A-_SOW_Open-Channel_Grinder.pdf

ATTACHMENT A- 693JF717R00006

STATEMENT OF WORK

REPLACEMENT OF THE OPEN CHANNEL GRINDERS

AT THE SEWAGE PUMPING STATION

U.S. MERCHANT MARINE ACADEMY

KINGS POINT, NEW YORK

May 9, 2017

U.S. DEPARTMENT OF TRANSPORTATION

MARITIME ADMINISTRATION

U.S. MERCHANT MARINE ACADEMY

STATEMENT OF WORK

REPLACEMENT OF THE OPEN CHANNEL GRINDERS

AT THE SEWAGE PUMPING STATION

BACKGROUND

The open channel grinders at the sewage pumping station frequently break down and are at the end of their service life. The purpose of these grinders is to shred any solid material contained in the sewage waste stream and thereby protecting the pumping equipment.

Therefore, in order to protect the pumps and eliminate costly breakdowns, back-ups and repairs, it is recommended that they be replaced.

OBJECTIVE

To replace two (2) open channel grinders at the sewage pumping station.

SCOPE

Contractor to provide all labor, materials, equipment, tools and incidentals required to provide two (2) influent grinders, controls, supports, control panel, and miscellaneous appurtenances required for a complete installation. Contractor shall provide all parts, equipment, wiring and devices necessary to meet the functional requirements of the system.

TASKS

This work shall consist of, but not limited to, the contractor providing all supervision, labor, materials, tools, transportation and equipment to

Task Areas

1.1. Provide turn-key installation of two (2) open channel grinders and required accessories including the following:

a. Open channel grinder and support system.

b. Grinder controls mounted in a control panel, alarms, dry control contacts, and electrical wiring.

DESIGN REQUIREMENTS

The influent channel grinder shall comply with the following minimum design requirements:

a. Liquid Wastewater

b. Location USMMA Pump Station – Influent Channels

c. Number required 2

d. Cutter Spacing Size ¼”

e. Maximum Horsepower 3

f. Maximum Speed 1725 RPM

REFERENCE STANDARDS

Work shall comply with applicable provisions and recommendations of the following standards except as otherwise shown or specified

1. American Society for Testing and Materials (ASTM)

2. American Iron and Steel Institute (AISI)

3. Society of Automotive Engineers (SAE)

4. National Electrical Manufacturer’s Association (NEMA)

5. National Electric Code (NEC)

6. Underwriters Laboratory (UL)

7. International Electrotechnical Commission (IEC)

SUBMITTALS

Submit the following product data and shop drawings for approval:

1. Manufacturer’s information, specifications, and data showing dimensions, materials of construction, and weight of all major items of equipment specified.

2. Installation diagrams showing location, arrangement, and size of all anchor bolts required for equipment, if applicable.

3. Control panel wiring schematic and layout drawings.

Submit the following Operation and Maintenance Manuals as follows:

1. Operation and maintenance manuals shall include all approved shop drawings associated with this specification, complete instructions for installation, parts list for all components, and wiring schematics and diagrams.

2. Include a list and frequency of specific maintenance activities. Include lubrication frequency, application points, lubrication type, and method of application

QUALITY ASSURANCE

All equipment provided under this SOW shall be a standard product in regular production by manufacturers having a minimum of five (5) years and one hundred (100) installations of proven and reliable experience in providing the equipment and services intended for this project. Supplier shall provide a list of names and dates, if requested, of installations for verification by the Engineer.

A factory-authorized maintenance and parts facility shall be located within a five-hundred (500) mile radius from equipment installation. The manufacturers shall show evidence of a parts inventory for all routine maintenance items associated with the supplied equipment.

INSTALLATION & START-UP

Contractor shall provide the services of a factory trained representative to check installation and review start-up of equipment and controls. The manufacturer’s representative shall also provide at least two (2) days of training on the operation and maintenance requirements of the equipment.

WARRANTY

Contractor shall provide a written warranty to the Owner for all materials and workmanship of equipment provided under this SOW for a period of one (1) year from the date of successful Start-Up. Any defects due to the use of improper materials or workmanship occurring within that time shall be promptly rectified as approved by the

Engineer without cost to the Owner.

The equipment furnished under this SOW shall be guaranteed to be free of defects in workmanship, design, and material. The Contractor shall replace, without cost to the Owner, any equipment or part that is defective or shows undue wear, within one (1) year after successful Start-Up.

The Contractor shall include the services of a factory-trained representative to provide repair service for the equipment under this SOW for the period of one (1) year. The cost of all replacement parts required during this one (1) year period shall be included the contract price.

EQUIPMENT SPECIFICATION

Contractor shall provide 2 (two) open channel grinders complete with a control panel as manufactured by JWC Environmental Series 30005-0012, Franklin Miller Model TM8516, or approved equal.

1. GRINDER

A. General

1. Grinder shall reduce or shred influent solids for protection of downstream equipment. Grinder shall be two shaft design consisting of individual cutters and spacers, with cutters on drive and driven shafts of equal diameter.

B. Components

1. Cutters and Spacers:

a. Cutting stack shall be a nominal height of twelve (12) inches.

b. Cutter shall be an individual disk constructed of AISI 8620 alloy steel surface ground to thickness of 0.438 inches +.000/-.001(11.1 mm +.000/-.003)

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

d. Cutters shall have 7 cam shaped teeth. Tooth height shall not be greater than ½ -inch (13 mm) above the root diameter of the cutter. Outside diameter shall be

4.71-inches (120 mm).

e. Spacers shall be an individual disk constructed of AISI 8620 alloy steel surface ground to a thickness of .446-inches +.001/-000 (11.3 mm +.003/-.000).

f. Spacers shall have a hardness of 34-38 Rockwell C

g. Spacers shall have a smooth outside diameter with no tooth profiles.

2. Shafts:

a. Shafts shall be constructed from AISI 4140 alloy steel with a minimum tensile strength of 149,000 PSI.

b. Shafts shall measure a nominal 2- inches across flats of hex.

c. Shafts shall be hardened to 38-42 Rockwell C.

3. Intermediate Shaft Supports:

a. Intermediate shaft supports shall be constructed of ASTM A743 stainless steel, AISI 17-4 stainless steel and SAE 660 bearing bronze

b. Shaft supports shall be lubricated with high temperature marine grade grease at the factory.

c. Grease fittings on the shaft supports shall be provided for periodic additions of grease.

d. Intermediate shaft supports shall provide additional support to the shafts during severe grinding demands.

4. Seal Cartridges:

a. Seal cartridges shall be rated to a maximum of 90 PSI

b. Seal cartridges shall not require flushing.

c. Dynamic and rotating seal faces shall be constructed of tungsten carbide with

6% nickel binder

d. O-rings shall be constructed of Buna-N.

e. Radial and axial loads shall be borne by sealed, oversized, deep-groove ball bearings.

5. Housings and Covers:

a. End housings and top cover shall be constructed of ASTM A536-84 ductile iron

b. End housings shall have integral bushing deflectors to guide solids from seal cartridges.

c. End housings shall have directional flow arrows cast into the external side wall.

6. Side Rails:

a. Side rails shall be connected of ASTM A536-84 ductile iron

b. Side rails shall have a UHMW sealing strip for creating an adjustable interface between the side rail and the rotating drum.

c. Cutter side rail shall have evenly-spaced horizontal slots to increase flow and decrease water head loss through the grinder. Slots shall only be located on th upstream or influent side of the rail and the effluent side of the rail shall be void of slots to allow for unobstructed flow.

d. Inside profile of the cutter side rail shall be concave and follow the radial arc of the cutters

e. Clearance between the outside diameter of the cutters and concave arc of the cutter rail shall not exceed 5/16-inch (7.9mm)

7. Cutter Speed Reducer:

a. Reducer shall be manufactured by Sumitomo Machinery Corporation of

America or approved equivalent.

b. Reducer shall be internal planetary mechanism with trochoidal curved tooth profile.

c. Reducer shall be vertically mounted with 29:1 single reduction.

d. Reducer shall be grease lubricated.

8. Cutter Motor:

a. Motor shall be explosion proof, 3 hp, 1725 rpm, 208 volt, 3 phase, 60 Hz.

b. Motor shall be U.L. rated NEMA 6P

c. Motor shall not utilize fan cooling at any time during operation.

d. Motor shall use ceramic shaft seal requiring no oil lubrication

e. Motor shall have a minimum service factor of 1.15, 84% minimum efficiency factor at full load, minimum 82% power factor at full load.

9. Performance

a. Grinder shall be capable of processing 490 GPM.

b. Grinder shall provide peak shaft torque of 4.756 le-in/hp.

c. Grinder shall provide peak force at cutter tip of 2.051 lbf/hp.

2. FRAME AND SUPPORTS

1. The custom fabricated frame shall be provided by the Manufacturer to meet the requirements of the Pump Station. Frame and/or supports shall provide a method for securing the grinder in the structure that allows for proper operation. Refer to the

Contract Drawing.

B. Components

1. Frame and/or supports shall be constructed of AISI 304 stainless steel.

2. Frame shall provide proper support and interface to prevent unwanted bypass.

3. CONTROL PANEL

1. Controls shall be mounted in lockable, dead front, tamper resistant, wall mounted

NEMA 7 stainless steel enclosure with stainless steel hardware in the Pump Station. All control and alarm components associated with the grinders shall be housed in the control panel. All grinder controllers, control switches, pilot indicators, elapse time meters, and operational devices shall be mounted on the inner door. All installed devices shall be permanently identified with engraved legends.

2. Control Panel shall provide control of the grinder and be designed to control two

(2) – 3 hp motors at 208 volts, 3 phase, 60 Hz. The control panel shall have indicator lights, switches and other control devices as specified herein.

3. Control panel shall provide two (2) sets of dry relay contacts for alarm signal and run status relays to a remote location.

4. Components:

a. Enclosures

1) Enclosures shall be NEMA 7 stainless steel.

2). Enclosure shall house the control devices motors starters, and PLC.

b. Grinder HOA ON-OFF-REMOTE three-position 22mm type, NEMA 7 selector switch

1) In the OFF position, the grinder shall not run.

2) In the ON position, the grinder shall run continuously

3. In the REMOTE position, the grinder shall start and stop as controlled by an external device

c. Reset Pushbutton

1) Pushbutton shall be momentary type 22 mm. rated NEMA 7.

2) Pushbutton shall be the only method of resetting the controller after failure.

d. Pilot Lights

1) Lights shall be LED type 22 mm NEMA 7.

2) Lights shall indicate POWER ON, RUN, and Fail modes

e. Programmable Logic Controller (PLC)

1) PLC shall be manufactured by Panasonic or approved equivalent

2) PLC shall have a minimum of 16K of memory.

f. Motor Starter

1) Starter shall be a full-voltage reversing type with 120 volt operating coils.

2) Overload relays shall be adjustable and sized to full load amperes

(FLA) of the motor.

g. The Main Circuit Breaker Disconnect and Motor Branch Circuit protection Circuit Breakers

1) Circuit breakers shall be molded case type, 3-pole, 208 volt.

2) Circuit breakers shall be sized to applicable NEC and UL standards.

h. Control Transformer

1) Control transformer shall be minimum 130 VA.

2) Control transformer primary and secondary shall be fused for over current protection.

i. Current Transducer

1) Current transducer shall be manufactured by Veris Industries or approved equivalent.

2) Current transducer shall have adjustable set point from1-35 A with a 200 ms or less response time.

j. Control Relays

1) Control relays shall be manufactured by Idec Corp or approved equivalent.

2) Control relays shall be rated for 10A (resistive load), DPDT, 120V with indicator light..

5. Panel shall be lockable and master-keyed as specified by the Owner. Enclosure shall have padlocking provision and be of tamper resistant construction.

6. Provide a thermostat and heater for panel

7. Terminal strip shall be provided for connecting control wire.

8. Provide grounding for panel.

9. Provide one set of spare lights, fuses and breakers.

10. Provide intrinsically safe barriers for panel connections of wiring and sensors from explosion proof Class I Division I areas

11. Performance:

a. When grinder jam condition occurs, the controller shall stop the grinder and reverse the grinder rotation to clear the obstruction. If the jam is cleared, the controller shall return the grinder to normal operation. If the three (3) reverses occur within a 30 second interval, the controller shall stop the grinder motor and activate the grinder FAIL indicator and relay.

b. When a power failure occurs while the grinder is operating, the grinder will resume operation once power is restored.

c. When a power failure occurs while the grinder is in FAIL condition, once the power is restored the FAIL indicator shall reactivate and remain until reset.

d. reset of the grinder and drums shall be accomplished from the controller only.

EXECUTION

1. INSTALLATION

A Grinder and control panel shall be installed in accordance with manufacturer’s installation instructions, and in accordance with all OSHA, local, state and federal codes and regulations

2. TESTING

A. Test of grinders shall demonstrate correct alignment and smooth operation. Test period shall demonstrate simulated jam conditions for both grinder and screen drums.

3. TRAINING

A. A field training course shall be provided for operation and supervisory staff members and shall consist of two (2) full day of onsite start-up assistance and training (16 hours). Field instruction shall cover items for successful operation contained in the Operation

& Maintenance manuals

DELIVERY

The Contractor is responsible for providing all labor, materials, equipment, tools and incidentals required to provide two (2) influent grinders, controls, supports, control panel, and miscellaneous appurtenances required for a complete installation. Contractor shall provide all parts, equipment, wiring and devices necessary to meet the functional requirements of the system.

The contractor will submit a schedule to the COR prior to commencement of work in order to coordinate with Academy staff utilizing these areas.

Work is to be performed between the hours of 7:00 AM and 4:30 PM. Any change in the schedule will be brought to the attention of the COR 48 hours prior to the change.

Contractor shall survey the site and have utility lines identified prior to commencement of work.

Contractor will maintain a normal safe work area, remove debris from the work areas, keep areas clean and secure, and will dispose of any waste and trade litter in accordance with local and state ordinances. Any damage to existing facilities or appurtenances will be repaired or replaced, in kind, by the contractor at no additional cost to the government.

The contractor will provide a valid written guarantee for the work performed. The guarantee will be effective for one year commencing on the date of final acceptance. The guarantee will provide for the remedy of any defects in workmanship or materials used. The contractor will bear the cost of any remedial work to be performed under the guarantee.

CLOSE OUT:

The contractor shall provide a signed warranty of any damage, defective material and improper workmanship on any material provided in this contract.

Materials and labor to be warranted for a minimum of one year after completion of installation, and equipment to be warranted per manufacturer.

GOVERNMENT FURNISHED PROPERTY, MATERIAL, EQUIPMENT OR

INFORMATION.

Not applicable

CONSIDERATIONS

• Submit schedule seven (7) days in advance of work to be accomplished for approval.

• Submit schedule showing area to be worked on, dates of work, and estimated timeline for completion of the task(s).

• Maintain communication with the COR (and immediately inform the COR of any unforeseen issues or problems that arise).

• Inform COR of any anticipated disruption in services for construction at least three (3) days in advance

PLACE OF PERFORMANCE

Contractor will perform the task at Sewage Pumping Station located at the USMMA, 300

Steamboat Road, Kings Point, N.Y. 11024.

PERIOD OF PERFORMANCE

Work is to be completed within 30 calendar days after NTP is approved. Work is to be performed during normal business hours 0700 to 1630, Monday through Friday unless approval is granted by the Contracting Officer.