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Issued as a part of ADDENDUM #3

SECTION 46 43 53 SOLIDS CONTACT CLARIFIER EQUIPMENT

PART 1 - GENERAL

1.1 DESCRIPTION

A. There shall be furnished replacement parts and new drive units for two (2) existing solidscontact clarifier mechanisms. The solids contact clarifier mechanism replacement parts anddrives shall be designed to mix and recirculate chemical additives and solids to produce asettleable floc that can be raked to the center for recirculation or solids removal.

B. The existing solids contact basins have a circular, raked area 45 feet in diameter with a side

water depth of 14 feet, a freeboard of 6 inches, and a bottom slope of 1 inch in 12 inches.

C. Influent currently enters the existing basins through a side influent pipe and discharges into acentral recirculation drum where it mixes with chemicals and previously precipitated solids. Thismixture of re-circulated solids and influent then discharges into the upper zone of a baffledcentral reaction well cylinder, where flocculation and particle contact take place. The mixturethen flows downward in an expanding reaction well cone with a large percentage of the flowreturning to the central recirculation drum to be re-contacted. The remainder of the flowcontinues outward under the deflection shelf at the periphery of the reaction well cone into the

clarification zone and upward into the effluent launders. Settled solids are positively raked tothe center of the mechanisms and either re-suspended within the recirculation drum ordischarged into the solids thickening trough. Internal recirculation is accomplished by a singlereaction turbine providing the specified internal recirculation capacity while operating at tipspeeds that are not destructive to the floc.

D. The new replacement parts for existing solids contact clarifier mechanism #1 shall include:

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1.2 PROCESS REQUIREMENTS

A. Design parameters are as follows:

1. Peak Hydraulic flow rate per unit: 3.0 MGD2. Minimum recirculation capacity (pumping rate): 5,300 GPM3. Maximum turbine tip speed: 4.5 ft/sec4. Turbine minimum speed range: 4:1 (VFD Operated)5. Maximum Sludge collector arm speed: 0.05 rpm6. Sludge collector arm minimum speed range: Constant Speed7. Mechanism design strength: 30,000 ft-lbs

1.3 REFERENCES

A. AFBMA Anti-friction Bearing Manufacturers' Association - Bearing Life Specifications

B. AGMA American Gear Manufacturers' Association -Gearing Ratings

C. AISC American Institute of Steel Constructors - Guidelines for the Design of Steel Structures

D. AISI 4140/42H American Iron and Steel Institute - Material Specifications

E. ASTM A-36 American Society for Testing and Materials - Structural Steel Specifications

F. ASTM A-48 Class 40A American Society for Testing and Materials - Cast Iron Specifications

G. ASTM A-53 Grade B American Society for Testing and Materials - Pipe Specifications

H. ASTM A283C American Society for Testing and Materials - Steel Plate Specifications

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project properly highlighted. All submitted information must include a certification that thesubmittal describes exactly the equipment to be provided.

B. The solids contact clarifier replacement parts manufacturer shall furnish as a minimum thefollowing design and description information to establish compliance with these specifications:

1. Certified general arrangement and tank dimensional drawings showing the parts to bereplaced.

2. Drive mechanism design calculations verifying the compliance of the drive gears andbearings with the specified continuous life.

3. Motor and electrical drawings.

C. All submitted calculations must be stamped by a Registered Professional Engineer.

1.6 OPERATION AND MAINTENANCE MANUALS

A. Operation and maintenance manuals will be provided by the replacement parts manufacturer atleast two (2) weeks prior to shipment of equipment components. Each manual shall be abound, indexed binder with drawings and parts lists prepared specifically for this project ratherthan general instructions.

B. As a minimum, the manual shall contain:1. General arrangement drawings.2. General arrangement detail drawings.3. Erection drawings.4. A complete bill of materials for the equipment including the weights of all structural steel

components.

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PART 2 - PRODUCTS

2.1 GENERAL

A. The solids contact clarifier mechanism replacement parts shall fit the existing bridge typemechanism which is supported by the basin walls. The recirculation turbine and rake andturbine shafts shall all be concentric about the center of the solids contact clarifier mechanism toprevent short circuiting flow patterns and produce uniform solids collection and effluentdischarge. Offset axial flow mixers or other designs in which these components are notconcentric allow asymmetric energy inputs resulting in localized floc shear and dead zones andwill not be allowed.

2.2 CENTER DRIVE ASSEMBLY

A. Each solids contact clarifier shall be provided a new center drive assembly for attachment toexisting center platforms. Each center drive assembly shall be made up of individual,concentric, counter rotating sludge collector and recirculation turbine drives, designed to attachto support beams with leveling bolts. Drives shall be in totally enclosed housings with sludgecollector and recirculation turbine drives separate, to allow independent maintenance and

lubrication.

B. All bearings shall run in an oil bath. Grease lubrication shall not be allowed. Oil pumps forlubrication will likewise not be allowed. A minimum 1-1/2 inch deep condensate collection areamust be provided below the main bearing. In lieu of the oil reservoir depth requirement acontinuous oil conditioner unit installed at each drive assembly and as specified herein shall beconsidered equal. The conditioner shall consist of an electrical continuous pre-pump filter and

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G. The main gears, main bearings, and torque overload control device that comprise the centerdrive assembly shall be a regularly manufactured in-house product of the solids contact clarifiermanufacturer. Drive assemblies purchased from third party vendors shall not be allowed.

2.3 RECIRCULATION TURBINE DRIVE

A. Each turbine drive mechanism shall consist of an inverter duty motor directly connected to aprimary speed reducer, which is directly connected to the turbine drive main gear, or connectedthrough a chain and sprocket arrangement enclosed in a steel guard. Each turbine drive maingear shall be designed in accordance with referenced standards for 24 hour continuous duty,moderate shock load, and a 100,000 hour design gear life at 75% of maximum speed. Each

turbine drive main output bearing shall be designed for a minimum B10 life of 100,000 hours.

B. Each turbine drive motor shall be 3.0 horsepower minimum.

C. The turbine speed shall be infinitely adjustable through a 4:1 range by the use of a variablefrequency drive (VFD).

D. Each turbine drive primary speed reducer shall be of in-line helical or spiral bevel-helicalconstruction with gears manufactured from case hardened steel. Each primary speed reducer

will be directly coupled to the main gear reducer or will drive the main gear reducer throughroller chain and sprockets enclosed in a steel guard. Power transmission devices will bedesigned with a minimum service factor of 1.5. Units will be supplied with high capacity, anti-friction bearings submerged in oil and splash lubricated. The reducer shall be rated for 24 hourcontinuous duty moderate shock load.

E. Each turbine main gear reducer shall consist of a worm and worm gear assembly, or a spur

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2. The inverter shall operate via vector technology in 4-quadrant operation with the ability tooperate at 16 kHz carrier frequency to minimize audible noise. It shall use a vector typecontroller to monitor the current to the motor to control the output speed.

3. The motor shall operate at constant torque range from 2-80 Hz or wider and operate at10 Hz and higher without the need for an additional cooling fan.

4. The motor shall meet CSA standards, be certified as inverter duty, and shall be approvedas a motor overload device. It shall contain overload, over voltage, and phase failureprotection. A fault relay and LED shall be provided on the inverter to advise the operatorduring a fault. Integral motor/VFD shall have a 1.0 service factor or higher.

5. The inverter shall be housed in an aluminum alloy enclosure, suited for outdoor service,and rated IP65 or higher.

6. The inverter shall be designed to match the motor specifications with no parameter setup

required.7. The inverter shall accept RS-485 protocol and be capable of interfacing with Profibus(r),

DeviceNet(r), InterBus-S(r), or AsI(r) with at least 2 auxiliary inputs and shall acceptanalog speed set points from 0-10V, 0-20mA or 4-20mA signals.

8. The inverter shall have selectable acceleration and deceleration times with at least 2adjustable preset speeds and shall have selectable addresses so that multiple drives canbe individually controlled from a PLC or PC or simultaneously controlled from one master.

9. Line and load reactors as well as appropriate on-line filters shall be provided to assureclean uninterrupted power to the variable frequency drive.

2.4 SLUDGE COLLECTOR DRIVE

A. Each sludge collector drive mechanism shall consist of a constant speed motor directlyconnected to a primary speed reducer which is connected through roller chain and sprockets tothe input shaft of the main gear and operates the drive torque overload protection system.

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F. Each sludge collector drive primary speed reducer shall be of in-line parallel helical constructionwith gears manufactured from case hardened steel. The primary speed reducer will be directlycoupled to the main gear reducer or will drive the main gear reducer through chain and

sprockets enclosed in a steel guard. Power transmission devices will be designed with aminimum service factor of 1.5. Units will be supplied with high capacity, anti-friction bearingssubmerged in oil and splash lubricated. Each reducer shall be rated for 24 hour continuousduty moderate shock load. Planetary or cycloidal gearing is not considered equal and will notbe allowed.

G. Each sludge collector main gear reducer shall consist of a worm and worm gear assembly or aspur gear and pinion assembly. If a worm gear is used, the gear shall be high strength,centrifugally cast manganese bronze with an AISI 4140/42H hardened alloy steel worm. The

worm gear assembly shall rotate on a precision 4-point contact ball bearing assembly that iscompletely separate from the worm gear, thereby allowing independent removal of the gear andbearing. Any sludge collector drive that utilizes a combination one piece gear and bearingassembly shall include one (1) extra combination gear and bearing assembly per drive as arequired spare part. The precision 4-point contact ball bearing assembly shall be made up ofpremium alloyed chrome/steel bearing balls and a raceway hardened to at least Rockwell C60and precision ground.

H. Where a spur gear is used the gear material shall be ductile iron per ASTM A536 grade 80-55-

06 or an equal in forged alloy steel. The gear shall have a minimum pitch diameter of 30-incheswith a 4-inch face width or the equivalent spur gear surface area of 377 square inches. Spurgear surface area is defined as the spur gear pitch diameter multiplied by the spur gear facewidth multiplied by 3.14. (diameter x depth x Pi). Drive manufacturers shall increase the mainspur gear diameter until this minimum gear surface area requirement is met.

I. The main gear shall be completely enclosed on three sides and the top with a rigid ASTM A-48

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not be allowed. Rake blades shall be properly spaced to insure complete raking of the tankbottom twice per revolution.

B. Each sludge collector replacement arm shall be designed to withstand one-half the mechanismdesign strength, or 15,000 ft-lbs, while maintaining structural steel stresses within the AISCallowable stress.

C. Rake blades 7-1/2 inch deep with type 304 stainless steel squeegees shall be provided on eachsludge collector arm.

D. Attached to the bottom of the rake blades shall be type 304 stainless steel squeegees designedto scrape the basin floor of accumulated sludge twice per revolution. Sludge shall be directed to

the center of the mechanism where it can be removed or recirculated.

E. The minimum angle size used in construction of the sludge collector replacement arms shall be2-inches x 2-inches.

F. At the bottom of the torque shaft or cage shall be a replacement cone scraper constructed ofsteel angles for agitating solids collected in the sludge thickening cone at the center of thesolids contact unit.

2.6 TORQUE SHAFT FOR CLARIFIER #1

A. The sludge collector mechanism #1 replacement parts shall include a sludge collector torqueshaft constructed of minimum schedule 40 steel pipe, which is sized to withstand themechanism design strength of 30,000 ft-lbs while maintaining structural steel stresses withinAISC allowable levels.

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1. One (1) set of sludge collector and turbine drive seals.2. One (1) set of overload control device switches.3. Five percent (5%) extra fasteners.

2.10 WELDING

A. All welding practices shall be in accordance with the requirements of the American WeldingSociety (AWS) "Welding in Building Construction". All welders shall be certified in accordancewith this AWS specification for any welding work performed under this section.

2.11 SURFACE PREPARATION AND PAINTING

A. All fabricated steel replacement parts shall be shipped to the jobsite bare metal without anysurface preparation and/or primer applied. The contractor shall install the replacement parts onthe existing solids contact clarifiers and then sandblast and paint both mechanisms as follows:1. Prior to installing the replacement parts the entire mechanism of both clarifiers, including

bridges, turbines, shafts, reaction well, draft tube, rake arms and trough scrapers shall bepower washed of all debris and thoroughly cleaned.

2. After power washing of the existing mechanisms, the contractor shall install the

replacement parts. All new and existing fabricated steel surfaces on each mechanismshall be sandblast cleaned to an SP-10 near white finish and field painted with one (1)protective primer coat and one (1) protective finish coat of NSF Series 61 CertifiedTnemec 20-1211 Potapox epoxy-polyamide coating to 3.0 to 5.0 mil dry film thicknesseach coat.

B. All machined metal surfaces will be coated with a suitable, easily removable rust inhibitive

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H. Motor starter for both the rake motor and the turbine motor shall be provided by the solidscontact clarifier manufacturer to be housed in the electrical control panel mounted on theclarifier center drive platform.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The solids contact clarifier mechanism replacement parts shall be installed in accordance withthe manufacturer's recommendations as approved by the Engineer. Prior to start-up of thesolids contact clarifier equipment, a field service engineer employed directly by the solids

contact clarifier manufacturer shall inspect the assembled equipment, make necessary minorfinal adjustments and certify the equipment ready for operation.

3.2 SERVICE AND TRAINING

A. The solids contact clarifier manufacturer shall supply a factory trained field servicerepresentative to inspect the installation of the replacement parts and the operation of the solidscontact clarifier equipment.

B. The field service representative shall instruct the owner's personnel in the proper operation andmaintenance of the solids contact clarifier equipment.

C. As a minimum, the field service representative must be available for two (2) trips of startupservice (one trip for each clarifier). Each trip shall consist of at least two (2) eight (8) hour dayson site.

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SECTION 01 29 00 PAYMENT PROCEDURES

PART 1 - GENERAL

1.1 SUBMITTALS

A. Informational Submittals:1. Schedule of Values: Submit on Contractors standard form.2. Schedule of Estimated Progress Payments:

a. Submit with initially acceptable Schedule of Values.b. Submit adjustments thereto with Application for Payment.

3. Application for Payment.

4. Final Application for Payment.

1.2 CASH ALLOWANCES

A. As detailed in Specification Section Supplemental Condition 25, there are no allowances for thisproject.

1.3 SCHEDULE OF VALUES

A. Prepare a separate Schedule of Values for each schedule of the Work under the Agreement.

B. Upon request of Engineer, provide support documentation to support the accuracy of theSchedule of Values.

C. Unit Price Work: Reflect unit price quantity and price breakdown from conformed Bid Form.

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1.5 APPLICATION FOR PAYMENT

A. Transmittal Summary Form: Attach one Summary Form with each detailed Application for

Payment for each schedule and include Request for Payment of Materials and Equipment onHand as applicable. Execute certification by authorized officer of Contractor.

B. Use detailed Application for Payment Form suitable to Engineer.

C. Provide separate form for each schedule as applicable.

D. Include accepted Schedule of Values for each schedule or portion of Work, the unit pricebreakdown for the Work to be paid on unit price basis, a listing of Owner-selected equipment, if

applicable, and allowances, as appropriate.

E. Preparation:1. Round values to nearest dollar.2. List each Change Order executed prior to date of submission as separate line item. The

totals will equal those shown on the Transmittal Summary Form for each schedule asapplicable.

3. Submit Application for Payment, including a Transmittal Summary Form and detailedApplication for Payment Form(s) for each schedule as applicable, a listing of materials on

hand for each schedule as applicable, and such supporting data as may be requested byEngineer.

1.6 PAYMENT

A. General:1. Progress payments will be made monthly.

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B. Final Payment: Will be made only for products incorporated in Work and following approval offinal operations and maintenance manuals; remaining products, for which partial payments havebeen made, shall revert to Contractor unless otherwise agreed, and partial payments made for

those items will be deducted from final payment.

1.9 PARTIAL PAYMENT FOR UNDELIVERED, PROJECT-SPECIFIC MANUFACTURED ORFABRICATED EQUIPMENT

A. Notwithstanding above provisions, partial payments for undelivered (not yet delivered to Site ornot stored in the vicinity of Site) products specifically manufactured for this Project, excluding offthe shelf or catalog items, will be made for products listed below when all following conditionsexist:

1. Partial payment request is supported by written acknowledgment from Suppliers thatinvoice requirements have been met.2. Equipment is adequately insured, maintained, stored, and protected by appropriate

security measures.3. Each equipment item is clearly marked and segregated from other items to permit

inventory and accountability.4. Authorization has been provided for access to storage Site for Engineer and Owner.5. Equipment meets applicable Specifications of these Contract Documents.

B. Applicable Items:

Specification Section Specific Product

13 34 23.13 FRP ONE PIECE MOLDED SHELTER26 32 13 STANDBY GENERATOR26 90 20 PROGRAMMABLE LOGIC CONTROLLERS

41 13 23.29 VOLUMETRIC FEEDERS41 23 23 LOW PROFILE LIFE TABLE

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INSPECTION REPORT

FOR CLARIFIER MECHANISM

Rev. Date Description

Customer:Hot Springs Village WWTP, AR

Project:Process: Solids Contact Clarifier (Eimco Reactor Clarifiers)


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INSPECTION REPORT

Customer: POA Hot Springs Village, ARContact: Charles H. Green, Chief Water Plant Operator

Tel. 501-922-1323Dennis Eskew, Water/Wastewater SuperintendentTel. 501-922-5523

DBS Manuf. Rep: Hydronics Inc, Dallas, TXRon Mayo

Tel. 214-850-4145, email: [email protected]

Contractor: Garver, North Little Rock, ARTom HubbardTel. 501-551-2702, email: [email protected]

Date: October 13, 2011

Purpose of TripIs to inspect the drive unit and clarifier mechanism on Clarifiers No.1 and No.2.

Customers Concerns1. The SC Clarifiers were placed in operation 1995. They want an evaluation of the condition of both clari

and recommendations The plant flow has increased and the existing SC Clarifiers are at maximum


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Findings

General Condition


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Findings

Clarifier Mechanism Arms: 3 bays, 4 plows


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1st Arm

1. There are no squeegees on the plows. Gap between floor and plow is about 2.5. Plows show somewear/corrosion on the bottom edge.

2. The innermost plow is slightly bent.3. All leading and trailing truss angles are straight and have no significant signs of wear/corrosion.4. All upper trailing truss angles are straight and there are no significant signs of wear/corrosion.5. All lower trailing truss angles are straight and there are no significant signs of wear/corrosion.6. Rake truss connectors are in good condition.

2nd Arm1. There are no squeegees on the plows. Gap between floor and plow is about 2.5. Plows show some

wear/corrosion on the bottom edge.2. The innermost plow is slightly bent.3. Second to last bay: Leading diagonal brace is bent.4. All other leading and trailing truss angles are straight and have no significant signs of wear/corrosion.5. All upper trailing truss angles are straight and there are no significant signs of wear/corrosion.6. All lower trailing truss angles are straight and there are no significant signs of wear/corrosion.7. Rake truss connectors are in good condition.


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Feedwell/Hopper


I d t f ADDENDUM #3

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1. Overall condition is okay. There is some corrosion/wear in a few spots.2 Lower skirt is good


I d t f ADDENDUM #3

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Cone/Scrapper



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Launders



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Turbine and Turbine Pipe



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Turbine Draft Tube



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Concrete Tank



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Feed Pipe



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Drive Unit

p


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Inspection Notes:

Comments and Recommendations

1. Clarifier mechanicals which include all metal structures below the bridge should be sand blasted andpainted, in particular structures above the water line.

2. Add squeegees to the rake plows.3. Replace the turbine raft tube and rake tube.4. Straighten the bent plows.5. Add a lower support bearing.6. Replace drive unit with a gear motor type. No hydraulics and variable speed achieved through AC

Frequency drives. AC frequency drives are clean, very reliable and efficient and provide many features obtained with hydraulic systems.

Regarding item 5, the shaft is 3.9375 and requires a lower support bearing. SCC No. 1 is not designed a lower support bearing. The rake shaft on the SCC No. 1 is an 8 pipe.

With a new drive unit, the clarifier rake shaft should be modified to be the same as SCC No. 1.

p


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INSPECTION REPORT

FOR CLARIFIER MECHANISM

Rev. Date Description

Customer:Hot Springs Village WWTP, AR

Project:Process: Solids Contact Clarifier (Eimco Reactor Clarifiers)


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INSPECTION REPORT

Customer: POA Hot Springs Village, ARContact: Charles H. Green, Chief Water Plant Operator

Tel. 501-922-1323Dennis Eskew, Water/Wastewater SuperintendentTel. 501-922-5523

DBS Manuf. Rep: Hydronics Inc, Dallas, TXRon Mayo

Tel. 214-850-4145, email: [email protected]: Garver, North Little Rock, AR

Tom HubbardTel. 501-551-2702, email: [email protected]

Date: October 13, 2011

Purpose of TripIs to inspect the drive unit and clarifier mechanism on Clarifiers No.1 and No.2.

Customers Concerns1. The SC Clarifiers were placed in operation 1995. They want an evaluation of the condition of both clari

and recommendations The plant flow has increased and the existing SC Clarifiers are at maximum


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FindingsClarifier Mechanism Arms: 3 bays, 4 plows


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Feedwell/Hopper


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Launders


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Turbine and Turbine Pipe


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Concrete Tank


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Feed Pipe


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Drive Unit


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Inspection Notes:

Comments and Recommendations

1. Clarifier mechanicals which include all metal structures below the bridge should be sand blasted andpainted, in particular structures above the water line. New components are not required.2. Squeegees should be removed before sand blasting.3. Replace drive unit with a gear motor type. No hydraulics and variable speed achieved through AC

Frequency drives. AC frequency drives are clean, very reliable and efficient and provide many features obtained with hydraulic systems.

The SC Clarifier is found fit for service. Recoating the metals structures will add service life to theclarifier.

Done by: Jorge L Iduate

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Outlet Launder:Remove & ReplaceWith Tube SettlerLaunder System

Collection Launder:Remove & ReplaceWith Tube SettlerLaunder System

Radial Launders:Remove & ReplaceWith Tube SettlerLaunder System

RotatingComponents:Clarifier 1: ReplaceClarifier 2: Repaint

Superstructure &

Handrails:

Clarifier 1: RepaintClarifier 2: Repaint

Drive Unit:Clarifier 1: ReplaceClarifier 2: Replace ADDENDUM #3

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Handrail:Clarifier 1: RepaintClarifier 2: Repaint

Superstructure:Clarifier 1: RepaintClarifier 2: Repaint

Drive Unit:Clarifier 1: ReplaceClarifier 2: Replace

Rake Arms:Clarifier 1: Replace

Clarifier 2: Repaint

Reaction Well:Clarifier 1: RepaintClarifier 2: Repaint

Rotating Drum:Clarifier 1: ReplaceClarifier 2 : Repaint

Cone Scraper:Clarifier 1: ReplaceClarifier 2: Repaint

Rake/Turbine Shaft:Clarifier 1: ReplaceClarifier 2: Repaint

Radial Launders:Clarifier 1: RemoveClarifier 2: Remove

Install TubeSettler LaunderSystem

Recirculation Drum:Clarifier 1: RepaintClarifier 2: Repaint

Center & Outlet Launder:Clarifier 1: RemoveClarifier 2: RemoveInstall Tube SettlerLaunder System

ADDENDUM #3

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ADDENDUM