bottom of the chamber.

4. Coarse bubble diffuser.

B. Blowers:

1. Two blowers shall be furnished, each to deliver 295 CFM of free air measured at the blower inlet at 5 PSI maximum.

2. Blowers shall be rotary positive displacement type with V-belt connection to the motors.

3. Each blower shall be driven by a 10 H.P., 1750 RPM, Three Phase, 60 cycle, 208 volt, horizontal ball bearing electric motor with T.E.F.C. enclosure. The motors shall have a 15% service factor but shall not be overloaded beyond the nameplate rating at the design conditions specified above.

C. Submersible Pumps:

1. See Section 43 26 13 – Submersible Sewage Pumps.

2.2 SECONDARY CLARIFIERS

Herbert, Rowland & Grubic, Inc. 46 43 21- 4 005153.0436

A. General Design

1. Hopper style clarifiers with two hoppers per clarifier.

2. Number of Units: 2.

3. Clarifier Length and Width: 24-feet by 12-feet (12-feet by 12-feet per hopper).

4. Clarifier Wall Height: 15-feet ¼-inch.

5. Surface Overflow Rate @ ADF: 130 gpd/ft2 (per unit).

6. The equipment shall be designed to operate without damage when the clarifier is empty.

7. Operating temperature range: 40 to 110 °F.

B. Two final settling basins shall have a design capacity of 16,667 gallons.

C. The bottom of each tank shall be formed into an inverted pyramidal hopper or hoppers.

All side walls shall have a slope of at least 60 degrees. Flat bottom area of each hopper shall be the minimum practicable and in no case greater than one square foot.

D. After flowing through each secondary settling tank the clarified liquid shall pass over the edge of the effluent trough weir into the effluent trough and through the effluent pipe to each settling tank outlet.

E. The sludge that settles to the bottom of each hopper or hoppers shall be returned continuously to the aeration tank by means of the air lift placed in each hopper.

F. Grating shall be provided covering all tank openings. See grating specifications below.

G. Submersible Pumps:

1. See Section 43 26 13 – Submersible Sewage Pumps.

2.3 POST AERATION TANK

A. General Design:

1. Number of Units: 1

2. Post Aeration Length and Width: 9-feet by 3.5-feet

3. Post Aeration Tank Height: 7-feet ¼-inch

B. The post aeration tank shall have a minimum capacity of 1,042 gallons. The tank shall be integral to the Secondary Clarifier No. 1 as shown on plans.

C. The tank shall be fabricated out of one fourth inch steel plate. It shall have the protective coating as specified below.

D. For post aeration of the plant effluent, a diffuser drop with fine bubble diffusers shall be installed in the post aeration tank. Diffused air shall be supplied by the post aeration blower.

Herbert, Rowland & Grubic, Inc. 46 43 21- 5 005153.0436

E. Grating shall be provided covering all tank openings. See grating specifications in Section

2.6 below.

F. After flowing through the post aeration tank, the aerated liquid shall pass over the edge of the effluent trough weir into the effluent trough and through the effluent pipe to the post aeration outlet.

G. Blower/Motor Unit:

1. One blower shall be furnished to deliver 12 CFM of free air measured at the blower inlet at 5 PSI maximum.

2. The blower shall be a rotary positive displacement type with V-belt connection to the motor.

3. The blower shall be driven by a 1 H.P., 1750 RPM, Three Phase, 60 cycle, 208 volt, horizontal ball bearing electric motor with T.E.F.C. enclosure. The motor shall have a 15% service factor but shall not be overloaded beyond the nameplate rating at the design conditions specified above.

2.4 BLOWER/MOTOR ASSEMBLIES

A. Each blower/motor unit shall be assembled and mounted in a weather proof fiberglass housing for outdoor installation.

B. Blowers shall be equipped with a filter silencer on the suction inlet, and discharge piping shall include a gas type check valve, a flexible connector, an air relief valve, and a discharge silencer.

C. Motors shall be mounted on an adjustable sliding base.

2.5 ELECTRICAL CONTROLS, ENCLOSURE, AND WIRING

A. The equipment manufacturer shall furnish the complete control system required for operating the secondary clarifier units, post aeration unit, equalization tank equipment, and recirculation wet well system. The control panels (40-CP-400 & 10-CP-102) shall meet the performance requirements detailed in Division 26 and 40 Specifications and as shown on the Contract Drawings. All integration shall be provided by the equipment manufacturer.

2.6 GRATING

A. Grating panels shall be provided covering all tank openings to service the equipment as shown on plans unless otherwise noted. The grating panels shall provide access to the plant equipment and offer safety protection for the system operator.

Herbert, Rowland & Grubic, Inc. 46 43 21- 6 005153.0436

B. Grating panels shall each consist of a one piece steel plank, a maximum of 11 ¾ inches wide and 2 inches deep. Each panel shall be so supported as to have a safe uniform load carrying capacity of 120 pounds per square foot @ 5’-6” maximum unsupported length.

C. An anti-skid surface, designed for skid resistance in all directions, shall be provided by a series of shoegripping ridges and slots approximately 1/16 inch high on the transverse tread ribs. Grating shall be manufactured from galvanized carbon steel sheets of commercial quality.

2.7 PROTECTION AGAINST CORROSION

A. After complete welding and fabrication of the tank, the following will occur:

1. Surface Preparation: All surfaces shall receive a SSPC-10 near white metal finish obtaining a 1.5 to 3.0 mil surface profile.

2. Paint: Interior and Exterior: coal tar epoxy coated to paint manufacturer’s recommended thickness:

a. Color: Black.

3. For cathodic protection, six packaged 17-pound magnesium anodes shall be provided. They shall be buried on opposite sides of the structure and shall be connected by means of heavy copper wires furnished with the anodes and solder less connector's factory installed on the plant structure. Installation of anodes are by general contractor.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The installation of the equipment shall be as indicated on the Drawings and in strict accordance with the manufacturer’s instructions and recommendations.

B. The manufacturer shall provide written installation manuals for the equipment prior to installation. Equipment shall be installed strictly in accordance with recommendations of the manufacturer. A copy of all installation instructions shall be furnished the Engineer's field representative one week prior to installation.

C. The Contractor shall have on hand sufficient personnel, proper construction equipment, and machinery of ample capacity to facilitate the work and to handle all emergencies normally encountered in work of this character. To minimize field erection problems, mechanical units shall be factory-assembled insofar as practical.

D. Equipment shall be erected in a neat and workmanlike manner on the foundations at the locations and elevations shown on the Drawings.

3.2 Certified Oxygen Transfer Performance Curve(s)

A. Submit certified oxygen transfer performance curves to demonstrate capability of the aeration equipment to meet the specified oxygen transfer requirements.

Herbert, Rowland & Grubic, Inc. 46 43 21- 7 005153.0436

B. Base oxygen transfer curves on the following criteria:

1. A minimum of 3 tests for each specified condition in complete accordance with ASCE Clean Water Test Procedure (2006 or latest edition).

2. Tests conducted in a full scale aeration test tank (minimum of 200 sq. ft.) at the specified submergence and water depth with a diffuser density equivalent to the specified tank configuration. Diffuser density is defined as the ratio of the total tank surface area to the total active diffuser surface area.

3. Tests conducted with air rate and mass rate of oxygen transfer directly proportional to the ratio of the shop test tank volume and the design tank volume.

4. Plot of standard condition pounds of oxygen transferred per day per 1000 cubic feet of tank volume versus standard condition cubic feet of air per minute per 1000 cubic feet of tank volume (lbs-02/day/1000 cubic feet-tank) vs. (SCFM/1000 cubic feet-tank):

a. Standard conditions of oxygen transfer are defined as 68 °F, 1 atmosphere ambient pressure, clean water.

b. Standard air is defined as 68 °F, 1 atmosphere, 36% R.H., containing 23% oxygen by weight.

C. Certify and stamp all curves by a Professional Engineer.

D. Submit curves for all specified conditions for approval by the Engineer prior to manufacturing aeration equipment.

3.3 MANUFACTURER’S FIELD SERVICES

A. Services of a field representative to advise on the field installation shall be provided. The services of the field representative shall include the number of days specified, exclusive of travel time, and two (2) travel trips during the time that the equipment is being installed. The Contractor shall notify the manufacturer of the time that the field services are to be provided.

B. After completion of the installation, the equipment shall be inspected and certified by an authorized representative of the manufacturer as being in compliance with the manufacturer’s recommendations and requirements. At such time as the manufacturer has deemed the installation to be acceptable, the manufacturer’s authorized service representative shall make any required adjustments and shall start the equipment to assure proper operation.

C. The manufacturer's authorized representative shall instruct the Owner's and Engineer's personnel on the operation and maintenance of the systems. The instruction shall include field training on proper operation and maintenance procedures, along with complete demonstrations of same.

D. The manufacturer’s authorized representative shall provide training for Owner personnel in the following aspects of each operating system:

1. Startup and shutdown procedures.

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2. Equipment adjustments and optimum settings.

3. Replacement of components.

4. Routine cleaning and maintenance.

5. Preventive maintenance scheduling and procedures.

E. The manufacturer's authorized representative shall provide minimum services in accordance with the following table.

Purpose No. of Days

Field Installation 10 Startup and Functional Testing 14

Operator Training 2

F. The date of Operator training shall be selected by the Owner.

G. In addition to the above requirements, provide a six (6) month performance review and post start-up training: One (1) trip of 8 hours minimum to make operating adjustments and provide additional instruction to Owner’s personnel within 6 months after final acceptance of equipment

3.4 FIELD TESTING

A. After completion of installation, Contractor shall provide for testing. Testing of the Systems shall demonstrate that the equipment is fully operational.

B. The manufacturer shall furnish the services of a factory trained field representative to the project site. The manufacturer’s representative will observe the start-up of equipment, verify all functions of the equipment, and make adjustments as needed to meet the performance goals specified. Complete testing of the equipment functionality shall be performed in the presence of the Engineer before final acceptance of the system is given.

END OF SECTION