Addendum 1 17466.pdf

STATE OF MICHIGAN Date Issued: February 4, 2020 Department of Technology, Management and Budget Index No(s):

Facilities and Business Services Administration File No: 472/17466.CDP 3111 W. St. Joseph Street Department: DOC

Lansing, MI 48917 Project Name: Lakeland Correctional – Water and Sewer Improvements

Subject: Addendum #1

Bid Opening Date: February 19, 2020 Professional: Nowak & Fraus Engineers

ADDENDUM #1

TO: All bidders

SUBJECT: Revision to Bidding Documents

INTENT: This Addendum is issued to

Item 1 –Grinding Equipment Specifications

Specifications enclosed for the proposed sewer grinding / screening equipment.

Item 2 – Pre-Bid Meeting Attendance

The sign in sheet for the pre-bid meeting held February 3, 2020 is enclosed.

ACKNOWLEDGEMENT: Two copies of this Addendum, properly signed in the space provided below, must be acknowledged and returned with the bidder's proposal for submission of a valid proposal. The changes and information shall become part of the contract documents. (Authority: 1984 PA 431)

Firm Name

Bidder's Signature Date

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 1 SCREENING & GRINDING EQUIPMENT

Nowak & Fraus - Lakeland - AGE480-Spec.doc

SULZER CONFIDENTIAL

SECTION 11330

AUGER MONSTER SYSTEM

SERIES AGE-480

SINGLE DRIVE-ELECTRIC 40002 GRINDER AND

ELECTRIC 480 MM AUGER

PART 1 GENERAL

1.1 SUMMARY

A. This section of the specification describes the screenings removal equipment consisting of a support system(s), grinder(s), auger(s), and motor controller(s). The equipment shall be installed as shown on the plans, as recommended by the supplier, and in compliance with all OSHA, local, state and federal codes and regulations.

B. The number of Auger Monster(s) systems shall be 1. Each system shall include the support system, grinder, auger, and motor controller.

C. The auger system shall be capable of processing 1 MGD (157.7 m³/h) with a maximum headloss of 16.65inches (422.9mm) at a downstream water level of 4.64inches (117.9mm).

1.2 REFERENCES

A. Support system(s), grinder(s), and auger(s) materials of construction shall, as applicable, meet the requirements of the following industry standards:

1. American Society for Testing and Materials (ASTM) A36: Standard Specification for

Carbon Steel Plate

2. American Society for Testing and Materials (ASTM) A536-84: Standard Specification for

Ferritic Ductile Iron Castings

3. American Iron and Steel Institute (AISI) 303 Stainless Steel

4. American Iron and Steel Institute (AISI) 304 Stainless Steel

5. American Iron and Steel Institute (AISI) 316 Stainless Steel

6. American Iron and Steel Institute (AISI) 4130 Heat Treated Alloy Steel

7. American Iron and Steel Institute (AISI) 4140 Heat Treated Hexagon Steel

8. Rockwell C

B. Motor controllers shall, as applicable, meet the requirements of the following Regulatory

Agencies.

1. National Electrical Manufacturer's Association (NEMA) Standards

2. National Electrical Code (NEC)

3. Underwriters Laboratory (UL and cUL)

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 2 SCREENING & GRINDING EQUIPMENT

PART 1 GENERAL

1.3 DOCUMENTS

A. Shop Drawing(s)

Supplier shall submit six (6) sets of shop drawings. Shop drawings shall include equipment descriptions, specifications, dimensional and assembly drawings, parts lists, and job specific drawings.

B. Operation and Maintenance Manuals

Supplier shall submit three (3) sets of Operation and Maintenance manuals prepared using best commercial practices. The manuals shall include equipment descriptions, operating instructions, drawings, troubleshooting techniques, a recommended maintenance schedule, and the recommended lubricants.

1.4 QUALITY ASSURANCE

Qualified suppliers shall have a minimum of five (5) years experience at manufacturing, support systems, two (2) shafted grinding equipment, inclined augers and motor controls with a minimum 500 installations of similar equipment. Supplier shall provide a list of names and dates of installations for verification by the Engineer or Owner's Representative.

Supplier shall provide the services of a factory-trained representative to check the installation and to start-up each grinder, auger and controller. The factory representative shall have complete knowledge of proper installation, operation, and maintenance of equipment supplied.

Representative shall inspect the final installation and supervise a start-up test of the equipment.

Each grinder, auger, and controller shall be factory tested to ensure satisfactory operation.

1.5 DELIVERY, STORAGE AND HANDLING

A. The equipment shall be packaged in containers constructed for normal shipping, handling and storage.

B. The containers shall provide adequate protection for the equipment in a dry indoor environment between +40F (+4.5C) and +100F (+37.8C) until time for installation.

1.6 IDENTIFICATION

Each unit of equipment shall be identified with a corrosion resistant nameplate, securely affixed in a conspicuous place. Nameplate information shall include equipment model number, serial number, supplier's name, and location.

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 3 SCREENING & GRINDING EQUIPMENT

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Support system(s), grinder(s), auger(s), and motor controller(s) shall be in compliance with these specifications and plans and shall be supplied by one of the following manufacturers:

1. JWC Environmental®: Auger Monster® system Model No. AGE1800-480-7500

2. Approved equal

B. Manufacturers requesting to be selected as an approved equal shall submit certified documentation showing compliance with these specifications a minimum of ten (10) days prior to bid opening. Selected equipment manufacturers shall be added to the list of approved manufacturers.

C. The manufacturer must certify that the unit can be returned for maintenance to the factory or a local repair facility. The certification shall include a statement that there will be no charge for repair labor.

2.2 SUPPORT SYSTEM(S)

A. GENERAL

1. A grinder and auger system support frame with adjustable mounting brackets shall be provided for a 24 inch (609.6 mm) wide and a 183.5 inch (4660.9 mm) deep channel.

2. An auger drive-end support shall be provided as required by the application. The drive end shall provide a method for pivoting the auger from the channel to perform simple maintenance. Installations with transport lengths of the auger greater than 4000 mm (157

in) shall require additional supports.

3. A horizontal support shall be provided for mounting an ultrasonic sensor upstream from the system support frame.

B. COMPONENTS

The support frame, tube and additional supports shall be of welded square tube, angle, and plate construction. The construction material shall be 304 stainless steel unless noted.l.

2.3 GRINDER(S)

A. GENERAL

1. Each grinder shall include cutters, spacers, shafts, bearings and seals, side rails, end housings, covers, reducer, and motor.

2. The grinder shall be of two (2) shaft design and be capable of continuous operation, processing wet or dry. Bar screens or single shaft devices utilizing a single rotating cutter bar with stationary cutters shall not be acceptable. Grinders designed with cutter and spacer cartridges rather than individual cutters and spacers shall not be acceptable.

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SULZER CONFIDENTIAL

PART 2 PRODUCTS (Cont'd)

2.3 GRINDER(S) (Cont'd)

A. GENERAL (Cont'd)

3. Two (2) shaft design shall consist of two (2) parallel shafts alternately stacked with individual intermeshing cutters and spacers positioned on the shaft to form a helical pattern. The two (2) shafts shall counter-rotate with the driven shaft operating at approximately two-thirds (2/3) the speed of the drive shaft. Cutter diameters on the drive and driven shafts shall be of equal diameter to ensure proper clean-out of the spacers.

B. COMPONENTS

1. Individual Cutters and Spacers

a. The cutting chamber shall be a nominal height of 18 inch ( 457.2 mm).

b. Individual cutters and spacers shall be AR500 abrasion resistant alloy steel, surface ground for uniformity with a hardness of 50-52 HRc.

c. The inside configuration of both the individual cutters and the individual spacers shall be hexagonal so as to fit the shafts with a total clearance not to exceed 0.015 inch (0.38

mm) across the flats to assure positive drive, minimize wear on the cutters.

d. Cutter configuration shall consist of individual eleven (11) tooth cam cutters on both shafts. To maintain particle size, the height of the tooth does not exceed 1/2 inch (13)

mm) above the root diameter. Cutter root diameter overlap is not less than 1/16 inch or greater than 1/4 inch to maintain the best possible cutting efficiency while incurring the least amount of frictional losses. Clearance between overlapping cutters of opposing shaft shall be no greater than 0.011 inches (0.28 mm).

e. The cutters shall exert a minimum force at the tooth tip of 1,624 lbs/hp (9,685 N/kW) during momentary load peaks.

2. Shafts

a. Grinder drive and driven shafts shall be made of 4140 heat treated hexagon steel with a tensile strength rating of not less than 149,000 psi (1,027 MPa).

b. Each hexagonal shaft shall measure a nominal two and one half (2 1/2) inch (64 mm) across parallel surfaces.

3. Shaft Bearings and Seals

a. The radial and axial loads of the cutter shafts shall be borne by sealed, oversized, deep-groove ball bearings at each end.

b. The bearings shall be protected by a combination of a replaceable and independent tortuous path device and mechanical seals.

c. Face materials shall be of tungsten carbide to tungsten carbide.

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SULZER CONFIDENTIAL

PART 2 PRODUCTS (Cont'd)

2.3 GRINDER(S) (Cont'd)

B. COMPONENTS (Cont'd)

3. Shaft Bearings and Seals (Cont'd)

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

e. Products requiring continuous or occasional lubrication or flushing shall not be accepted.

f. The mechanical seal shall be rated at 90 psi (620 kPa) continuous duty by the seal supplier.

g. The bearings shall be housed in a replaceable cartridge that supports and aligns the bearings and seals, as well as protects the shafts and end housings. The seal elements shall be independent of the stack height; therefore cutter stack tightness shall not affect seal performance. The seal elements shall maintain their factory set preload independent of the cutter stack tightness.

h. Seals shall meet required pressure rating regardless of cutter stack fit. The seal cartridge shall provide seal protection against axial loading on shafts and bearings during shaft deflection.

i. Each seal element shall be positively locked to its corresponding rotating or static cartridge element. This positive lock on the seal elements is critical to long seal life in applications where grit or other abrasive materials are present.

4. Side Rails

a. The inside profile of the side rails shall be concave to follow the radial arc of the cutters.

b. Clearance between the major diameter of the cutter and the concave arc of the side rails shall not exceed 5/16 inch (7.9 mm).

c. The side rails shall have evenly spaced slots that increase flow and decrease head loss.

d. The side rails shall be cast of A536-84 ductile iron.

5. End Housings and Covers

a. Grinder end housings shall be of cast A536-84 ductile iron with a cast-in-place flow deflector, designed to protect the bushings while guiding particles directly into the cutting chamber.

b. Top covers shall be A536-84 ductile iron and bottom covers shall be A36 hot rolled plates.

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SULZER CONFIDENTIAL

PART 2 PRODUCTS (Cont'd)

2.3 GRINDER(S) (Cont'd)

B. COMPONENTS (Cont'd)

6. Reducer

a. The speed reducer shall be a grease-filled planetary-type reducer with a 500% shock load capability. The reduction ratio shall be 43:1.

b. The input shaft of the reducer shall be directly coupled to the motor using a three-(3) piece coupling, and the output shaft of the reducer shall be directly coupled with the grinder using a two (2)-piece coupling.

7. Motor

a. The motor shall be 10 hp (7.5 kW), Immersible, 1725 rpm, 460 volt, 3 phase, 60 Hz.

b. Motor service factor shall be 1.15, the efficiency factor not less than 85% at full load and the power factor not less than 80% at full load.

c. Required Running Torque per Horsepower (kW):

At Momentary Load Peaks: 6,088 in-lbs/hp (922 Nm/kW)

2.4 AUGER(S)

A. GENERAL

1. The auger(s) shall be comprised of a perforated screen segment, transport segment, discharge segment, and drive segment with an internal rotating spiral.

2. Each auger shall be installed at an inclination of 35 degrees from horizontal immediately downstream of the grinder.

3. The auger screen segment trough with a rotating spiral shall provide particle capture and transport to the discharge segment outlet.

4. A wiper/brush shall be affixed to the outer edge of the spiral in the screen segment trough to provide trough cleaning and particle transport. The wastewater shall be permitted to pass through the screen segment and flow downstream.

5. Particles shall be washed both by the highly-agitated passing wastewater and by the discharge of a spray wash system. Dewatering shall occur as the rotating spiral conveys the washed screenings.

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 7 SCREENING & GRINDING EQUIPMENT

SULZER CONFIDENTIAL

PART 2 PRODUCTS (Cont'd)

2.4 AUGER(S) (Cont'd)

A. GENERAL (Cont'd)

6. A spray wash assembly shall be provided to rinse the organic material from the processed solids back into the waste stream. The spray wash system shall consist of a set of nozzles proving a covering spray of water for cleaning the captured solids along with a set of nozzles providing an impact spray to hold the solids against the screen trough for transportability. A spray wash solenoid valve shall be automatically energized by the system controller allowing wash water to spray into the screen segment whenever the auger spiral is in operation. The spray wash solenoid shall be automatically de-energized, stopping the flow of wash water whenever the auger spiral is stopped.

7. Starting of auger run cycles shall be initiated by signals from an ultrasonic level sensor.

B. COMPONENTS

1. Spiral

a. The 480 mm (18.89 in) spiral shall be made of high wear-resistant, alloy carbon steel.

b. The spiral shall have a groove designed into the outside diameter of the spiral for the mounting of the brush. The groove shall securely position the brush so that constant contact is maintained with the screen segment for the purpose of cleaning the perforations and the free passage of soft organics and liquids. Spirals that mount the brush to the face of the spiral shall not be acceptable.

c. The spiral shall have a welded drive plate for connection to the drive shaft.

d. The spiral tip speed shall not be more than 54 feet/minute (0.27 m/s).

e. The spiral transport speed shall not be more than 6.25 feet/minute (0.03 m/s).

2. Screen Segment

a. The screen segment trough shall be a replaceable, perforated stainless steel assembly.

The perforated area of the segment shall be constructed of 14 ga. Sheet.

b. The screen trough perforations shall be 6 mm for separation of the liquids from the solids. The sharp edges of the perforations shall be removed.

3. Transport Segment

a. The transport segment shall be a stainless steel assembly with inspection port(s). The segments shall be constructed of 10 ga. sheet

b. The transport segment shall have stainless steel wear bars to support the rotating spiral.

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 8 SCREENING & GRINDING EQUIPMENT

PART 2 PRODUCTS (Cont'd)

2.4 AUGER(S) (Cont'd)

B. COMPONENTS (Cont'd)

4. Discharge Segment

a. The discharge segment shall be a stainless steel assembly with an inspection port and a full-width bottom discharge flange. The segment shall be constructed of 10 ga. Sheet.

b. The discharge segment shall have a stainless steel endplate for mounting the drive segment.

5. Drive Segment

a. The drive segment shall be comprised of a drive shaft with welded drive plate, shaft seal, drive adapter spool, speed reducer and electric motor.

b. The shaft seal shall consist of a packing housing; four (4) PTFE impregnated packing cords, and adjustable packing ring.

c. The drive adapter spool shall be cast A536-84 ductile iron coated to inhibit corrosion.

d. The speed reducer shall have a reduction ratio of 160:1.

e. The electric motor shall be of 2 hp (1.5 kW), Immersible, 1725 rpm, 460 volt, 3-phase, 60-Hz.

6. Spray Wash Assembly

a. Spray Wash Assembly shall consist of a one (1) inch spray wash manifold, solenoid operated valve, manually operated ball-valve, and a remotely installed basket strainer.

b. The spray wash manifold shall be of stainless steel pipes and fittings. The spray nozzle shall consist of 40° “V” spray nozzles rated for 1.5 GPM @ 40 PSI and high impact 50° spray nozzles rated for 1.0 GPM @ 40 PSI.

c. The solenoid valve shall be of bronze construction, fitted with an explosion proof enclosure, housing a 120 volt, ac coil.

d. The manually operated ball valve shall be of 316 stainless steel and shall provide adjustment for the spray wash water flow.

e. A one (1) inch NPT strainer shall be of SST material, with an 80 mesh 304 stainless steel screen and a threaded drain.

f. A one (1) inch NPT double back-flow preventer (not supplied by equipment manufacturer) is recommended when using potable water for spray wash.

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 9 SCREENING & GRINDING EQUIPMENT

SULZER CONFIDENTIAL

PART 2 PRODUCTS (Cont’d)

2.5 LEVEL SENSORS

A. GENERAL

1. The Auger Monster system shall be provided with upstream and downstream ultrasonic level sensors.

2. The level sensors will initiate auger run cycles based on channel head differential and the parameters set in the operator interface.

3. The PLC logic shall determine differential levels using signals from two (2) separately-mounted ultrasonic level sensors.

a. One (1) level sensor shall be installed upstream of the system and measure the system’s upstream water level.

b. One (1) level sensor shall be installed downstream of the system and measure the channel’s downstream water level.

c. The head in front (upstream) of the system shall be compared to the head behind

(downstream) of the system to determine the water level differential.

2.6 MOTOR CONTROLLER(S)

A. GENERAL

1. The controller shall provide independent control of the grinder, auger and spray wash assembly.

2. Controller shall be the supplier's standard UL/cUL listed Model PC-2251D.

3. The controller shall be rated for 10 hp (7.5 kW) and 2 hp (1.5 kW), 460 volts, 3-phase, 60-

Hz.

B. OPERATION

1. The controller shall be equipped with a GRINDER ON/OFF/RESET-REMOTE three (3) position selector switch.

a. In the OFF/RESET position the grinder shall not run.

b. In the ON position the grinder will run.

c. In the REMOTE position the grinder shall start and stop as controlled by a remotely-located contact.

d. The grinder shall only be reset by switching the GRINDER ON-OFF/RESET-

REMOTE switch to the OFF/RESET position.

AGE ELECTRIC AUGER MONSTER SYSTEM 11330 - 10 SCREENING & GRINDING EQUIPMENT

2.6 MOTOR CONTROLLER(S) (Cont'd)

B. OPERATION (Cont'd)

2. The controller shall be equipped with an AUGER ON/OFF/RESET-LEVEL three (3) position selector switch.

a. In the OFF/RESET position the auger shall not run.

b. In the ON position the auger shall continuously initiate Auger Run Cycles.

c. In the LEVEL position, auger run cycles shall be initiated by the ultrasonic level sensors or the Level Sensor Backup Timer. Auger Run Cycles in the LEVEL position shall only be enabled when the grinder is running.

d. The auger shall only be reset by switching the AUGER ON/OFF/RESET-LEVEL switch to the OFF/RESET position.

3. The controller shall be equipped with a digital operator interface.

a. The operator interface shall display grinder and auger run times, elapsed times, reversals, jams, motor overloads and over-temperature occurrences.

b. The operator interface shall display Fail, Service Reminder, and Operational Messages.

c. Operator interface function keys shall select the following displays: Date and Time, Auger Run Cycle, Auger Start Time Interval, and System Monitor.

d. The Auger Cycle Run times, and Level Sensor Backup Timer shall be programmable.

Settings shall be entered at the operator interface using panel keys to initiate a desired run sequence.

4. The controller shall be equipped with a programmable Level Sensor Backup Timer.

a. The Level Sensor Backup Timer shall initiate an auger run cycle if the ultrasonic sensor fails to start an auger cycle within a preset interval of 0 to 999 minutes.

b. The Level Sensor Backup Timer shall run the system continually when the timer is set to 0.

C. COMPONENTS

1. Enclosure

a. Enclosures shall be NEMA 4X, 304 stainless steel construction and shall be suitable for wall mounting. Doors shall have corrosion-resistant hinges and latches.

b. Enclosure shall house the control devices, relays, terminal blocks and reversing motor

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SULZER CONFIDENTIAL

starters.

PART 2 PRODUCTS (Cont'd)

2.6 MOTOR CONTROLLER(S) (Cont'd)

C. COMPONENTS (Cont'd)

2. Control Devices

a. Operator interface and pilot devices shall be mounted on the enclosure front panel door.

b. The controller shall have indicator lights for GRINDER RUN, AUGER RUN, and common FAIL.

c. POWER ON, GRINDER JAMMED, AUGER JAMMED,GRINDER MOTOR

OVERLOAD, AUGER MOTOR OVERLOAD, GRINDER MOTOR OVERTEMP,

and AUGER MOTOR OVERTEMP, LEVEL SENSOR 1 FAILED, LEVEL SENSOR 2 FAILED and HIGH LEVEL ALARM shall be displayed by the operator interface.

d. Control devices are mounted in the front panel of the enclosure. Indicator lights shall be LED type pilot lights. Lights and the selector switches shall be heavy duty NEMA 4X type.

e. Control transformer shall be protected by two (2) primary fuses and one (1) secondary fuse. The 120 volt secondary shall have one (1) leg grounded.

f. Relay contacts shall be included for GRINDER RUN, AUGER RUN, and common

FAIL signal outputs. The contacts shall be rated 10 ampere, 240 VAC, resistive load.

3. Motor Starters

a. Starters shall be a full-voltage reversing type with 120 volt operating coils.

b. Forward and reverse contactors on the starters shall have both mechanical and electrical interlocks.

c. Overload relays (OL) shall be adjustable so that the range selected includes the full load amperes (FLA) rating and service factor.

D. SAFETY FEATURES

1. When a grinder jam condition occurs in the grinder ON or REMOTE mode the controller shall stop the grinder and reverse grinder rotation to clear the obstruction. If the jam is cleared, the controller shall return the grinder to normal operation. Up to two (2) additional reversing cycles (3 times total) may occur within 30 seconds before the controller de-energizes the grinder motor and activates the grinder fail indicator and relay.

The auger shall continue operating during a grinder fail condition.

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2.6 MOTOR CONTROLLER(S) (Cont'd)

D. SAFETY FEATURES (Cont'd)

2. When an auger jam condition occurs in the auger ON or LEVEL modes the controller shall stop the auger, and reverses auger rotation to clear the obstruction. If the jam is cleared, the controller shall return the auger to normal operation. One (1) additional auger reversal (2 times total) may occur within 30 seconds before the controller de-energizes the auger motor and activates the auger fail indicator and common fail relay. The grinder shall continue operating during an auger fail condition.

3. If a power failure occurs while a grinder or auger is running, operation will resume running when power is restored.

4. If a power failure occurs while the grinder or auger is in a fail condition the fail indicator shall be reactivated when power is restored.

5. The controller shall provide overload protection for the motor through an overload relay mounted directly on the grinder and auger starters.

6. The controller shall be equipped with a main power disconnect switch. Motor branch circuits shall be short circuit protected.

7. Controller reset shall be from the local panel controls only.

PART 3 EXECUTION

3.1 INSTALLATION

Support system(s), grinder(s), auger(s), and motor controller(s) shall be installed in accordance with the supplier’s installation instructions, and in compliance with all OSHA, local, state, and federal codes and regulations.

END OF SECTION