R3 Attachment 2 _ Phase 2 O_M as sent with AD.pdf

F. WAYNE HILL WATER RESOURCES CENTER

PHASE II, CONTRACT 3

SOLIDS, STORAGE, AWT FACILITIES

VOLUME 1

11530: EGG SHAPED DIGESTERS & APPURTENANCES

OPERATION & MAINTENANCE MANUALS

DRAFT TUBE MIXERS 40:DSL-MIX-3 THRU 5

STERLING FLUID SYSTEMS (USA) ORIGINAL SHOP ORDER 23030042

F. WAYNE HILL WATER RESOURCES CENTER

PHASE II, CONTRACT 3

SOLIDS, STORAGE, AWT FACILITIES

11530: EGG SHAPED DIGESTERS & APPURTENANCES

CONTRACT DRAWINGS: VOLUMES 9 & 10

RESIDUALS GALLERY 2

VOLUME 1

OPERATION & MAINTENANCE MANUALS

DRAFT TUBE MIXERS 40:DSL-MIX-3 THRU 5

STERLING FLUID SYSTEMS (USA) ORIGINAL SHOP ORDER 23030042

CONTRACTOR

ATLANTIC SKANSKA,

INC.

2030 Powers Ferry Road Building 400 Suite 444 Atlanta, GA 30339 Phone: (678) 460-2600 Phone: (678) 460-2638

SUBCONTRACTOR LOCAL CONTACT

STERLING FLUID SYSTEMS STERLING FLUID SYSTEMS

30 Industrial Boulevard 30 Industrial Boulevard Grand Island, NY 14072 Grand Island, NY 14072

Phone: (716) 773-6450 Phone: (716) 773-6450

FAX: (716) 773-2330 FAX: (716) 773-2330

DRAFT TUBE SLUDGE MIXER

F.WAYNE HILL WATER RESOURCES CENTER GWINNETT COUNTY PHASE II, CONTRACT 3

SOLIDS STORAGE, AWT FACILITIES 11530: EGG SHAPED DIGESTERS & APPURTENANCES

VOLUME 1 OPERATION & MAINTANENACE MANUAL

CB & I/CONTRACT NO. 127047 CBI PO 139424

DRAFT TUBE SLUDGE MIXERS TAG: 40:DSL-MIX-3/4/5

STERLING FLUID SYSTEM SO 23030042 REVISED 2/2004 REPLACES MARCH, 2003

DRAFT TUBE SLUDGE MIXERS

O & M Manual Index

SECTION 1: GENERAL INFORMATION

1.1 EQUIPMENT MANUFACTURER

1.2 MIXER MODEL NUMBER

1.3 PRELIMINARY REMARKS

1.4 EQUIPMENT SUMMARY DATA SHEETS

1.5 CONTACT MANUFACTURER

1.6 EQUIPMENT MANUFACTURERS

1.7 STERLING FLUID SYSTEMS (USA) WARRANTY

SECTION 2: SAFETY

2.0 GENERAL COMMENTS REGARDING SAFETY

2.1 QUALIFICATION AND TRAINING OF PERSONNEL

2.2 HAZARDS IN THE EVENT OF NON-COMPLIANCE OF SAFETY

INSTRUCTIONS

2.3 SAFE WORKING PRACTICES

2.4 SAFETY INSTRUCTIONS TO BE OBSERVED BY THE

USER/OPERATOR

2.5 SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND

ASSEMBLY WORK

2.6 UNAUTHORIZED CONVERSIONS AND PRODUCTION OF SPARE

PARTS

2.7 UNAUTOHORIZED MODES OF OPERATION

SECTION 3: TRANSPORT AND STORAGE

3.0 SAFETY MEASURES

3.1 DELIVERY

3.2 SHORT TERM STORAGE

3.3 LONG TERM STORAGE

SOLIDS STORAGE, AWT FACILITIES 11530: EGG SHAPED DIGESTERS & APPURTENANCES

VOLUME 1 OPERATION & MAINTANENACE MANUAL

CB & I/CONTRACT NO. 127047 CBI PO 139424

SECTION 10: MOTORS – MIXER & GREASE PUMP (CONTINUED)

10.2 GREASE PUMP MOTOR (INTEGRAL WITH GREASE PUMP –

REFER ALSO TO SECTION 11 FOR GREASE PUMP)

? DESCRIPTION PAGE (F + G (FELBER - GUILLAUME)

? GREASE PUMP MOTOR WIRING DIAGRAM.

? OPERATING INSTRUCTIONS

SECTION 11 GREASE PUMP & COUPLING

11.1 GREASE PUMP - WOERNER

Model GMF-B/10/1250/N/0/0/4/0/0/0/0/6/0

• LEAFLET NO. 0009.06.90.GB

• LEAFLET NO. 9002.06.90.GB

• LEAFLET NO. 0005.06.90.GB

• LEAFLET NO. 0006.06.90.GB

• DRAWING 110.000-15E

• Exploded View

• Gear Pump Parts List

• Installation/Operating Hints for Pumping Elements

• DRAWING 110.031-30

11.2 DRIVE COUPLING – FLENDER N-EUPEX , SIZE A140

• INSTALLATION AND ALIGNMENT INSTRUCTIONS - V 420

• COUPLING DRAWING

SECTION 12: APPROVED SHOP TESTS:

• APPROVED MIXER SHOP TEST REPORT

• APPROVED MIXER MOTOR SHOP TEST REPORT

OPERATING INSTRUCTIONS - General Information Gwinnett County Phase II F. Wayne Hill Water Resources Center MFS - 4, Draft Tube Sludge Mixer Sterling Fluid Systems SO 23030042

3/2003

1.4 EQUIPMENT SUMMARY DATA SHEETS:

EQUIPMENT ITEM: DRAFT TUBE SLUDGE MIXER

MANUFACTURER: STERLING FLUID SYSTEMS

COMPONENT INFORMATION: NAMEPLATE DATA

MODEL/PART: MFS 4 RATED OUTPUT: 6,500 GPM

TYPE: NA MAX. RPM: 600 RATED RPM: 720

SIZE: NA OPERATION: REVERSIBLE

CAPACITY: 6,500 GPM +/-10% SERVICE: CONTINUOUS

PERTINENT DRAWINGS: QUANTITY:

MiXER ASSEMBLY : L141.5498.51.0238 Rev.3 MFS – 4 Mixers : (3)

MiXER SECTION : L127.5498.26.0172

PARTS LIST : L127.5498.35.0016 Rev. A SERIAL NUMBERS:

359386-011/LU0209845301

359386-021/LU0209845302

359386-031/LU0209845303

EQUIPMENT ITEM: MIXER DRIVE MOTOR

MANUFACTURER: GENERAL ELECTRIC

COMPONENT INFORMATION: NAMEPLATE DATA

MODEL/PART: 5KS364GT501P FULL LOAD RPM: 705

HORSEPOWER: 20 SF: 1.15 PF: 79.0 EFF: 90.5

ENCLOSURE: TEFC-XP FRAME: l364HP16 PH/FREQ/VOLT: 3/60/460

DESIGN: 36DS5052A TYPE: KS AMPS (FL): 26

QUANTITY: 3 SERIAL NUMBERS:

0107336A, 0107336B, 0107336C

This Page Revised 2/2004 Replaces 3/2003

Gwinnett County Phase II F. Wayne Hill Water Resources Center

1.4 EQUIPMENT SUMMARY DATA SHEETS: (CONTINUED)

EQUIPMENT ITEM: MIXER GREASE PUMP & MOTOR

MANUFACTURER: WOERNER GEASE PUMP & FELTEN &

GUILLEAUME MOTOR

COMPONENT INFORMATION: NAMEPLATE DATA

GREASE PUMP INFO QUANTITIES

MODEL: GMF-B/10/1250/N/0/0/4/0/0/0/0/6/0 GREASE PUMP: 3

GREASE PUMP MOTOR INFO PUMP MOTOR: 3

HORSEPOWER (kW): 0.3 (0.21)

RPM: 1800

CATALOG NO.:

FRAME:

ENCLOSURE: IP 55 EEx e d IICT4 (Explosion-proof))

FULL LOAD RPM: 1770

SF: 1.15 PF: 50.0 EFF: 75.5

PH/FREQ/VOLT: 3/60/460

Gwinnett County Phase II F. Wayne Hill Water Resources Center

1.4 EQUIPMENT SUMMARY DATA SHEETS: (CONTINUED)

EQUIPMENT ITEM: FLEXIBLE COUPLING

MANUFACTURER: FLENDER

COMPONENT INFORMATION: NAMEPLATE DATA

MODEL/PART: N-EUPEX QUANTITIY: 3

TYPE: A

SIZE: 140

OPERATING INSTRUCTIONS – Sect. 4 – Description & Working Principle Gwinnett County Phase II F. Wayne Hill Water Resources Center

4.1 DESCRIPTION OF EQUIPMENT (continued):

Draft tube sludge mixer Draft tube sludgemixer in egg shaped digester

Mixer Motor

Grease Pump Grease Pump Motor

Couplings

Thrust Bearing Splash Disc

Inlet Head

Conical Flanged Pipe

Draft Tube

Outlet Head

Draft Tube Support Base

DESCRIPTION OF EQUIPMENT

OPERATING INSTRUCTIONS – Sect. 4 – Description & Working Principle Gwinnett County Phase II F. Wayne Hill Water Resources Center MFS - 4, Draft Tube Sludge Mixer Sterling Fluid Systems SO 23030042

3/2003 the sludge over the sludge surface area softening and dispersing any existing supernatant sludge layer.

Exact operating details for the mixer depend on the composition of the sludge and should be established based on plant personnel experience. Therefore, only general instructions as to the mode of operation are given.

CCW LOOKING DOWN CW LOOKING DOWN

MIXING TOP TO BOTTOM MIXING BOTTOM TO TOP

NOTE: REFER ILLUSTRATION ON NEXT PAGE

OPERATING INSTRUCTIONS – Sect 5 – Installation Procedure

Gwinnett County Phase II F. Wayne Hill Water Resources Center

MFS - 4, Draft Tube Sludge Mixer Sterling Fluid Systems SO 23030042

3/2003

5.1 GENERAL DESCRIPTION

a) The mixing unit consists of the sludge mixer and the draft tube, which is vertically installed in the digester center.

b) The mixer is installed with its seating ring in a conical opening of the digester ceiling.

c) The draft tube is vertically supported in the lower digester area by a three legged support base.

d) The draft tube upper section is braced in four directions using cables.

e) An erecting scaffold should be used for the first erection in the digester.

f) Review the existing customer-provided elevations of the digester and compare them with the required elevations specified on the arrangement drawing. Deviations should be corrected when adjusting the draft tube height.

Moreover, measure and define the adjustment center of the draft tube in relation to the installation opening in the upper digester ceiling.

5.2 SCAFFOLDING INSTALLATION

a) Working platforms shall be installed about five (5) feet below the draft tube flanged joints except at bottom which is to be five (5) feet above the bottom of the digester

b) Outside dimensions of the working platform shall be approximately twenty

(20) feet BY (20) feet. The center opening shall be approximately five (5) feet by (5) feet.

c) The scaffolding shall be extended to the wall anchors (73.22 & 73.23) at the anchor plate (89.31) and should be readily accessible right to the wall of the digester (used to install center and upper cables).

d) Wall Anchor mounting plates (73.23) will be supplied by Sterling Fluid

Systems to the digester manufacturer, and welded to the digester at the proper locations by others.

Gwinnett County Phase II F. Wayne Hill Water Resources Center

e) After installing the mixer the scaffolding must be raised to shutter the seat ring area.

f) Reinforce the scaffold in the lower region at the Inlet Head/Support Foot elevation.

g) Steel Consoles (Drawing Z253) to be supplied by others, and mounted to the digester doubler plates.

5.3 INSTALLING THE LOWER SUPPORT FOOT (18.3)

a) Coat all bolt threads with anti-seize compound prior to assembly.

b) Torque all bolts to grade 5 specification.

c) Lower the three (3) Support Foot Legs (18.3) into the digester separately with a crane. Secure the Support Foot Legs to the scaffolding.

d) Lower the Inlet Head (72.01) into the digester. Place it on the lower scaffold platform.

e) Lower the Support Plate (89.3) into the digester on top of the Inlet Head

(72.01). Attach the Inlet Head (72.01) to the Support Plate (89.3) with the

FOUR (4)) full thread bolts (*90.114A) from the bottom upwards. Note, for larger size mixers, the Support Plate (89.3) will be in two sections. Torque bolts. *90.114A = 90.114 EXCEPT FULL THREAD

f) Lift the Support Plate (89.3) and Inlet Head (72.01) off the lower scaffolding platform. Attach the Support Foot Legs (18.3) to the bottom of the Support

Plate (89.3) with bolts (90.14) and split washer (93.24). Torque bolts.

Position Support Foot Assembly in the digester.

g) Remove the bottom scaffolding platform and lower the support table assembly into position.

Gwinnett County Phase II F. Wayne Hill Water Resources Center

h) Accurately align the centricity of the Support Foot Assembly in relation to the Seat Ring opening in the top of the digester with a plumb bob and set at the correct height. Check and compare all dimensions relevant to proper mounting. Make necessary corrections.

i) Check all length dimensions of the Draft Tube (71.1, 71.11 and 71.12) including the Anchor Plate (89.31) and Outlet Head (72.03). Determine overall length. Dimensional deviations (plus or minus) compared to specified dimensions must be compensated for by adjusting the height of the Support Foot Assembly. Re-check level of Support Foot Assembly.

FOR ALL STEEL DIGESTERS - USE THE FOLLOWING PROCEDURE TO

COMPLETE THE SUPPORT TABLE ASSEMBLY

k) With Support Table Assembly hanging at the correct location and leveled, clamp angle brace to each support foot, and tack weld to each digester doubler plate to maintain mounting locations.

l) Attach steel console templates to each foot to determine digester curvature, and console length at each Support Foot (18.3) location.

m) Use the templates to accurately mark the cutting line on each Steel Console and cut to scribed line as closely as possible.

n) Attach cut Steel Console to the appropriate Support Foot (18.3), and precision fit so that the contact between the bottom of the Console and digester will be a minimum of 80% contact area onto the digester doubler plates.

o) If fit is acceptable, assemble precision fitted console to the correct Support

Foot (18.3) using bolts (91.7), split washers (93.27) and hex nuts (92.06).

p) Remove angle brace, check concentricity and height of the Support Plate

(89.3) in relation to the top of the digester gas dome.

q) Tack weld fitted console to doubler plate.

Gwinnett County Phase II F. Wayne Hill Water Resources Center

MFS - 4, Draft Tube Sludge Mixer Sterling Fluid Systems SO 23030042

3/2003

r) Use same procedure for two remaining steel console

s) After all consoles have been fitted and tack welded, check concentricity and height of Support Plate (89.3) to bottom of digester before finish welding.

t) After weld have cooled, precision level the top of the Support Plate (89.3) using the level screws in the support feet base, and put shims between foot base and top of the consoles to maintain a tolerance of 0.005 in./ft, and no more than +/- 0.25 in. off center of the plum bob line in a horizontal circle.

u) Remove adjusting screws, and torque all bolts and nuts. Check level, re-shim if necessary.

5.4 ASSEMBLING THE DRAFT TUBE

a) If the crane has sufficient lifting height, assemble two (2) Draft Tube

Straight Sections (71.1 and 71.12) on the ground using bolts (90.12), split washers (93.22) and hex nuts (92.02). Torque bolts to specification

b) If the crane lifting height is not sufficient to lift two (2) sections of draft tube, each section must be lifted, lowered and assembled sequentially into the digester.

c) If method b) above is used, install the lowest Draft Tube Section (71.12) onto the Support Plate (89.3) guiding it over the four (4) threaded bolts

(90.114A) protruding from the support table (89.3) and secured with split washers (93.22) and hex nuts (92.02). Install remaining bolts (90.114), split washers (93.22) and nuts (92.02). Torque bolts to specification.

d) Continue to install the remaining draft tube. Install and assemble with bolts, split washers and hex nuts described above. Torque bolts to specification

e) After the assembly of lower Draft Tube Sections to the Support Table (89.3), assemble Anchor Plate (89.31) to the top Draft Tube using four (4) full thread bolts (90.115A) inserting from the bottom of the Draft Tube flange holes into the threaded holes of the Anchor Plate (89.31).

Gwinnett County Phase II F. Wayne Hill Water Resources Center

f) Assemble and properly torque the combination Wall Anchor/Cable assemblies (73.22 & 59.61) to the Wall Plates (73.23) welded to the sides of the digester, using 5/8 inch bolts (90.17) and split washers (93.27).

g) Coat the spool ends of the Anchor Plate (89.31) with anti-seize compound.

h) Wrap loose ends of Wire Cable around Anchor Plate spools (89.31), mounted to the top draft tube section , and secure the ends with a Cable

Clamp (57.21). Mount cable tensioning devices.

i) Tension the Cables in accordance with mounting instruction

(L170.5498.10.0073). Accurately align center of the Draft Tube with the center of the digester gas dome using a plumb bob. Observe center alignment and correct tension on cables. Secure cables with Wire Rope

Clamps (57.21). Torque clamps as per manufacturer’s specifications. Note the cable assemblies, at the digester walls, are factory pre-tensioned.

j) Remove cable tensioning devices from cable

k) Install the remaining upper three Draft Tube Sections onto the previously installed anchor plate (89.31), at top of lower draft tube assembly. Guide bottom part of the upper section over the four (4) threaded bolts (90.115A) protruding up from the Anchor Plate (89.31). Secure with the split washers

(93.22) and hex nuts (92.02). Install remaining bolts (90.115), split washers

(93.22) and nuts (92.02). Torque bolts.

l) Install Outlet Head (72.03) casting, guiding the lower flange over the draft tube flange. Secure with bolts (90.113), split washers (93.22) and hex nuts

(92.02) and torque.

m) Coat the attachments on the Outlet Head ( 72.03) with anti-seize compound.

Wrap Wire Cable around attachments on Outlet Head (72.03). Follow procedures (i) - (j).

Gwinnett County Phase II F. Wayne Hill Water Resources Center

MFS - 4, Draft Tube Sludge Mixer Sterling Fluid Systems SO 23030042

3/2003

5.5 INSTALLING THE MIXER

a) Set the Mixer Assembly complete with the Seat Ring (without electric motor) with the three (3) Set Screws in place (i.e. screwed into the Seat

Ring) on the shim plates in the digester. The shim plates are to be placed on top of the seat ring mounting brackets.

b) When aligning the Mixer adjust the distance from the top of the Outlet

Head (72.03) to the top of the Splash Disc as shown on the arrangement drawing. Height corrections are to be made with the set screws in the seat ring. Allowable tolerance ± 0.75 inches.

c) Measure horizontal positioning of the mixer with a precision spirit level 0.1 mm/m and a flat precision straight edge set at 90º on the motor seating flange. Corrections are made with the set-screws. The propeller must not contact the Outlet Head (72.03).

d) Using a feeler gauge at least four (4) points at 90º adjust the clearance between the propeller and Outlet Head (72.03). After checking the propeller clearance recheck the horizontal position per paragraph 1.2 c). Permissible off-center deviation is ± 0.118 inches.

e) After adjusting of the mixer, the set-screws are to be welded to the shim plates and the shim plates are to be welded to the steel supports of the digester.

f) To avoid unnecessary forces acting on the seat ring and mixer, the temporary shuttering must not be supported on the seat ring or the mixer shaft.

g) Secure the seating ring with non-shrink, high sulfate resistant grout.

h) Install the motor with the coupling half mounted. Align coupling halves to within 0.002 inches. (Refer to coupling manufacturer’s recommendations)

i) Check motor and mixer for easy running by rotating the coupling by hand.

OPERATING INSTRUCTIONS – Sect 6 – Commissioning, Operating and Maintenance Gwinnett County Phase II F. Wayne Hill Water Resources Center

6.2.1.1 FLOW FROM BOTTOM TO TOP (CW LOOKING DOWN)

During right hand rotation (as seen from above), the propeller circulates sludge from the bottom of the digester up through the draft tube to the rotating splash disc. The splash disc distributes the sludge over a large sludge surface area softening and dispersing the supernatant sludge layer.

6.2.1.2 FLOW FROM TOP TO BOTTOM (CCW LOOKING DOWN)

During left hand rotation, the propeller forces surface sludge, including coarse floating residue, down the draft tube resulting in an ideal intermixing and blending action that agitates settled sludge in the bottom of the digester. In the event foam forms on the top of the digester, it will be forced down the draft tube and remixed with the digester contents.

The time period for each flow direction is established based on the plant personnel experience with the digestion process.

CCW LOOKING DOWN CW LOOKING DOWN

MIXING TOP TO BOTTOM MIXING BOTTOM TO TOP

OPERATING INSTRUCTIONS – Sect. 7 – Routine Maintenance & Mixer Removal Gwinnett County Phase II F. Wayne Hill Water Resources Center

7.2 (CON’T)

WOERNER GREASE PUMP

FITTINGS FOR GREASE

LINES

GREASE PUMP RESERVOIR

GREASE PUMP

MOTOR – MOUNTED

EITHER VERTICAL

OR HORIZONTAL

REFER TO MAIN

MIXER

ARRANGEMENT

DRAWING

ADJUSTING NIPPLES

BEHIND REMOVABLE

CAPS

Gwinnett County Phase II F. Wayne Hill Water Resources Center

The grease supply from the grease pump can be checked by unscrewing the nipple plug out of the respective distributor hole, using a wrench, until the inspection hole is exposed and grease comes out.

The grease coming out of the upper and lower bearing housing is collected laterally at the bottom in the seat rings well as on the support lantern casing.

This grease is left in the seat ring during mixer operation and shall only be removed prior to withdrawal of the rotor assembly for inspection purposes.

NOTE: A pipe with a bleeder screw for the seat ring inner space is arranged on the top surface of the mixer seat ring, inside the motor lantern flange.

7.3 FLEXIBLE COUPLING

Transmission of the torque from the electric motor to the mixer shaft is via a resilient Flender N-Eupex size A140

During normal maintenance periods, the flexible coupling blocks should be examined and replaced if there are any signs of excess deterioration or destruction. The flexible inserts can be allowed to wear down to 1/3 of the original thickness before replacement is required.

The electric motor need not be removed to examine or replace the synthetic rubber blocks.

For details see enclosed "Installation and Alignment Instructions “Flender N-

Eupex, type A Couplings." In Section 8 of this manual.

Gwinnett County Phase II F. Wayne Hill Water Resources Center

11/2002

Lifting Lugs Mounted on Bearing Housing

Motor Stand/Top Plate

REMOVAL OF EXISTING

MIXER FROM SEAT

RING IN THE DIGESTER

Mixer Motor w/Half coupling Weight = 1,150 lbs.

Grease Pump/Motor

Approximate Lifting Weight:

Mixer Rotor Assy: 2,725 lbs.

SOLIDS STORAGE, AWT FACILITIES 11530: EGG SHAPED DIGESTERS & APPURTENANCES

VOLUME 1 OPERATION & MAINTANENACE MANUAL

CB & I/CONTRACT NO. 127047 CBI PO 139424

SECTION 11 GREASE PUMP & COUPLING

11.1 GREASE PUMP - WOERNER

Model G/PMF-B/10/1250/N/0/0/4/0/0/0/0/6/0

• LEAFLET NO. 0009.06.90.GB

• LEAFLET NO. 9002.06.90.GB

• LEAFLET NO. 0005.06.90.GB

• LEAFLET NO. 0006.06.90.GB

• DRAWING 110.000-15E

• Exploded View

• Gear Pump Parts List

• Installation/Operating Hints for Pumping Elements

• DRAWING 110.031-30

11.2 DRIVE COUPLING – FLENDER

N-EUPEX , SIZE A140

• INSTALLATION AND ALIGNMENT

INSTRUCTIONS - V 420

• COUPLING DRAWING