Specifications-Mobile LiquidSolid Separation System - Specs.docx

Mobile Liquid/Solid Separation System Specifications Description: To build a mobile, trailer mounted treatment system for the removal of solids and phosphorus from liquid animal manures. The goal is to achieve 90% solids removal and 50-60% phosphorous removal with a flow rate of 80-100 gallons per minute. A screw press will be used to remove bulk solids followed by a pair of decanter centrifuges. All equipment and controls must be automated for continuous operation without the need for constant operator supervision. The entire system will be designed to deploy on site with one operator in less than 30 minutes.

General Considerations

· All exterior electrical panels, junction boxes, switches and conduits should be NEMA 4X or better because the system will spend most of its time outdoors and be subject to washdown. Panels are not required to be explosion proof or gas purged. NEMA 4X does not apply to those items already located within a controlled environment (ex. control room)

· System must have manual valves installed for draining to prevent the accumulation of liquids in lines and pumps when not in use.

· All valves and fittings should be of full port design.

· Materials of construction should be selected to provide good resistance when in constant contact with manure. Some stages of the process will emit corrosive gasses like hydrogen sulfide. Material selections should be made to give several years of service without need for replacement. Stainless steel construction would provide the best service.

· This is a mobile unit that must be fully self-supported. Selections of pumps and equipment must be made to conserve onboard resources like fresh water.

· Manure pH generally runs in a range of 5-8.

· The macerator and all pumps must be installed where they can be easily accessed for repair and maintenance. Plumbing connections to these devices should be selected to provide for quick and easy removal via flanges, unions or band/clamp connections.

· A flow diagram for the system is included at the end of this document.

Engineering and Design

· USDA will provide guidance on machine selection and placement. Michael Reiner [michael.reiner@usda.gov; (814)-470-7018] will work directly with the builder to finalize the layout and design of the system.

· Builder must submit drawings detailing the trailer layout to USDA for approval prior to start of construction. Drawings must include placement of main machines, tanks, pumps, control room, generator, leveling system components and conveyors.

· Builder must submit drawings detailing the control room/lab layout to USDA for approval prior to start of construction.

· Builder is responsible for design and engineering of the following items

· Layout of equipment on trailer to meet space and USDOT requirements.

· Electrical and control system including control panels and control room.

· Plumbing and sizing of all related liquid handing components.

· Placement and sizing of leveling system components.

· Centrifuge solids auger and screw press solids discharge conveyor.

· Surge tanks.

· Sizing of the generator.

Trailer Description:

· USDA will deliver a 48 ft step deck trailer for the installation of the treatment equipment.

· Upper deck is 11 ft in length and the lower is the remaining 37 feet. Axles are centered ~91” from the rear of the trailer

· Upper deck is approximately 60” from the ground and the main deck is approximately 40 inches with air bags inflated.

· Trailer is equipped with air ride suspension, manual suspension drop valve, and bar grate flooring (can provide pictures)

· Trailer width is 99” and has a load carrying capacity of 50,000 lbs. Empty weight is 13,100 pounds with GVW listed at 63,100 pounds.

· Finished trailer dimensions cannot exceed 8.5 feet wide and 13.5 feet high

· Trailer has new tires and air bags in addition to a current safety inspection.

· Modifications to the main trailer frame that will lower or compromise its structural integrity will not be allowed.

· Trailer must be equipped with a hydraulic leveling system.

· Level system will use hydraulic landing legs powered by an engine or electrically powered hydraulic pump. This pump must meet the specifications of the landing legs used.

· Should an electrically powered hydraulic pump be selected, the standard manual crank landing gear on the front of the trailer must remain to allow for coupling and uncoupling of the trailer when an electric power source is not available.

· Should an engine driven hydraulic pump be selected, the standard manual crank landing gear on the front of the trailer can be replaced with hydraulic landing legs.

· A pair of front mounted hydraulic landing legs will be installed near the front of the trailer. A second pair of hydraulic landing legs will be installed near the rear of the trailer. Mid-mounted landing legs may also be required. Builder is responsible for engineering the locations and number of landing legs required based on the total weight and positioning of all trailer mounted items. The effect of lateral loads on the landing legs must also be accounted.

· The landing legs must level and fully support the weight of the trailer and components in operation mode.

· All landing legs will be controlled via valves at a single control point. Each landing leg must be individually controlled.

· Landing legs must be capable of leveling the trailer on at least a 5% slope. Cribbing can be used to gain additional lift in some situations. Landing legs must retract upward with enough clearance to prevent damage from scraping or dragging. A good rule of thumb would be roughly equivalent to the current landing gear on the front of the trailer and not below the ICC bumper at the rear of the trailer.

· Hydraulic power would be available for other accessories if needed (example: conveyor positioners).

· Additional mounting and structural supports must be added to the main trailer frame to facilitate the mounting of the landing legs.

Screw Press

· A brand new Boerger RC-40 screw press with a self-contained control panel, macerator and rotary lobe feed pump will be provided. The screw press is equipped with 0.5 mm screens.

· These items have been purchased and will be shipped to the builder with the trailer.

· All equipment will be mounted on a steel skid that will need to be positioned and fastened to the trailer. Use of this skid is not required, a custom-built skid can be used.

· A drawing is attached but it does not include the macerator

· The macerator will be factory mounted on the pump inlet, however it can be moved and replumbed as needed. Moving it to the side of the trailer and partially below the floor could be a better use of space.

· The feed pump is a rotary lobe type pump with automatic VFD control built into the control box.

· Plumbing will need to be provided from the side of the trailer into the macerator. Connection will be 4” female camlock coupling and must include a knife or gate style valve immediately following the camlock coupling. This connection should be located on the opposite side of the conveyor discharges.

· A flow meter must be installed in line between the Boerger rotary lobe pump and the screw press.

· A clean water, high flow flush line with valve must be included on the inlet plumbing to the macerator. Flush line must be connected to the clean water pump.

· All controls for the skid mounted screw press equipment will be mounted and housed in a provided control panel.

· The VFD controlled feed pump is automatically adjusted based on a pressure sensor located on the screw press. Screw press motor load may also be used as a control feature, please consult Boerger.

· Use of this panel is not required, controls can be relocated to the main control area for the trailer provided all the Boerger logic components are used. Modification of the logic controls can be done if they meet the specifications set forth by Borger and do not void any warranties.

· Motor sizes that were provided (will need verified at time of delivery), all 3 PH, 460/480V

· Macerator: 5 hp

· Screw Press: 10 hp

· Feed Pump: 10 hp

· Liquid from the screw press will be discharged from the bottom of the press. This will gravity drain through plumbing to a surge tank.

· Surge tank should be of stainless steel and designed as a full drain tank with a sloping floor. Must be of closed top design with a closing access hole roughly 12” in diameter to allow for manual washdown and collection of liquid samples. Suggested volume of roughly 100-200 gallons.

· A level control system in the surge tank will automatically start and stop the screw press feed pump as needed. Level controls should also be included to start and stop the centrifuge feed pumps.

· Tank must be equipped with a drain valve to prevent buildup of liquid when the system is not in use.

· Tank will also include a high flow water port for flushing of the centrifuges.

· Tank must be equipped with a ½” NPT port for induction of chemicals.

· An adequate vent stack should be added to the surge tank to prevent the buildup of manure gases.

· Solids will be discharged from the screw press to a conveyor to carry them from the trailer

· The builder is responsible for providing a belt or similar style conveyor suitable to this application, for discharge/stacking of the solids from the screw press. Approximate conveyor length is 10 feet.

· The conveyor must be mounted on a swiveling base and the discharge end must be height adjustable. All positioning of the conveyor must be part of the trailer itself. We will not have access to forklifts or loaders for movement/positioning/setup of the conveyor.

· A hopper must be added to the feed end of the conveyor to assure solids from the screw press will fall in the conveyor in any position.

· Conveyor must swing into the trailer and sit in fixed a cradle for transport. Conveyor must pin or strap into cradle to prevent dislodging in transport.

· Conveyor swing will be manual or hydraulic with a positional holding device.

· Conveyor height can be manual via a cable winch or powered by a hydraulic jack. Can also use a hydraulic cylinder powered by the trailer leveling system. The conveyor should be capable of discharging material into a dump truck (10 ft high sides) or other farm machinery for handling of solids.

· Estimated conveyor motor size is 1.5 hp (3 PH, 460/480V) and will be controlled by a VFD control on the main control panel.

Centrifuge

· A currently owned Sharples P-3400 fixed back drive centrifuge will be delivered with the trailer.

· This unit was purchased reconditioned with a new electric drive motor and new stand. Since purchase, it has only seen roughly 100 hours of use.

· A second reconditioned Sharples P-3400 centrifuge must be provided.

· Both the owned and provided centrifuges must be equipped with adjustable back drive units and individual control panels. The feed tubes of both units should be redesigned to help reduce foaming/aeration of the separated liquid.

· To best use available trailer floor space, it is recommended to mount the centrifuges parallel to each other along the length of the trailer. This idea suggests that both the centrifuge and back drive units be of inline design.

· A new framework will need to be fabricated to hold the centrifuges and the drive motors. This frame must then be attached to the trailer. Additional system components like the water tank, surge tank, etc. can be housed under the centrifuges.

· Both centrifuges will be controlled from the centralized control location. Each centrifuge will have a dedicated control to allow for individual operation.

· Each centrifuge will be fed by a its own progressive cavity, VFD controlled pump connected to the screw press surge tank. A safety pressure relief/control should be included on the outlet of each pump.

· Feed pumps must be VFD controlled via operator configured presets and readings from appropriate flow meters. Three phase, 460/480V.

· Each centrifuge must have a flowmeter and shutoff valve on the liquid feed. Flow readings and controls located on the central control panel. The feed to centrifuge 1 will also require a TSS meter (see Sensor section for more details).

· Each pump must be equipped with a ½” NPT port near the inlet for induction of chemicals.

· Pumps can be mounted beneath the trailer floor.

· Pumps will use level switches in the screw press surge tank for starting/stopping. They will also need a manual option that does not require the level switches when the centrifuges are used without the screw press.

· Pumps must have a drain valve to prevent the accumulation of liquid when not in use

· Pumps must be of self-priming design (25 ft) and capable of handling solids. Screw press should limit solids size to 1.0 mm max.

· Inlets of pumps should be configured with an auxiliary inlet (2”male camlock). Auxiliary inlet and surge tank plumbing must have manual valves (individual 2-way or single 3-way) for operator configuration selection. This allows for use of the centrifuge(s) without the screw press. When used in auxiliary inlet mode, the pumps could see up to 1” spherical solids.

· An accessible sample port of ½” nominal size with ball valve should be included in the feed line to each centrifuge.

· A port at each centrifuge inlet fitting will be required to winterize the centrifuges with RV antifreeze.

· Solids from the centrifuges must be discharged from a single conveyor

· This conveyor must be separate from the screw press conveyor.

· Expected material consistency suggests use of a screw type conveyor.

· Conveyor can be an incline or horizontal unit that will discharge at least 6 feet from the trailer and at least 6 feet high. Height adjustment is preferred but not required if the 6 ft minimum height is met.

· This conveyor must fold, slide, roll, or swing in for transport much like the screw press solids conveyor. Deployment of the conveyor must be manual, cable winch or hydraulic. A forklift or loader will not be available.

· Estimated conveyor motor size is 3 hp (3 PH, 460/480V) and will be controlled by a VFD control on the main control panel.

· Centrifuge solids conveyor must discharge to the same side of the trailer as the screw press solids conveyor.

· Liquid from the centrifuges will be directed by gravity to a single centrifuge effluent surge tank.

· A single VFD controlled progressive cavity pump will discharge the centrifuge liquid from the surge tank. Pump must have a drain valve to prevent the accumulation of liquid when not in use.

· Surge tank should be of stainless steel and designed as a full drain tank with a sloping floor. Must be of closed top design with a closing access hole of at least 12” in diameter to allow for manual washdown and collection of liquid samples. Suggesting volume of roughly 100-200 gallons.

· A level control system in the centrifuge liquid surge tank can be used to automatically start and stop the discharge pump as needed.

· Tank must be equipped with a drain valve to prevent buildup of liquid when the system is not in use.

· Tank will also include a high flow water port for flushing of the tank.

· An accessible sample port of ½” nominal size with ball valve should be included in the pressure side of the discharge plumbing.

· Discharge pump must provide for 100’ of distance and 25 feet of head from the location of the trailer.

· Discharge pump must be equipped with a ½” NPT port near the inlet for induction of chemicals.

· Surge tank must be equipped with a ½” NPT port for induction of chemicals.

· Discharge plumbing must contain a flow meter and a location for installation of a TSS meter in the future (see sensor section for more details on the TSS meter)

· A fixed outlet line from the discharge pump should terminate at the side of the trailer with a valve and 2” male cam lock connector. The discharge connection will be located on the same side of the trailer as the screw press inlet connection. User provided hose assemblies will connect there for discharge of the liquid to the appropriate holding area.

· Liquid will be discharged through user provided 2” reinforced PVC suction hose with a maximum pressure rating of 50 PSI. Discharge pump will need a safety pressure relief included on the outlet to limit pressure to below the 50 PSI maximum.

· An adequate vent stack should be added to the surge tank and/or centrifuge covers to prevent the buildup of manure gases. A single outlet is preferred so gas monitoring equipment can be added in the future.

· Our current centrifuge is producing a highly aerated effluent which is causing pumping issues and is preventing us from doing further treatment effectively. The previously mentioned feed tube design change should reduce foaming/aeration. Changes to the bowl liquid exit design may also reduce foaming.

Water System

· A non-potable water tank capable of transporting 300-500 gallons of fresh water is required. Metal construction is preferred.

· A horizontal aluminum, 400 gallon tank could be provided. 97”L x 46”W x 59”H (photo available)

· A pump must be included to provide adequate flow for flushing all equipment with dedicated flush lines.

· A flush line with valve from the pump to both surge tanks is required. A wash nozzle should be located inside each tank to distribute the flush water.

· A flush line with valve from the pump to the manure feed line prior to the macerator is required.

· Flush line valves should be automated and controlled from the control panel.

· A minimum of one standard garden hose connection is required for cleanup.

· Previous system used a well pressure tank and pressure switch to control the clean water pump. This gave access to water for the garden hose without the pump running and delivers high flow when needed for flushing equipment.

Electrical System

· A transformer will supply a single-phase distribution box. This will be used if we choose to add lights for nighttime operation, dosing pumps, additional flow meters, and other 120-volt accessories. The transformer may also be used for signal voltages, control room electrical, lab equipment and any low voltage the controls.

· All circuits for motors and transformers should be fuse protected ahead of the switchgear.

· Thermal overloads or equivalent protection devices must be used on all motor circuits.

· Entire system will be powered by a diesel generator specified in next section.

Power Generation/Generator

· A generator will be required to power the system and must be included.

· The builder responsible for load analysis and sizing of the generator.

· Generator will be a diesel-powered unit meeting at least Tier 4i emissions requirements. Fuel capacity of unit must provide for at least 24-hour continuous operation. Generator must be housed in a sound attenuated enclosure.

· Generator may be a brand-new unit, or a low hour used unit that meets the needs of the system. A used unit must include a one-year parts and labor warranty that covers all non-maintenance items and repairs.

· Use of the generator will meet one of the two following layouts.

· Generator can be mounted on the trailer with equipment if space is available. This is the highly preferred option.

· Generator could be a separately towed unit that would connect to the trailer using portable cables with camlock connectors. This option would require the installation of a connection panel for the connectors (Hubbell series 16).

· Ultimate location of generator will be set based on availability of trailer space and weight capacity.

Control System

· All machines must have master controls on the main control panel. Secondary controls on machine sub panels are acceptable but not required.

· There should be at least one emergency stop button on each side of the trailer. These buttons will shut down all pumps, conveyors, and the screw press. The centrifuges should stay running when the emergency shutdown is enabled.

· All liquid level/pump controls must use a three-tiered approach: low limit/pump off, high limit/pump on and an overfill limit alarm that will stop all pumps prior if the alarm is triggered.

· Level controls selected must read liquid and/or foam levels. Float style switches will not be acceptable.

· Overview

· All machines will be controlled at the master control point. The master control point will be located inside an insulated climate-controlled room. This room will also serve as a small lab for basic testing of collected samples. Minimum size of 8’ by 8’ (outside dimension) is required.

· Operators will have access to switches and controls for adjusting all system parameters.

· Control panel must also provide feedback to the operator in the form of measured values, sensor readings, machine diagnostics, and record keeping.

· Actuation of non-manual control valves would also be completed though the control panel.

· Space for additional controls must be provided should future work necessitate the need for additional controls.

· Flowmeters/controls used must be able to provide flow readings to other devices like chemical dosing pumps should they be added at a later date. Flow meters used must use a full port design with no moving parts. Magnetic or ultrasonic type flow meters are recommended.

· Datalogging

· The control panel must also contain a data logging feature with built in hard drive.

· Extra space for future sensor connections (6-12) is required.

· We will want to record all flows, system settings, senor readings, etc. for record keeping as well as decision making.

· Connection

· We would like to be able to connect to the system remotely to view data, adjust setting/parameters and check system status.

· The connection should be a WiFi setup that can be configured to use a currently owned Jetpack/Mobile hotspot.

· Sensors

· The four liquid flowmeters will provide the necessary flow measurements.

· A pH meter should be installed in the discharge plumbing from the centrifuge effluent surge tank.

· A pH meter should be installed in the inlet plumbing prior to the screw press.

· A Valmet TSS meter will be installed in the line feeding centrifuge 1. The controller for the TSS meter will be located on main control panel.

· An access point with a “blank” will be installed in the centrifuge discharge plumbing. This will allow us to manually move the single TSS meter for pre and post centrifuge measurements. Should the unit prove effective in both locations, a second until would be purchased in the future. The TSS unit must be sized to work in both locations.

Paint

· New steel work will need to be prepared, primed and painted. The trailer chassis must be painted to match. Some light sandblasting may be required on trailer frame to prepare rusty areas. Preferred color is ‘Safety Blue’ or a similar shade of blue.

· Galvanized steel components will not require painting unless the galvanized coating has been damaged. Galvanized surfaces must be properly prepared before any paint application.

· Stainless steel, rubber, and plastic components are not required to be painted.

Training

· Training of system operators prior to delivery is required. Training would be completed at location of system construction and be provided by the builder and any related equipment suppliers.

Trailer Accessories

· Side mounted mesh storage area located below floor to hold five 20’ lengths of 4” hose and five 20’ lengths of 2” hose. Area should be at least 21’ long to allow for fittings. We can reduce the length of the hoses to 15’ if the length is not available on the trailer. This box would be located on the same side of the trailer as the input and outlet connections.

· A smaller storage mesh storage box should be included to hold wood blocking and weight distributing pads that would be used under the legs of the leveling system.

· A ladder or approved stair section will be needed to access the trailer control area from the ground.

· Sampling locations not accessible from the side of the trailer will also need stairs or a ladder to gain access from the ground.

· Any stairs, ladders, railings, walkways or catwalks must meet OSHA requirements.

· The control room will have a work area for performing lab analyses. Size of the work area is subject to the available space remaining in the control room. The workspace will require a solid countertop, drawers and shelves for storage below the counter, wall mounted storage, several 120V outlets, place for a small sampler oven and place for a small sample refrigerator. Please work with Mike Reiner and Sarah Fishel to layout and setup the actual lab workspace.

Transportation

· USDA will work with the builder to arrange for transportation of the trailer and all currently owned items needed for construction of the system to the manufacturing location.

· Some items may be direct shipped to the manufacturer to reduce shipping expenses.

· USDA will arrange for transport of the completed system back to Pennsylvania.

USDA/User Added Items (after delivery)

· Garden hose with nozzle and hose reel.

· Four-inch suction hoses with camlock fittings to feed system.

· Two-inch discharge hoses with camlock fittings for discharge of processed liquid.

· Portable power cords and adapters to connect generator (dependent on generator layout; 4/0 type W portable cord, Hubbell series 16 connectors)

· Additional lighting (if required)

· Automatic sampling equipment (if required)

· Miscellaneous 4” and 2” adapter fittings

· Additional storage boxes for tools, maintenance supplies, equipment, etc.

· Lab and testing equipment.

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