Section 11398 - Dissolved Air Flotation Thickeners City of San Diego, CWP Guidelines 1 - General
Section 11398 - Dissolved Air Flotation Thickeners City of San Diego, CWP Guidelines 1 - General
PART 1 -- GENERAL
A. The WORK of this Section includes providing equipment for dissolved air flotation thickener
(DAFT) units for the concentration of mixed primary and secondary sludges and scums as
follows: float and sludge collection equipment suitable for a circular tank, drive equipment,
access bridge, float troughs, air dissolution equipment including tank and backpressure
valve, air compressors, pressurization pumps, tank covers and miscellaneous appurtenances.
Equipment shall be suitable for installation in a circular concrete tank with the applied solids
stream entering at the bottom of the tank.
B. The WORK also requires that one manufacturer accept responsibility for furnishing the
WORK as indicated but without altering or modifying the CONTRACTOR'S responsibilities
under the Contract Documents.
C. The WORK additionally requires that the one manufacturer who accepts the indicated
responsibilities shall, as a minimum, manufacture the sludge collection mechanism.
$#
#$
A. The WORK of the following Sections applies to the WORK of this Section. Other Sections
of the Specifications, not referenced below, shall also apply to the extent required for proper
performance of this WORK.
11. ASME Section VIII Boiler and Pressure Vessel Code; Pressure Vessels,
Division I
B. Structural Standards:
2. Structural Design: All steel structural components shall be so designed that the
stresses developed under the indicated conditions will not exceed the allowable
stresses defined by the AISC standards and the aforementioned standards.
1.4 DEFINITIONS
3. Cutout Torque: The torque load at which a motor cutout switch is activated to shut
down the unit. The cutout torque is defined to be 120 percent of the continuous
operating design torque.
4. Momentary Peak Torque: The maximum or peak torque of the drive unit assumed to
be equal to twice the calculated AGMA torque rating of the spur gear set or 3 times
the calculated AGMA torque rating of the worm gear set, whichever is lower.
1. Complete certified equipment drawings and details, showing all dimensions, weights,
materials of construction, structural members, float and sludge collection members,
beach assembly, welds, torque ratings, and gears.
4. Anchor bolt placement measured from construction joints in the concrete structure.
Anchor bolt details shall include projections from concrete.
5. Type and size of structural details, float and sludge drawoff pipes, including method
of return sludge flow control, and all pipe connection details and supports.
9. Air compressor details, including performance curve, dimensions, and mounting details.
10. Backpressure regulating valve details including performance data over the indicated
flow range.
11. Specifications, detail drawings and information for the drive mechanism including type,
input and output speeds, exact gear ratios, service factor and efficiency of gear
reducer units and drive assembly.
13. Size, make, type designation and mounting details of all electric motors indicated in
this Specification.
14. Details and description of the overload protection assembly and alarms. Details
submitted shall clearly demonstrate the adequacy of the overload protection provided
by the assembly proposed.
15. A copy of the Contract Document control diagrams and process and instrumentation
diagrams, with addenda updates, that apply to the equipment in this Section marked
to show specific changes necessary for the supplied equipment. If no changes are
required, the drawing shall be marked "no changes required."
17. Information on at least one successfully performing installation of comparable size and
complexity constructed in the recent past including contact name, address, and
telephone number.
1. Calculations substantiating the output torque rating of the drive selected, including
gears and pinions. The calculations shall clearly specify the values used for the
following design parameters for surface durability and strength ratings:
Number of Pinions
Actual Face Width
Tooth Geometry Factor (I and J Factors)
Load Distribution Factor
Allowable Contact Stress
Allowable Bending Stress
Pinion Pitch Diameter
Tooth Diametral Pitch
Hardness Ratio Factor
Elastic Coefficient
Life Factor
The load distribution factor shall be determined as described in the referenced AGMA
standards. The net face width for surface durability calculations shall not exceed 90
percent of the actual face width of the narrowest of the two mating gears. For
parameters which are material dependent, such as allowable contact stress, the
calculations shall include a full description of the materials and heat treatments used.
2. Calculations showing the related stresses developed in the drive cage and sludge
collection arms at 200 percent of the continuous operating torque per paragraph
[2.4C].
1. Startup procedures
2. Shutdown procedures
3. Troubleshooting
4. Selection of proper polymer types and dosages
5. Backpressure control valve adjustment
6. Operating adjustments for performance optimization
7. Preventive maintenance
8. Maintenance procedures
9. Emergency procedures
10. Records keeping
The training manuals will be retained by the trainees, and not returned to the manufacturer.
1.8 QUALIFICATIONS
$#
NTS: In the paragraph below, define the terms "comparable size and complexity"
for the equipment or system specified. Requiring experience of more than
one successful project requires sound justification and prior written approval
from the City Project Manager.
#$
PART 2 -- PRODUCTS
2.1 GENERAL
A. The following equipment shall be included with the dissolved air flotation thickener system:
I.D.
Quantity Equipment No.
[ ] Drive unit [
]
[ ] Sludge and float collector mechanism [
]
[ ] Pressurization pumps [
]
[ ] Air dissolution tank (s) [
]
[ ] Dissolution tank solenoid (s) [
]
[ ] Dissolution tank level controller (s) [
]
[ ] Air compressors [
]
[ ] Backpressure control valves [
]
[ ] Torque switch (shutdown) [
]
A. Performance Requirements: The system shall be designed to perform under the following
conditions:
2. Influent characteristics:
Note 1: Surface loading rate is defined as the average loading based on the total loading
with [one] tank out of service.
Note 2: Hydraulic loading rate includes pressurized flow and feed sludge at [ ] to [ ]
percent solids concentration.
Note 3: Pressurized flow is based on one pressurization pump in operation per air
saturation system at given loading.
B. Design Criteria: The following shall be used for design of the equipment provided under this
Section:
1. Tank Dimensions:
Diameter, feet [ ]
Sidewater depth, feet at wall [ ]
Floor slope [ 1:12 ]
[Submerged launder, internal diameter, feet [ ]]
5. Pressurization Pumps:
Live load
Uniform, lb/sq ft [ 50 ]
Concentrated, point load, lbs [ 400 ]
Note 4: The system shall be designed to permit the use of polymers as a flocculating aid.
However, the design shall be based upon operation under average conditions without
chemicals. Polymer, prepared in diluted liquid form elsewhere in the plant, may be pumped
to DAFTs by positive displacement pumps.
Note 5: Saturation efficiency is defined as the ratio of the actual amount of air dissolved
in the full pressurization flow to the theoretical amount that could be dissolved in the
pressurization flow at the design pressure and test temperature.
Note 6: Dissolution tank detention time is defined as the pressurized flow detention time
in a volume equivalent to the volume of air space above the controlled liquid level in the
tank.
$#
NTS: Design Consultant shall specify additional requirements for the covers, such
as unbalanced loading and wind loading, as necessary based on type of
dome used and geographical area of the project.
#$
Main bearing races AISI 4140 alloy steel 38-46 HRC per ASTM E18
Flights (bottom sludge) 1/4-inch, ASTM A 36, steel blade flights with
adjustable 20-gauge, AISI type 316 stainless steel
squeegees
Access bridge
Air dissolution tank Steel designed per ASME Code, Section VIII, Division
1, for 125 psig design working pressure
Pressurization pumps
DAFT cover structural supports [ASTM B 308 aluminum, 6061-T6 or 6063-T6 alloy]
2.4 EQUIPMENT
A. Influent Structure: The tank influent structure shall consist of the center column and
influent distribution well, with adjustable influent distribution weir plate.
Six to eight equally-spaced ports shall be provided in the center column for discharging
liquid from within the column into the distribution well. The ports shall be sized by
the DAFT equipment manufacturer to minimize head loss at this location. [Under no
circumstances shall the ports be submerged at any flow. An allowance of at least 6
inches shall be provided between the free water surface in the center column and the
top of the ports.] [A deflector plate shall be located in the influent center column as
indicated to direct sludge flow out of the center column ports into the tank. A seal
between the deflector plate and carrier pipe housing shall be provided to prevent water
and foam from entering the center column above the ports. The seal shall consist of
the rubber boot and mechanical fastener which can be secured around the carrier pipe
from outside the center column. The influent center column shall have ports that shall
be below the tank minimum water surface elevation.]
2. Carrier Pipe: The carrier pipe, which shall contain the pressurized flow and polymer
pipe shall be removable and designed as a stiffened structural member projecting down
the center column to near the tank bottom. The carrier pipe shall resist all forces that
result from release of the pressurization flow and its encounter with the incoming
sludge flow. The pipe shall be designed to bolt securely to the top of the center
column and to bolt to intermediate supports attached within the center column and
located above the water surface in an area not exposed to sludge. Access to these
attachments shall be provided by two openings in the center column, minimum 18
inches in diameter, located above the operating water surface; associated covers shall
be attached with stainless steel hardware. No spiders, stiffeners, or other structural
attachments or obstructions will be permitted in the annular space between the carrier
pipe and center column in the path of the mixed sludge and pressurization recycle
flow. The drive unit configuration shall be designed such that, with the worm gear
housing removed, the entire carrier pipe assembly, with the skirt removed, can be
removed from the center column through the drive unit.
3. Carrier Pipe Skirt: The bottom of the carrier pipe shall have a bolt on two piece
removable skirt. The skirt shall extend one foot below the backpressure control
devices and shall be securely fastened to the carrier pipe with stainless steel hardware
and rubber seal that allows the skirt to be dismantled and removed from the center
column through access ports. The skirt shall have two access ports with covers,
attached with stainless steel hardware, which will allow inspection and repair of the
backpressure control devices from outside the center column.
4. Pressurized Flow Pipes: The pressurized flow pipes shall extend just beyond the
terminus of the carrier pipe such that the backpressure devices are located within the
5. Distribution Well and Weir: The distribution well and weir shall be arranged to promote
uniform distribution of the influent flow radially over the entire surface of the DAFT
by inducing a slight headloss over a submerged weir. The influent distribution well
and weir shall be supported from the drive cage and shall rotate therewith. A seal
shall be provided at the bottom of the well between the rotating floor and the
stationary center column to prevent the passage of liquid into the DAFT at this point.
The well shall be designed and supported to preclude distortion and deflection of the
weir when the well is full and the tank empty and vice versa.
The influent distribution weir shall be mounted on the outside of the influent
distribution well as indicated. The weir shall be adjustable to allow overflow depth to
vary from a minimum of 3 inches to a maximum of 12 inches from the liquid level
indicated, and be designed to allow for expansion and contraction. The interface
between the weir and distribution well shall be sealed with a neoprene gasket. The
overflow depth shall initially be set for [7.5] inches.
[B. Submerged Subnatant Collection Launders: Fabricated submerged collection launders shall
be supported from the inside of the tank wall and shall be fabricated of steel pipe with
regularly spaced orifices. The number, size, and construction details of the orifices and
launder supports shall be as indicated.]
[B. Effluent Weirs and Baffles: The effluent weirs shall be mounted on the inside PVC lined
concrete periphery of the tank and shall be fabricated of 1/4-inch thick close-fitting injection
molded fiberglass which complies with Section 06610. Rectangular notches, 1-1/4 inches
in width shall be provided as indicated. Weir plate anchor bolts shall be 316 stainless steel
located as indicated. The weirs shall be slotted to permit not less than 6 inches of
adjustment.
The effluent baffle shall be fabricated of continuous steel and shall extend completely around
the tank approximately 10 inches in from the effluent weir. Baffle mounting and width shall
be as indicated. A positive seal shall be provided where the weir intersects the float
troughs.]
C. Drive Cage: Torque shall be transmitted from the drive unit to the rotating components of
the mechanism by a drive cage. The drive cage shall encompass the center column and
shall be fabricated of structural steel shapes of sufficient strength to transmit and/or carry
all loads and stresses associated with 200 percent of the continuous operating torque
without deflection or distortion. The rotating drive cage shall be designed to maintain the
minimum wiper clearance above the operating water surface without conflict with the tank
cover. The drive cage shall be designed to allow access to both cover plates in the center
column at the same time. Means shall be provided at the connection to the main gear to
permit vertical alignment of the cage in the field.
E. Float Collectors:
1. General: The float collector shall consist of float collector flights supported by a
pinwheel-type structure in a manner conforming to that indicated. The primary
structural member shall extend radially from the center drive cage to wheels that ride
on the outer rail. Pairs of secondary supports shall be placed as chords between each
primary member. Operation of the float collection system shall be smooth and without
sudden motion [at all speeds within the indicated range]. Skidding, jerking, stalling,
bumping, deflection of the primary radial members, or any interruption to the smooth
motion of the collector will not be acceptable.
2. Flights: The flights shall be supported on axles that span the chords in a manner
which will leave the flight wipers radial when their tips are 6 inches below the float
trough lip on the collection box. The float collector flights shall be equally spaced and
shall be designed to move the float up the collection beach and into the flat trough
with less than 1 inch of horizontal deflection when the flight moves vertically 3 inches
in either direction from the above referenced radial setting. No portion of the collector
mechanism other than the wiper blades shall be allowed to engage or enter the liquid
contents.
The float sludge collector flights shall be suspended from above by bearings on a fixed
shaft or fixed to a shaft mounted in bearings on the secondary supports. The
bearings shall be of the self-aligning, permanently lubricated, sealed type. The
attachment between the flights and chords shall allow the flight to deflect toward the
center of the tank as it tips up above the water surface while passing over the beach
and float trough. This connection shall also allow individual flights to be taken out of
service by rotating up and securing to the carousel, without the flight interfering with
the tank wall and cover while in this position. In normal operation, the outboard-side
flight wiper blade shall firmly contact the peripheral tank wall. This shall be
accomplished by spring or other apparatus made from Type 316L stainless steel with
adjustable tension, such that the flights move smoothly throughout rotation and do
not bind when passing over the float trough. The inboard-side of the flight wiper
blade shall maintain sufficient contact with the beach inboard curb to minimize leakage
of captured float back into the tank.
The method used for attachment of wipers to the wiper suspension system shall
permit at least 3 inches of vertical adjustment of wiper position (in 1-inch increments)
above and below the liquid elevation indicated. Adjustments shall be achieved using
permanently fixed carriage bolts, lockwashers, and wing nuts not less than 1/2-inch
nominal diameter. Adjustment of wiper blades and liquid level within the range
indicated shall not result in other members dragging in the liquid and stirring the tank
contents.
Each flight shall have two 1-inch holes by which it can be secured in a raised position
when out of service. The holes shall be placed for minimum lateral deviation from
underneath the chord supports as the flight travels around the tank. The ties between
the flight and the chord supports shall be stainless steel chain. Stainless steel
fasteners shall be provided at the flight and at the chords. Fasteners at the chords
shall allow easy adjustment of length of tie.
3. Support Wheels and Rails: The wheels for the primary structural members shall be
designed to support the full load of all attached structural components and shall have
enough width to account for all of the rail eccentricity. Transverse movement of the
axles will not be permitted. Wheels shall have permanently lubricated, sealed bearings
and shall be mounted on the primary structural member in a manner which will
accommodate the radius of the support rail. Casters, if furnished, shall also have
permanently lubricated and sealed bearings. All bearings shall be specifically designed
to provide not less than 5 years' continuous duty in a moist atmosphere where gritty
materials may be present.
The rail or similar steel section on which the primary support arms ride shall be
attached with brackets to the peripheral concrete wall of the tank. The rail shall be
curved (±1/4 inch tolerance) to match the curvature of the tank at the point of
support. The rail shall have supports (such as a rolled channel underneath the rail) to
prevent deformation by arm loading. The rail shall be level and meet a ±0.01-foot
tolerance in elevation. Provisions shall be made to allow adjustment of rail level at
each support.
F. Float Troughs: The trough assembly shall be fabricated as indicated and shall consist of a
collection beach, the float trough, and a trailing ramp. The leading ramp and trailing ramp
shall be constructed to provide continuous contact between the entire length of the wiping
blades and the ramp surfaces throughout the duration of contact. The trough length shall
be a minimum of 4 feet. The beach shall be vertically adjustable.
The underside of the trough shall be shaped to avoid flat or concave surfaces which could
trap float. At the CONTRACTOR'S option, inner spaces within the troughs may be filled
with polyurethane foam to prevent the spaces from filling with liquid. The troughs shall be
supported by cantilevered brackets attached to the tank wall. The trough, including the
skimming beach, shall be fitted with braces and otherwise stiffened and supported to
prevent movement when the tank is being filled with liquid and when the skimming arm
passes over the trough. Movement (tank empty to tank full) shall not exceed plus or minus
1/8 inch.
G. Drive Mechanisms:
1. General: The drive assembly shall include an [electric gear motor,] [variable speed
drive,] worm gear and worm gear reducer, pinion gear, turntable type main spur gear,
drive base, shear pin hub coupling, steel roller drive chain, torque overload protection
system and non-rotation detection system. Gears shall be AGMA Quality 8 or better.
The driving and driven gears shall be designed in accordance with AGMA 6034-A for
a service factor of 1.25 applied to the continuous operating torque; AGMA 908-B and
The drive assembly shall be firmly mounted to a cast iron turntable base with a
minimum wall thickness of 1/2-inch. The drive base shall be mounted on the center
column and be provided with a positive leveling feature. The drive mechanism shall
be mounted on the influent column with the top of the spur gear housing capable of
supporting the total access bridge load by means of equally loaded, removable bridge
supports. Drive mechanism components shall be designed for the rated torque
indicated in paragraph [2.2.A.] All drive equipment, including gears, bearings, motor
and variable speed drive shall be located above the cover and accessible from the
bridge.
[2. Drive and Primary Reduction, Variable Speed: The electric motor for the drive shall be
suitable for operation under all weather conditions and shall be provided with a sealed
conduit box. The motor shall be the heavy duty type per Section 16040. A 12
gauge steel belt guard, hot-dip galvanized after fabrication, shall be provided.
The variable speed drive shall be V-belt driven and shall be a hydrostatic type, positive
displacement unit designed to transmit a constant output torque over a 27 to 1
variable output speed range. The hydraulic drive shall be fitted with a flange-mounted
reduction gear and modified to obtain only the collector rotational speed range
indicated. The drive shall be compact, self-contained, and totally enclosed in a cast
iron housing suitable for outdoor service. Oil fill and drain plugs and level indicators
shall be provided and shall be easily accessible. The drain shall be at the lowest point
of the oil reservoir. Speed control shall be through a manual indicating mechanism
capable of adjusting speed with the drive speed within 0.5 percent of the indicated
speed over the full range of out put loads. Oil temperature rise shall not exceed 60
degrees C at maximum rated load at a maximum ambient temperature of 50 degrees
C. Drive efficiency shall be at least 70 percent at full speed and 65 percent at half
speed. ]
[2. Drive and Primary Reduction, Variable Speed: The collector mechanism shall be
capable of operation through the speed range specified through the adjustment of a
variable frequency drive. The variable frequency drive shall conform to the
requirements of Section 11032 and shall be specifically selected to provide continuous
(24 hour) smooth, steady operation at the torques indicated with the speed range
specified. The variable frequency drive shall be located as indicated in the motor
control center serving the DAFT.]
[2. Gear Motor: The drive motor shall be an 1800 RPM heavy duty motor in accordance
with Section 16040. The gear motor shall be designed for continuous duty, Class II
applications in accordance with AGMA 6019-E.]
The [variable speed drive] [motor] shall be directly coupled to a primary gear reducer.
The gear reducer shall be self-contained and enclosed in a cast iron housing and
provided with oil fill and drain plugs. Gear reducers shall be designed in accordance
with AGMA 6010-E with a minimum safety factor of 1.5 or greater.
Power transmission between the primary gear reducer and the intermediate gear
reducer shall be made through a roller chain and sprocket drive assembly. Chain shall
be permanently lubricated "O"-ring type chain. Sprockets shall be hub type, plain
bore, steel or cast iron. The drive sprocket shall be fitted with a shear pin designed for
3. Intermediate Gear Reducer: The intermediate gear reducer shall be a worm gear type
specifically designed for this service. The assembly shall consist of a ground worm
and a centrifugally cast worm gear. The worm gear assembly shall be self-contained
and enclosed in a cast iron gear case and with oil fill, level, and drain fittings and a
sight gauge. The drain shall be at the lowest point of the oil reservoir and shall be
accessible. Oil fill and level indicators shall be easily accessible. The worm shall be
integral with the worm shaft. The worm gear torque capacity shall be determined
according to AGMA 6034-A for service factor of 1.50 applied to the continuous
operating torque.
4. Spur Gear Assembly: The pinion and pinion shaft which drive the internal spur gear
shall be made as an integral unit from forged alloy steel. The pinion shall be rigidly
supported by bearings located above and below the pinion gear. Overhung pinions
shall not be acceptable.
The spur gear shall be AGMA Quality 5 and shall be designed and rated in accordance
with AGMA 908-B and 2001-B with a service factor of 1.5 or greater applied to the
continuous operating torque. If the spur gear is of a split gear design, the two halves
shall be furnished with precision mating surfaces with self-registered and indexed fits.
The spur gear housing shall be cast iron. A felt or neoprene seal and dust shield shall
be included with each spur gear housing in two locations; a lower seal located
between the stationary drive base and main gear, and an upper seal located between
the main gear and stationary drive cover. The gear case shall have oil fill and drain
plugs and an oil level indicator pipe. The drain shall be at the lowest point of the gear
case and shall be accessible. Oil fill and level indicators shall be readily accessible.
The spur gear housing shall be designed to allow 75 percent submergence of the gear
face in the oil bath. The drain line, suitable for removing condensate, shall be located
at the lowest point in the oil reservoir and shall be accessible.
To permit inspection and maintenance of the interior of the center column, each spur
gear shall have an access opening of not less than [30] inches in diameter. A
reinforced fabricated [aluminum] cover plate with lifting holes securely attached shall
be provided for the cover plate.
5. Main Bearing: The entire float and sludge collector mechanism shall be suspended
from the turntable which in turn shall be supported on a ball bearing assembly that
uses large-diameter hardened vacuum degassed alloy steel bearing balls. The bearing
balls shall run in an oil bath on replaceable carbon corrected steel liners and placed in
annular raceways in the gear and turntable base. A minimum 75 percent of the gear
face shall be submerged in oil. A cross-contact or four-point angle contact ball bearing
arrangement is prohibited. Bearings shall be designed for an L-10 life of at least
375,000 revolutions.
6. Torque Overload Protection: The drive mechanism shall be provided with an overload
protection system (consisting of an electro mechanical overload device and a backup
shear pin) and an overload alarm system. The overload device shall be designed to
measure thrust of the worm gear shaft and be provided with an indicator showing the
load on the mechanism. The indicator shall be visible from the access bridge, shall
The overload device shall include two switches; the first is to activate a remote alarm
at continuous maximum operating torque, and the second is to shut down the unit at
shut off torque. The device shall be factory calibrated to activate the alarm switch
(normally open) when the torque load on the mechanism reaches the alarm torque and
activate the main cutout switch (normally closed) at the cutout torque. The overload
device shall be enclosed in watertight cast iron or aluminum housing. The switches
shall be double pole, double throw (DPDT), housed in a NEMA 4X enclosure, and
rated at 5 amps at [120] [240] volts AC and shall be arranged to open on alarm.
The drive mechanism shall be equipped with a non-rotation detection device to sense
lack of shaft rotation on the intermediate work gear reducer input shaft, when the
drive motor is running. The device shall be an active magnetic pickup type with zero
speed switch and normally closed contact for remote indication of non-rotation and
alarm.
A backup shear pin shall be provided in a shear pin hub mounted on the output shaft
of the [gear motor] [variable speed drive]. The shear pin shall be selected to break
when the load on the mechanism achieves 140 percent of the continuous operating
torque indicated. A NEMA 4X limit switch shall be provided to activate an alarm when
the shear pin breaks.
H. Bridges:
1. Access Bridge: The bridge shall have a 48-inch wide walkway and an access platform
around the drive unit, and shall include [aluminum] grating, structural steel support
members, and handrailing as indicated. The bridge and access platform shall be
supported on the main spur gear housing which, in turn, shall be supported by the
center column. Minimum clearance around the drive mechanism shall be 24 inches.
All walkway surfaces shall be at the same elevation.
1. General: Air dissolution equipment includes the dissolution tank with liquid level
controls, air control panel, and pressurized flow system with backpressure control
valve(s), and all associated instrumentation and accessories. The dissolution system
shall be suitable for using either recycled thickener effluent or [reclaimed water].
Thickener effluent may contain fine solids, small grit particles, and small amounts of
grease. [Reclaimed water may contain up to 15 mg/l of chlorine.]
The DAFT equipment supplier shall be responsible for the design of the dissolution
system to achieve the performance indicated. Pipe sizes and fittings and accessories
indicated and the pressurization pump's characteristics indicated shall be verified.
2. Air Dissolution Tank: The tank shall be vertical, cylindrical welded steel sized by the
manufacturer for efficient air dissolution (saturation of the pressurized flow with air)
and large bubble removal required to achieve the indicated performance. The tank shall
be designed in accordance with ASME Code, Section VIII, Division 1, for the pressure
rating indicated. The tank shall bear an ASME inspector's stamp, complete with design
working pressure, and date and place of manufacture. The liquid level control system
for the dissolution tank shall be of excess air bleed-off type and shall maintain a
The internal arrangement of the static air dissolution tank shall be the responsibility of
the manufacturer to achieve the saturation efficiency indicated at the indicated rated
pressure and maximum fluid temperature without the aid of mixers, internal diffusers
or internal baffles. Internal packing, secondary recycle pumps, and mixers will not be
allowed. The pressurized dissolution flow nozzle(s) shall have a minimum discharge
velocity of 20 feet per second. Nozzle(s) shall discharge onto a replaceable stainless
steel target baffle(s) and shall not impinge directly upon the pressure vessel.
a. Pressure manhole.
b. Flanged full skirt support suitable for anchor bolting. The supports shall have
access holes for access to the drain.
d. A 1-inch safety valve bearing the ASME seal set for 80 psig stamped by an
ASME inspector.
e. A 24-inch armored sight gauge fitted with gauge valves visible from the air
control panel.
f. A level control device with a monel float-actuated mercury switch which controls
the operation of the air bleed-off solenoid valve. The float shall be mounted in
cast iron chamber, external to the dissolution tank, with Type 316 stainless
steel internal trim, Type 400 stainless steel magnetic sleeve, and brass inner
liner. The chamber shall be attached to the dissolution tank with two 1-inch ball
valve connections and shall have a 1-inch ball valve drain. The level control
device shall have a NEMA 4X switch enclosure and a hand-off-auto switch, for
selection of air bleed off control modes. A control panel for the controls shall
be provided. The control panel external wiring shall be as indicated. The panel
enclosure shall be NEMA 4X.
k. A 3/4-inch diameter air bleed off connection and 3/4-inch solenoid valve.
The tank shall be fitted with plate baffles and the entrance to the pressurized flow
outlet pipe shall be sized and located to prevent the formation of vortices and the
ingestion of bubbles from the tank gas space.
Fittings shall be provided so that the sight glass, the level control valve float chamber,
and instrumentation connections can be purged with high-pressure plant water without
draining the dissolution tank.
3. Air Control Panel: The air supply regulation system shall be wall mounted on a
corrosion-resistant panel with a removable cover, through which components are
operable and pressure and flow indications are visible, or shall be mounted directly to
the dissolution tank. Components of the air control panel shall be 3/4-inch line size and
shall include an air filter, a pressure regulating valve, a calibrated [0-25] scfm direct
reading rotameter with a Type 316 stainless steel float, safety shield and needle valve,
a check valve, a pressure indicator (0 to 100 psig), and all other valves and fittings
as indicated.
4. Pressurized Flow System: The manufacturer shall provide the portion of the
pressurized flow piping system indicated, including the backpressure control valve, so
that during equipment commissioning the proper backpressure setting can be selected
to achieve the indicated system parameters. The backpressure control valve shall be
designed to balance total head loss of the system against the pressurization pump
characteristics.
Backpressure control valve shall be suitable for operation at all pressure differentials
between 40 and 100 psig. The backpressure control valve shall be an extended shaft
cone valve, connected to a vertical shaft for operation. Flat disc or plug type valves
will not be acceptable. This shaft shall extend from the backpressure valve, internally
through the pressurized flow pipe to the top of the access bridge, where a manual
(hand wheel) operator shall be located. The manual operator shall permit changing
flow and pressure while the system is in operation. The unit shall be designed so that
no leakage from the pressurization pipe occurs. Steady bearings shall be provided for
the shaft, within the pressurized flow pipe, to maintain proper position of the
backpressure control valve and prevent deflection and vibration. The backpressure
control valve shall be attached to the vertical shaft such that it can be removed for
maintenance or can be replaced from the bottom of the shaft. The face of the
backpressure control valve, the base of the pressurized flow pipe, and the last 3
inches of the interior of the pressurized flow pipe, shall be hard faced with No. 6
Satellite to a hardness of 45 Rockwell C.
5. Corrosion Protection: The inside of the pressurized flow pipes and the inside of the
air dissolution tank shall be coated with two shop coats of [coal tar epoxy] [vinylester]
[alphatic polyurethane] conforming to Section 09800.
J. Air Compressors: Air compressors, receiver, and control shall be skid mounted. The air
compressors shall be air-cooled reciprocating type, 2-stage, receiver mounted units, rated
L. DAFT Tank Covers: [Aluminum] fixed tank covers shall be constructed as indicated with
an [aluminum] frame. [Aluminum dome components shall be anodized to M12-C22-A41
in accordance with Aluminum Association Standard 45.] [Aluminum dome components
shall have a clear satin anodized architectural Class I finish of minimum 0.7 mil thickness.]
[Cover frame shall be designed in accordance with the AA-30.] The physical configuration,
as well as the strength of the dome, shall be designed to provide for all thermal stresses,
both in expansion and contraction. Additionally, the design shall incorporate the full dead
load plus the indicated live load conditions.
Design computations, utilizing the design criteria indicated herein, shall be submitted with
the Owner's Manual. The computations shall include analysis of all structural members and
appurtenances, and shall be prepared by or under the direct supervision of a registered
professional engineer. The engineer responsible for the design computations shall provide
an engineer's certificate stating that the dome covers meet the design criteria indicated
herein.
[The cover shall be an aluminum semi-spherical structure designed to fit between the wall
of the thickener and the thickener center column, but below the access bridge and walkway.
The cover shall conform to the overall dimensions indicated. The structure shall include the
following items: extruded aluminum frame, aluminum tension ring, aluminum gussets,
expansion base shoes, stainless steel anchor bolts, all fasteners, base flashing, seal hatches,
observation hatches, air inlet and exhaust openings, access hatches providing full access
to the float trough and beach areas, two access hatches at the center column and sealant.
Non-skid walkways and ladders shall be provided for access to the hatches from both the
thickener wall and the bridge.
The exterior panels shall be non-corrugated flat panels, having a minimum thickness of 16
gauge. The use of steel shall be minimal, but when it is necessary, it shall be stainless
steel.
2. The roof shall be clear span and self-supporting from the circular periphery of the
reinforced concrete thickener tank.
4. Access shall be provided for maintenance for the two float collection troughs, including
their leading and trailing ramps, the wheels of all primary radial arms, and the influent
distribution well. Access shall be provided for removal of equipment from the tank and
for general access to the thickener collectors and interior. Access shall be a minimum
of [6 feet by 8 feet], clear. Those areas where access is required and the nominal
dimensions for the desired openings are indicated in a general nature. These shall be
coordinated with the actual location in the manufacturer's final design of the
equipment. These dimensions may be adjusted to accommodate the roof framing plan.
However, the final arrangement shall not unduly hamper access to the equipment.
5. All openings and hatches shall have a finished appearance, set in frames, edges rolled
or rounded.
[6. The dome panels shall be attached by means of clamping bars which engage the
panels in an interlocking joint. The use of panel attachment fasteners which penetrate
both the panel and the flange of the structural member is expressly prohibited.]
[7. The dome structural members shall be attached to the gusset plates by means of bolts
connecting the flanges of the structural members to the gusset plates. A minimum of
four bolts per flange shall be used.]
8. The cover shall be designed by a structural engineer, registered to practice in the State
of California. All drawings associated with the cover shall bear the engineer's
registration stamp and seal.
$#
NTS: Cover material and specifications shall be coordinated with the architect and
structural engineer to be consistent throughout the plant.
#$
M. Protective Coatings: All items shall be coated in accordance with Section 09800 unless
otherwise indicated. The inside of the pressurized flow pipes and the inside of the
dissolution tanks shall be coated with System 103, Coal Tar Epoxy.
1. 1 set - all bearings and bearing seal rings for drive unit, except the main turntable
bearing
2. 1 set - all gaskets for drive unit
3. 1 set - spur gear seal and replaceable bearing races
4. 1 set - shear pins
5. 1 set - nozzles (if required) and impingement plates for dissolution tank
6. 1 - backpressure regulating valve assembly included shaft, positioner, and disc
7. 1 - carrier pipe skirt
2.6 MANUFACTURERS
a. Eimco
b. Envirex (a Rexnord Division)
c. Walker Process Corporation
d. Komline-Sanderson
e. Westech
2. Pressurization pumps:
a. Allis-Chalmers
b. Fairbanks Morse
c. Goulds
3. Compressors:
a. Gardner-Denver
b. Kellogg-American
c. Quincy (Colt Industries)
PART 3 -- EXECUTION
3.1 INSTALLATION
A. General: Products and equipment shall be installed in accordance with the manufacturer's
written installation instructions.
A. Products shall be field-tested for compliance with the indicated requirements. All testing
shall be conducted under the supervision of factory-trained representatives furnished by the
manufacturer. If the equipment should fail to successfully complete the testing program,
this will be sufficient cause for the CONSTRUCTION MANAGER to require that the
equipment be replaced or reconstructed and retested.
1. Torque Tests: As part of the test and inspection program, the entire sludge removal
mechanism shall be load tested by the CONTRACTOR by anchoring bottom sludge
2. Freshwater Test: As part of the testing program, the DAFT tanks shall be filled with
fresh water to their operating level and the mechanism operated continuously at its
maximum speed for a period of not less than 48 hours. Following the maximum
speed test, the mechanism will be operated at 25, 50, and 75 percent speeds for
continuous periods of not less than 6 hours. At no time during the operating tests
shall the equipment fail on torque overload or exhibit indications of binding or uneven
operation. The CONTRACTOR shall record torque values registered on the drive
mechanism torque indicator and motor amperage (all three phases) at 3-hour intervals.
3. Air Saturation Tests: Prior to startup of the equipment and operation on sludge, each
air dissolution system shall be operated with fresh water to demonstrate that the
indicated design requirements for air dissolution saturation efficiency have been
satisfied. Testing shall include operation of both one and two pressurization pumps,
dissolution systems, and backpressure control devices at one time. Saturation
efficiency shall be determined based upon the average of the data points recorded after
discarding the highest and lowest observed dissolution efficiencies for each system.
Dissolution efficiency shall be defined as the ratio of the actual amount of air dissolved
in the full pressurization flow to the theoretical amount of air that could be dissolved
in the pressurization flow at the design pressure and test temperature. Representative
samples shall be withdrawn from the discharge line of the dissolution tank at design
pressure with pump on at design rate. At least five samples shall be taken from each
system over a 6-hour run. The following steps shall be performed for each sample:
b. Correct the volume of gas for temperature differences between the gas sample
and the pressurization flow and for water vapor pressure.
c. Determine the dissolved oxygen (DO) content in the sample liquid immediately
and after 2 hours. DO may be measured with an electronic probe provided the
CONTRACTOR documents the probe's calibration to barometric pressure, and
verifies the probe's accuracy using the azide modification of the Winkler titration
(Standard Methods, latest edition).
d. Calculate the dissolved nitrogen content in the sample liquid and correct for
supersaturation, assuming the same degree as for dissolved oxygen (ratio of DO
immediately to DO after 2 hours).
g. Calculate the dissolution efficiency by dividing the actual air content in the
sample by the theoretical air content in the pressurized sample.
A. [Six] copies of the test reports shall be submitted which will include the results of all field
tests conducted in Section 3.2.
** END OF SECTION **