1240 Addendum 3

Issued as a part of ADDENDUM #3
SECTION 46 43 53 SOLIDS CONTACT CLARIFIER EQUIPMENT PART 1 - GENERAL 1.1 A. DESCRIPTION There shall be furnished replacement parts and new drive units for two (2) existing solids contact clarifier mechanisms. The solids contact clarifier mechanism replacement parts and drives shall be designed to mix and recirculate chemical additives and solids to produce a settleable floc that can be raked to the center for recirculation or solids removal. 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. Influent currently enters the existing basins through a side influent pipe and discharges into a central recirculation drum where it mixes with chemicals and previously precipitated solids. This mixture of re-circulated solids and influent then discharges into the upper zone of a baffled central reaction well cylinder, where flocculation and particle contact take place. The mixture then flows downward in an expanding reaction well cone with a large percentage of the flow returning to the central recirculation drum to be re-contacted. The remainder of the flow continues 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 to the center of the mechanisms and either re-suspended within the recirculation drum or discharged into the solids thickening trough. Internal recirculation is accomplished by a single reaction turbine providing the specified internal recirculation capacity while operating at tip speeds that are not destructive to the floc. The new replacement parts for existing solids contact clarifier mechanism #1 shall include: 1. New combination sludge collector and turbine drive 2. New rake motor and new turbine motor equipped with a built-in variable frequency inverter to adjust motor speed 3. All new submerged rotating parts to include; new rake and turbine shafts, new turbine, new rake arms, new squeegees, new sludge trough scraper 4. New electrical control panel 5. All necessary assembly bolts. The new replacement parts for existing solids contact clarifier mechanism #2 shall include: 1. New combination sludge collector and turbine drive 2. New rake motor, new turbine motor equipped with a built-in variable frequency inverter to adjust motor speed 3. New squeegees 4. New electrical control panel 5. All necessary assembly bolts. All replacement components shall be designed to withstand with a prudent safety factor all stresses that may occur during fabrication, erection, intermittent, or continuous 24 hour per day operation. All fabricated steel members shall have a minimum thickness of 1/4-inch. Structural carbon steel shall conform to ASTM A-36 requirements, carbon steel plate will conform to ASTM A283C requirements, and all carbon steel pipe will conform to the ASTM A-53 Grade B designation. All anchor bolts and assembly fasteners shall be manufactured from type 304 stainless steel.
B.
C.
D.
E.
F.
G.
08059580 Hot Springs Village Water Treatment Plant Expansion
Section 46 43 53 Solids Contact Clarifier Equipment
1.2 A.
PROCESS REQUIREMENTS Design parameters are as follows: 1. Peak Hydraulic flow rate per unit: 3.0 MGD 2. Minimum recirculation capacity (pumping rate): 5,300 GPM 3. Maximum turbine tip speed: 4.5 ft/sec 4. Turbine minimum speed range: 4:1 (VFD Operated) 5. Maximum Sludge collector arm speed: 0.05 rpm 6. Sludge collector arm minimum speed range: Constant Speed 7. Mechanism design strength: 30,000 ft-lbs REFERENCES A. B. C. D. E. F. G. H. I. AFBMA AGMA Anti-friction Bearing Manufacturers' Association - Bearing Life Specifications American Gear Manufacturers' Association -Gearing Ratings
1.3
AISC American Institute of Steel Constructors - Guidelines for the Design of Steel Structures AISI 4140/42H ASTM A-36 American Iron and Steel Institute - Material Specifications
American Society for Testing and Materials - Structural Steel Specifications
ASTM A-48 Class 40A American Society for Testing and Materials - Cast Iron Specifications ASTM A-53 Grade B American Society for Testing and Materials - Pipe Specifications ASTM A283C American Society for Testing and Materials - Steel Plate Specifications ASTM 304 American Society for Testing and Materials - Stainless Steel Material Specifications AWS American Welding Society - Welding in Building Construction Specifications NEMA National Electrical Manufacturers Association - Motor Design Standards and Standards for Control Enclosures QUALITY ASSURANCE
J. K. 1.4 A.
The manufacturer of the replacement parts shall modify their standard equipment to meet the values specified for dimensions, design, and the intent of this specification. The solids contact clarifier mechanism replacement parts shall be manufactured by: 1. 2. Ovivo USA, LLC. of Salt Lake City, Utah. OR DBS Manufacturing, Inc. of Atlanta, Georgia
B.
1.5 A.
CONTRACTOR SUBMITTALS The Contractor shall submit complete shop drawings of all equipment furnished including cut sheets describing purchased sub-components with the specific sub-components used for this
project properly highlighted. All submitted information must include a certification that the submittal describes exactly the equipment to be provided. B. The solids contact clarifier replacement parts manufacturer shall furnish as a minimum the following design and description information to establish compliance with these specifications: 1. 2. 3. C. 1.6 A. Certified general arrangement and tank dimensional drawings showing the parts to be replaced. Drive mechanism design calculations verifying the compliance of the drive gears and bearings with the specified continuous life. Motor and electrical drawings.
All submitted calculations must be stamped by a Registered Professional Engineer. OPERATION AND MAINTENANCE MANUALS Operation and maintenance manuals will be provided by the replacement parts manufacturer at least two (2) weeks prior to shipment of equipment components. Each manual shall be a bound, indexed binder with drawings and parts lists prepared specifically for this project rather than general instructions. 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. 5. Installation and maintenance instructions for the specific equipment including the erection sequence, maintenance and trouble-shooting check points, and complete lubrication procedures with recommended grades of lubricants. 6. Cut sheets for all items of equipment purchased from other manufacturers. 7. A list of the solids contact clarifier manufacturer's recommended spare parts specifically denoting wear items, long delivery items, and all items convenient for stocking as optional replacement items. DELIVERY
B.
1.7 A.
Fabricated assemblies shall be shop assembled and properly match marked for ease of field erection and then shipped in the largest sections permitted by carrier regulations. All components shall be erected immediately upon receipt from the solids contact clarifier manufacturer or stored in strict conformance with storage recommendations provided by the solids contact clarifier manufacturer in the operation and maintenance manual. The units shall be lubricated in strict accordance with the instructions of the solids contact clarifier manufacturer's field service representative.
B.
C.
PART 2 - PRODUCTS 2.1 A. GENERAL The solids contact clarifier mechanism replacement parts shall fit the existing bridge type mechanism which is supported by the basin walls. The recirculation turbine and rake and turbine shafts shall all be concentric about the center of the solids contact clarifier mechanism to prevent short circuiting flow patterns and produce uniform solids collection and effluent discharge. Offset axial flow mixers or other designs in which these components are not concentric allow asymmetric energy inputs resulting in localized floc shear and dead zones and will not be allowed. CENTER DRIVE ASSEMBLY A. Each solids contact clarifier shall be provided a new center drive assembly for attachment to existing center platforms. Each center drive assembly shall be made up of individual, concentric, counter rotating sludge collector and recirculation turbine drives, designed to attach to support beams with leveling bolts. Drives shall be in totally enclosed housings with sludge collector and recirculation turbine drives separate, to allow independent maintenance and lubrication. All bearings shall run in an oil bath. Grease lubrication shall not be allowed. Oil pumps for lubrication will likewise not be allowed. A minimum 1-1/2 inch deep condensate collection area must be provided below the main bearing. In lieu of the oil reservoir depth requirement a continuous oil conditioner unit installed at each drive assembly and as specified herein shall be considered equal. The conditioner shall consist of an electrical continuous pre-pump filter and 150 micron stainless steel oil filter. All conditioner mounting hardware, electrical wiring/controls and necessary piping shall be provided by the clarifier manufacturer. Sight glasses and condensate drains for each drive shall be easily accessible without removing plates or structures. Inspection of the completed drive unit shall be accomplished at the solids contact clarifier manufacturer's shop, with reports of all tests and certifications of material hardness being made available for review at the Engineer's request prior to shipment to the job site. All drive components will be assembled via a machined, registered fit or pilot to insure proper alignment. In order to preserve the alignment of key drive components, no welding on the drive will be permitted following machining operations. Drives without totally enclosed oil lubricated bearings and gearing will not be permitted. The turbine motor shall be inverter duty, while the rake drive motor shall be constant speed. Both motors shall be totally enclosed, fan cooled, with a 1.15 service factor, and have bearings with a minimum B10 rating of 40,000 hours. Operating electric current will be 480 volt, 3 phase, 60 hertz, NEMA Design B employing Class F insulation designed for an ambient temperature of 40C. Motors shall conform to the standards of NEMA. Electric motors shall be sealed for operation in a moisture-laden atmosphere and suitable for washdown and outdoor severe duty. Conduit boxes shall be gasketed with neoprene or an equivalent material to prevent moisture from entering the stator through the conduit box. Moisture drains will be placed in suitable positions to prevent accumulation of moisture in the motor housing. Sealed, grease lubricated ball or roller bearings shall be provided. Nameplates shall be stainless steel. All windings shall be copper with a grounding lug, the stator bores and rotor cores shall be coated with lacquer, and the entire enclosure shall be sealed with a corrosion-resistant paint to provide additional protection against moisture and contaminants.
2.2
B.
C.
D. E.
F.
G.
The main gears, main bearings, and torque overload control device that comprise the center drive assembly shall be a regularly manufactured in-house product of the solids contact clarifier manufacturer. Drive assemblies purchased from third party vendors shall not be allowed. RECIRCULATION TURBINE DRIVE
2.3 A.
Each turbine drive mechanism shall consist of an inverter duty motor directly connected to a primary speed reducer, which is directly connected to the turbine drive main gear, or connected through a chain and sprocket arrangement enclosed in a steel guard. Each turbine drive main gear 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. Each turbine drive motor shall be 3.0 horsepower minimum. The turbine speed shall be infinitely adjustable through a 4:1 range by the use of a variable frequency drive (VFD). Each turbine drive primary speed reducer shall be of in-line helical or spiral bevel-helical construction 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 through roller chain and sprockets enclosed in a steel guard. Power transmission devices will be designed with a minimum service factor of 1.5. Units will be supplied with high capacity, antifriction bearings submerged in oil and splash lubricated. The reducer shall be rated for 24 hour continuous duty moderate shock load. Each turbine main gear reducer shall consist of a worm and worm gear assembly, or a spur 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 is completely separate from the worm gear, thereby allowing independent removal of the gear and bearing. Any sludge collector drive that utilizes a combination one piece gear and bearing assembly shall include one (1) extra combination gear and bearing assembly per drive as a required spare part. The precision 4-point contact ball bearing assembly shall be made up of premium alloyed chrome/steel bearing balls and a raceway hardened to at least Rockwell C60 and precision ground. Where a spur gear is used the gear material shall be cast 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-inches with a 4-inch face width or the equivalent spur gear surface area of 377 square inches. The drive manufacturer shall increase the main gear size until this surfaced area requirement is met. Spur gear surface area is defined as the spur gear pitch diameter multiplied by the spur gear face width multiplied by 3.14. The turbine main gear shall be completely enclosed on three sides with a rigid ASTM A-48 Class 40A cast iron housing at least 1/2-inch thick on the vertical sides and 3/4-inch thick on the base, to insure fit and alignment and provided with accessible oil fill and oil drain plugs. Drives without totally enclosed gearing on three sides shall not be allowed. The motor speed shall be infinitely adjustable through the use of an integral motor attached variable frequency inverter (VFD) with the following features integrated into a single unit: 1. The inverter shall mount directly on the turbine motor in place of a terminal box, shall be installed without conduit, and shall be capable of remote speed control.
B. C.
D.
E.
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H.
2. 3. 4.
5. 6. 7. 8. 9.
The inverter shall operate via vector technology in 4-quadrant operation with the ability to operate at 16 kHz carrier frequency to minimize audible noise. It shall use a vector type controller to monitor the current to the motor to control the output speed. The motor shall operate at constant torque range from 2-80 Hz or wider and operate at 10 Hz and higher without the need for an additional cooling fan. The motor shall meet CSA standards, be certified as inverter duty, and shall be approved as a motor overload device. It shall contain overload, over voltage, and phase failure protection. A fault relay and LED shall be provided on the inverter to advise the operator during a fault. Integral motor/VFD shall have a 1.0 service factor or higher. The inverter shall be housed in an aluminum alloy enclosure, suited for outdoor service, and rated IP65 or higher. The inverter shall be designed to match the motor specifications with no parameter setup required. 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 accept analog speed set points from 0-10V, 0-20mA or 4-20mA signals. The inverter shall have selectable acceleration and deceleration times with at least 2 adjustable preset speeds and shall have selectable addresses so that multiple drives can be individually controlled from a PLC or PC or simultaneously controlled from one master. Line and load reactors as well as appropriate on-line filters shall be provided to assure clean uninterrupted power to the variable frequency drive.
2.4 A.
SLUDGE COLLECTOR DRIVE Each sludge collector drive mechanism shall consist of a constant speed motor directly connected to a primary speed reducer which is connected through roller chain and sprockets to the input shaft of the main gear and operates the drive torque overload protection system. Each sludge collector drive mechanism component shall be designed in accordance with referenced standards for 24 hour continuous duty, moderate shock load. The torque value used in the sizing calculation shall be a minimum continuous torque based upon AGMA Standards of 12,500 ft-lbs. In addition, the sludge collector drive must be able to sustain a minimum momentary peak torque of 47,000 ft-lbs. The sludge collector main gear support bearing shall be designed for a minimum B10 life of 100,000 hours at maximum load and speed. Each sludge collector drive shall be designed for the specified continuous torque rating. Continuous torque shall be defined as the minimum torque at which the sludge collector drive mechanism may operate continuously 24 hours per day, 365 days per year, for 20 years, at the specified maximum sludge collector arm speed. Gearing shall be designed and rated to equal or exceed the specified continuous torque and life. The basis for rating shall be AGMA 6034-B92 for worm gears, or AGMA 2001-C95 for spur gears. Rating standard shall include design values for materials used, pressure angle, addendum modifications, and allowable stresses with appropriate re-rate for life cycles required. The following design parameters must be included in the drive calculations: 1. Gear materials, and physical properties 2. Gear pitch or effective diameter 3. Actual face width 4. Tooth pressure angle 5. Number of gear teeth 6. Worm material, heat treatment, and finish Each sludge collector drive motor shall be a minimum 3/4 horsepower. The sludge collector speed shall be constant speed.
B.
C.
D. E.
F.
Each sludge collector drive primary speed reducer shall be of in-line parallel helical construction with gears manufactured from case hardened steel. The primary speed reducer will be directly coupled 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 a minimum service factor of 1.5. Units will be supplied with high capacity, anti-friction bearings submerged in oil and splash lubricated. Each reducer shall be rated for 24 hour continuous duty moderate shock load. Planetary or cycloidal gearing is not considered equal and will not be allowed. Each sludge collector main gear reducer shall consist of a worm and worm gear assembly or a spur 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 is completely separate from the worm gear, thereby allowing independent removal of the gear and bearing. Any sludge collector drive that utilizes a combination one piece gear and bearing assembly shall include one (1) extra combination gear and bearing assembly per drive as a required spare part. The precision 4-point contact ball bearing assembly shall be made up of premium alloyed chrome/steel bearing balls and a raceway hardened to at least Rockwell C60 and precision ground. Where a spur gear is used the gear material shall be ductile iron per ASTM A536 grade 80-5506 or an equal in forged alloy steel. The gear shall have a minimum pitch diameter of 30-inches with a 4-inch face width or the equivalent spur gear surface area of 377 square inches. Spur gear surface area is defined as the spur gear pitch diameter multiplied by the spur gear face width multiplied by 3.14. (diameter x depth x Pi). Drive manufacturers shall increase the main spur gear diameter until this minimum gear surface area requirement is met. The main gear shall be completely enclosed on three sides and the top with a rigid ASTM A-48 Class 40A cast iron or fabricated steel housing at least 1.0-inch thick on the vertical sides and 1.0-inch thick on the base, to insure fit and alignment and provided with accessible oil fill and oil drain plugs. Drives without totally enclosed gearing shall not be allowed. Each sludge collector drive unit shall be equipped with an electro-mechanical overload control device. This device shall be activated by thrust from the worm shaft. A calibrated spring will react to the worm thrust and allow axial movement of the worm shaft to activate a pointer. The overload control device shall provide a visual reading of the output torque on a 0 to 100 percent scale graduated in 10% increments. The device shall also activate an alarm switch and a motor cutout switch. The alarm and motor cutout switches in the control device shall be factory calibrated and set to the required torque. The settings shall be as follows: 1. Alarm torque set at 40% of mechanism design torque or 12,000 ft-lbs 2. Motor cutout set at 85% of mechanism design torque or 25,500 ft-lbs 3. Emergency motor cutout set at 100% of mechanism design torque or 30,000 ft-lbs. The entire control device shall be mounted in a weatherproof cast aluminum or stainless steel enclosure with an integral conduit box and terminals. Amperage sensing devices are not acceptable for torque overload protection due to their inability to react quickly enough to prevent damage to the drive. SLUDGE COLLECTOR ARMS FOR CLARIFIER #1
G.
H.
I.
J.
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2.5 A.
The sludge collector mechanism #1 replacement parts shall include two (2) sludge removal arms of steel truss construction with steel raking blades and stainless steel squeegees. Sludge removal arms shall be attached to the sludge collector drive mechanism by means of a replacement steel torque shaft or cage. Support tie rods in the sludge collector arm design will
not be allowed. Rake blades shall be properly spaced to insure complete raking of the tank bottom twice per revolution. B. Each sludge collector replacement arm shall be designed to withstand one-half the mechanism design strength, or 15,000 ft-lbs, while maintaining structural steel stresses within the AISC allowable stress. Rake blades 7-1/2 inch deep with type 304 stainless steel squeegees shall be provided on each sludge collector arm. Attached to the bottom of the rake blades shall be type 304 stainless steel squeegees designed to 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. The minimum angle size used in construction of the sludge collector replacement arms shall be 2-inches x 2-inches. At the bottom of the torque shaft or cage shall be a replacement cone scraper constructed of steel angles for agitating solids collected in the sludge thickening cone at the center of the solids contact unit. TORQUE SHAFT FOR CLARIFIER #1 A. The sludge collector mechanism #1 replacement parts shall include a sludge collector torque shaft constructed of minimum schedule 40 steel pipe, which is sized to withstand the mechanism design strength of 30,000 ft-lbs while maintaining structural steel stresses within AISC allowable levels. The torque shaft shall be attached to the output shaft of the sludge collector drive and shall have provisions for connections to support the sludge collector arms. RECIRCULATION TURBINE FOR CLARIFIER #1 A. For clarifier #1, provide a replacement center recirculation turbine a minimum of 5-feet in diameter. Turbine shall be capable of a minimum clear water recirculation rate of 5,300 gallons/minute as noted in section 1.2 PROCESS REQUIREMENTS, at the specified maximum allowable tip speed. The turbine shall be located directly above the recirculation drum and arranged concentrically about the center line of the solids contact clarifier mechanism for uniform mixing and solids recirculation within the reaction well. SQUEEGEES A. Replacement squeegees made from 26 gauge type 304 stainless steel shall be provided for both existing solids contact units. SPARE PARTS A. The intent of this specification is to provide uninterrupted operation for a minimum period of two (2) years. To meet this objective, the solids contact clarifier manufacturer shall supply any spare parts that are required to meet this time frame. As a minimum, the following spare parts will be furnished:
8 Section 46 43 53 Solids Contact Clarifier Equipment
C.
D.
E.
F.
2.6
B.
2.7
2.8
2.9
1. 2. 3. 2.10 A.
One (1) set of sludge collector and turbine drive seals. One (1) set of overload control device switches. Five percent (5%) extra fasteners.
WELDING All welding practices shall be in accordance with the requirements of the American Welding Society (AWS) "Welding in Building Construction". All welders shall be certified in accordance with this AWS specification for any welding work performed under this section. SURFACE PREPARATION AND PAINTING All fabricated steel replacement parts shall be shipped to the jobsite bare metal without any surface preparation and/or primer applied. The contractor shall install the replacement parts on the 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 be power 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 mechanism shall 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 Certified Tnemec 20-1211 Potapox epoxy-polyamide coating to 3.0 to 5.0 mil dry film thickness each coat. All machined metal surfaces will be coated with a suitable, easily removable rust inhibitive compound prior to shipment. Upon receipt of any materials coated with a rust inhibitive compound, the Contractor shall insure that the coating is intact prior to storage and maintain the coating until installation of the solids contact clarifier equipment. CONTROL PANEL A replacement control panel with the capacity to control all functions described in this specification section shall be provided for each solids contact clarifier mechanism. The control panel shall be of stainless steel construction conforming to NEMA 4X requirements and suitable for handrail mounting by the Contractor. A hinged front door shall be provided on the control panel adequately sized to contain all of the required controls with access for repairs. Each control panel shall have a 480 volt, 60 hertz, three phase power supply. The control panel shall be factory wired and tested with clearly identified, industrial type terminal strips for all external field connections. An industrial type alarm horn and reset shall be supplied to indicate a high torque situation. The following indicators and control devices shall be mounted on the front of the panel: 1. Turbine drive: "ON-OFF-REMOTE" selector switch. 2. Sludge collector drive: "ON-OFF-REMOTE" selector switch. 3. An alarm horn with reset push button.
9 Section 46 43 53 Solids Contact Clarifier Equipment
2.11 A.
B.
2.12 A.
B.
C.
D. E.
F. G.
H.
Motor starter for both the rake motor and the turbine motor shall be provided by the solids contact clarifier manufacturer to be housed in the electrical control panel mounted on the clarifier center drive platform.
PART 3 - EXECUTION 3.1 A. INSTALLATION The solids contact clarifier mechanism replacement parts shall be installed in accordance with the manufacturer's recommendations as approved by the Engineer. Prior to start-up of the solids contact clarifier equipment, a field service engineer employed directly by the solids contact clarifier manufacturer shall inspect the assembled equipment, make necessary minor final adjustments and certify the equipment ready for operation. SERVICE AND TRAINING A. The solids contact clarifier manufacturer shall supply a factory trained field service representative to inspect the installation of the replacement parts and the operation of the solids contact clarifier equipment. The field service representative shall instruct the owner's personnel in the proper operation and maintenance of the solids contact clarifier equipment. As a minimum, the field service representative must be available for two (2) trips of startup service (one trip for each clarifier). Each trip shall consist of at least two (2) eight (8) hour days on site. Inspection and startup services by a representative of the solids contact clarifier manufacturer who is not a direct, full time employee of the manufacturer is not acceptable. MECHANICAL TESTING AND CERTIFICATION A. After start-up and prior to final acceptance, the Contractor shall conduct Engineer witnessed performance demonstration tests on the solids contact clarifier mechanism. The field service representative will cause the solids contact clarifier mechanism to perform all mechanical functions that the mechanism is designed to perform. Tests will be scheduled with the Engineer at least two (2) weeks prior to the planned test date. The field service representative shall submit to the Engineer a written report stating that the equipment has been checked and is suitable for operation.
3.2
B.
C.
D.
3.3
B.
C.
END OF SECTION
10
SECTION 01 29 00 PAYMENT PROCEDURES PART 1 - GENERAL 1.1 A. SUBMITTALS 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. CASH ALLOWANCES A. 1.3 A. B. C. D. As detailed in Specification Section Supplemental Condition 25, there are no allowances for this project. SCHEDULE OF VALUES Prepare a separate Schedule of Values for each schedule of the Work under the Agreement. Upon request of Engineer, provide support documentation to support the accuracy of the Schedule of Values. Unit Price Work: Reflect unit price quantity and price breakdown from conformed Bid Form. Lump Sum Work: 1. Reflect Schedule of Values format included in conformed Bid Form, specified allowances, alternates, and equipment selected by Owner, as applicable. 2. List bonds and insurance premiums, mobilization, demobilization, preliminary and detailed progress schedule preparation, facility startup, and contract closeout separately. 3. Break down by Division 2 through 44 with appropriate subdivision of each Specification for each Project facility. The apparent low bidder is required to deliver a Bid breakdown by specification within 2 working days after Bid opening. An unbalanced or front-end loaded schedule will not be acceptable. Summation of the complete Schedule of Values representing all the Work shall equal the Contract Price. Submit Schedule of Values on a compact Disk (CD) in a spreadsheet format compatible with latest version of Excel. SCHEDULE OF ESTIMATED PROGRESS PAYMENTS A. B. Show estimated payment requests throughout Contract Times aggregating initial Contract Price. Base estimated progress payments on initially acceptable progress schedule. Adjust to reflect subsequent adjustments in progress schedule and Contract Price as reflected by modifications to the Contract Documents.
1.2
E. F. G. 1.4
Section 01 29 00 Payment Procedures
1.5 A.
APPLICATION FOR PAYMENT 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 on Hand as applicable. Execute certification by authorized officer of Contractor. Use detailed Application for Payment Form suitable to Engineer. Provide separate form for each schedule as applicable. Include accepted Schedule of Values for each schedule or portion of Work, the unit price breakdown for the Work to be paid on unit price basis, a listing of Owner-selected equipment, if applicable, and allowances, as appropriate. 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 as applicable. 3. Submit Application for Payment, including a Transmittal Summary Form and detailed Application 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 by Engineer. PAYMENT A. General: 1. Progress payments will be made monthly. 2. The date for Contractors submission of monthly Application for Payment shall be established at the Preconstruction Conference. Payment for all the Work shown or specified in Contract Documents is included in the Contract Price. No measurement or payment will be made for individual items. Payment for Lump Sum Work covers all Work specified or shown in the Contract Documents. NONPAYMENT FOR REJECTED OR UNUSED PRODUCTS A. Payment will not be made for following: 1. Loading, hauling, and disposing of rejected material. 2. Quantities of material wasted or disposed of in manner not called for under Contract Documents. 3. Rejected loads of material, including material rejected after it has been placed by reason of failure of Contractor to conform to provisions of Contract Documents. 4. Material not unloaded from transporting vehicle. 5. Defective Work not accepted by Owner. 6. Material remaining on hand after completion of Work. PARTIAL PAYMENT FOR STORED MATERIALS AND EQUIPMENT A. Partial Payment: No partial payments will be made for materials and equipment delivered or stored unless Shop Drawings and preliminary operation and maintenance manuals are accepted by Engineer. Thereafter, partial payment for materials and equipment delivered and stored, but not yet incorporated in work, shall not exceed 90% of the equipment or material value.
2 Section 01 29 00 Payment Procedures
B. C. D.
E.
1.6
B. C. 1.7
1.8
B.
Final Payment: Will be made only for products incorporated in Work and following approval of final operations and maintenance manuals; remaining products, for which partial payments have been made, shall revert to Contractor unless otherwise agreed, and partial payments made for those items will be deducted from final payment. PARTIAL PAYMENT FOR UNDELIVERED, PROJECT-SPECIFIC MANUFACTURED OR FABRICATED EQUIPMENT
1.9 A.
Notwithstanding above provisions, partial payments for undelivered (not yet delivered to Site or not stored in the vicinity of Site) products specifically manufactured for this Project, excluding off the shelf or catalog items, will be made for products listed below when all following conditions exist: 1. Partial payment request is supported by written acknowledgment from Suppliers that invoice 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. Applicable Items: Specification Section 13 34 23.13 26 32 13 26 90 20 41 13 23.29 41 23 23 44 42 46.19 44 42 56.23 44 42 56.29 44 42 65 44 43 29 44 43 33.13 Specific Product FRP ONE PIECE MOLDED SHELTER STANDBY GENERATOR PROGRAMMABLE LOGIC CONTROLLERS VOLUMETRIC FEEDERS LOW PROFILE LIFE TABLE VERTICAL TURBINE MIXERS VERTICAL TURBINE PUMPS SUBMERSIBLE PUMPS TUBE SETTLER SYSTEM WATER FILTRATION EQUIPMENT INTAKE SCREEN
B.
C.
Payment shall not exceed 15% of the equipment value, not including shipping and handling charges for undelivered, Project-specific manufactured equipment and will only be made following Shop Drawing approval. Failure of Contractor to continue compliance with above requirements shall give cause for Owner to withhold payments made for such equipment from future partial payments.
D.
PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED)
END OF SECTION
Section 01 29 00 Payment Procedures
INSPECTION REPORT FOR CLARIFIER MECHANISM

Rev.
Date
Description
Customer:
Hot Springs Village WWTP, AR
Project:
Process: Solids Contact Clarifier (Eimco Reactor Clarifiers) Contract No.:
Location:
895 DeSoto Blvd Hot Springs Village, AR 71909
45 SouthWoods Parkway Atlanta, Georgia 30354 USA
Page 1 of 17
Tel. 404-768-2131 www.dbsmfg.com
INSPECTION REPORT
Customer: Contact: POA Hot Springs Village, AR Charles H. Green, Chief Water Plant Operator Tel. 501-922-1323 Dennis Eskew, Water/Wastewater Superintendent Tel. 501-922-5523 Hydronics Inc, Dallas, TX Ron Mayo Tel. 214-850-4145, email: hydronics-inc@westelweb.com Garver, North Little Rock, AR Tom Hubbard Tel. 501-551-2702, email: tmhubbard@garverusa.com October 13, 2011
DBS Manuf. Rep:
Contractor:
Date:
Purpose of Trip
Is to inspect the drive unit and clarifier mechanism on Clarifiers No.1 and No.2.
Customers Concerns
1. The SC Clarifiers were placed in operation 1995. They want an evaluation of the condition of both clarifiers and recommendations. The plant flow has increased and the existing SC Clarifiers are at maximum capacity. They are evaluating a couple of options which include: Upgrade the capacity of the existing SC Clarifiers by adding tube settlers or plate settlers. 2. Add a third SC Clarifier mechanism.
Observations
SC CLARIFIER No2
No. 1
Clarifier has been de-watered and pressure washed clean for inspection of the clarifier mechanicals (rake cage, rake arms, feedwell, launders) and the drive unit.
Clarifier Information
Manufacturer: Type: Size: Drive Unit Model: Eimco Reactor Clarifier (Solids Contact Clarifier) 45 ft B22/W18 combination assembly
Page 2 of 17
Findings
General Condition
1. The tank, internal components, and water were dirty.
Page 3 of 17
Findings
Clarifier Mechanism Arms: 3 bays, 4 plows
Page 4 of 17
Page 5 of 17
Page 6 of 17
1st Arm 1. 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. 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 Arm 1. 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.
Page 7 of 17
Feedwell/Hopper
Page 8 of 17
1. 2. 3. 4. 5.
Overall condition is okay. There is some corrosion/wear in a few spots. Lower skirt is good. Braces (threaded rods) have minor corrosion. Hopper has several divots formed around the outside surface. The inside of the hopper is in good condition.
Page 9 of 17
Cone/Scrapper
1. The tube has some corrosion and wear. 2. Lower support bearing is missing allowing the rakes to rock back and forth easily. 3. The cone scrapper looks good.
Page 10 of 17
Launders
1. The launders are in good condition.
Page 11 of 17
Turbine and Turbine Pipe
Page 12 of 17
Turbine Draft Tube
1. Turbine impeller has minor wear and corrosion. It is in acceptable condition. 2. Turbine draft tube and rake pipe are not concentric and collinear with each other. It appears that one of the pipes is not round and plumb or possibly both. There is a rub mark where it appears that the two pipes come in contact during operation. 3. The inside of the draft tube shows some corrosion and also that is not round.
Page 13 of 17
Concrete Tank
1. Floor of tank have several areas showing hairline cracking, some traveling from the center and all the way to the wall. However, there are no perceivable gaps in the cracks or elevation differences or signs of concrete movement. No floor irregularities. Overall, floor is in acceptable condition.
Page 14 of 17
Feed Pipe
1. The buildup shown around the pipe is not rust and comes off. The pipe is in acceptable condition.
Page 15 of 17
Drive Unit
1. The drive unit mechanism is combination rake and turbine drive unit made of two separate worm type gearboxes and assembled together. Both drives are driven by a hydraulic system. 2. The worm gear type is inefficient. Rake drives with low horsepower requirements, inefficiency is generally not an issue, however are not desirable for turbine drives with larger horsepower requirements. 3. Hydraulic system is also inefficient. The same rule applies for larger horsepower requirements. 4. Hoses are not neatly placed around the platform. 5. Air to oil heat exchangers are laying on top of electric motors.
Page 16 of 17
Inspection Notes:
Comments and Recommendations

1. Clarifier mechanicals which include all metal structures below the bridge should be sand blasted and painted, 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 not obtained with hydraulic systems. Regarding item 5, the shaft is 3.9375 and requires a lower support bearing. SCC No. 1 is not designed with 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. The SC Clarifier is not adequate for service. As a minimum, squeegees and a lower support bearing should be installed and the turbine draft tube and rake pipe should be replaced. Not having a lower support bearing for the rake shaft is probably the reason why the plows do not have squeegees.
Done by: Date:
Jorge L Iduate October 13, 2011
Page 17 of 17
INSPECTION REPORT FOR CLARIFIER MECHANISM

Rev.
Date
Description
Customer:
Hot Springs Village WWTP, AR
Project:
Process: Solids Contact Clarifier (Eimco Reactor Clarifiers) Contract No.:
Location:
895 DeSoto Blvd Hot Springs Village, AR 71909
Page 1 of 13
INSPECTION REPORT
Customer: Contact: POA Hot Springs Village, AR Charles H. Green, Chief Water Plant Operator Tel. 501-922-1323 Dennis Eskew, Water/Wastewater Superintendent Tel. 501-922-5523 Hydronics Inc, Dallas, TX Ron Mayo Tel. 214-850-4145, email: hydronic@dallas.net Garver, North Little Rock, AR Tom Hubbard Tel. 501-551-2702, email: tmhubbard@garverusa.com October 13, 2011
DBS Manuf. Rep:
Contractor:
Date:
Purpose of Trip
Is to inspect the drive unit and clarifier mechanism on Clarifiers No.1 and No.2.
Customers Concerns
1. The SC Clarifiers were placed in operation 1995. They want an evaluation of the condition of both clarifiers and recommendations. The plant flow has increased and the existing SC Clarifiers are at maximum capacity. They are evaluating a couple of options which include: Upgrade the capacity of the existing SC Clarifiers by adding tube settlers or plate settlers. 2. Add a third SC Clarifier mechanism.
Observations
SC CLARIFIER No1 Clarifier has been de-watered and pressure washed clean for inspection of the clarifier mechanicals (rake cage, rake arms, feedwell, launders) and the drive unit.
No. 2
Clarifier Information
Manufacturer: Type: Size: Drive Unit Model: Eimco Reactor Clarifier (Solids Contact Clarifier) 45 ft W24P/W211P3 combination assembly
Page 2 of 13
Findings
Clarifier Mechanism Arms: 3 bays, 4 plows
Page 3 of 13
1. 2. 3. 4.
All upper trailing truss angles are straight and no significant signs of wear/corrosion. All lower trailing truss angles are straight and no significant signs of wear/corrosion. Plows are fairly straight. There could be minor corrosion between the squeegees and plows. Rake truss connectors are in good condition.
Page 4 of 13
Feedwell/Hopper
1. 2. 3. 4.
Upper portion (above water line) has some corrosion/wear. Lower skirt has minor bents. Braces (threaded rods) have minor corrosion. Hopper has several divots formed around the outside surface.
Cone/Scapper
Page 5 of 13
1. No signs of corrosion or wear. No bent pieces. All structure is in good condition.
Page 6 of 13
Launders
1. The sections above the water line have some corrosion.

Page 7 of 13
Turbine and Turbine Pipe
1. Turbine appears to be in good structural condition. 2. Pipe and flange look very good. Turbine Draft Tube
Page 8 of 13
1. Tube is in very good condition.
Page 9 of 13
Concrete Tank
1. Floor of tank in three areas show hairline cracking. There are no signs of concrete movement. There are no perceivable gaps in the cracks or elevation differences. No floor irregularities. Overall, floor is in good condition.
Page 10 of 13
Feed Pipe
1. Feed Pipe is in acceptable condition.
Page 11 of 13
Drive Unit
1. The drive unit mechanism is combination rake and turbine drive unit made of two separate worm type gearboxes and assembled together. Both drives are driven by a hydraulic system. 2. The drive unit mechanism was out of service and waiting for parts. 3. The worm gear type is inefficient. Rake drives with low horsepower requirements, inefficiency is generally not an issue, however are not desirable for turbine drives with larger horsepower requirements. 4. Hydraulic system is also inefficient. The same rule applies for larger horsepower requirements. 5. Hydraulic system is messy. Drive unit shows oil leaks everywhere.
Page 12 of 13
Inspection Notes:
Comments and Recommendations

1. Clarifier mechanicals which include all metal structures below the bridge should be sand blasted and painted, 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 not obtained with hydraulic systems. The SC Clarifier is found fit for service. Recoating the metals structures will add service life to the clarifier.
Done by: Date:
Jorge L Iduate October 13, 2011
Page 13 of 13
Outlet Launder: Remove & Replace With Tube Settler Launder System
Drive Unit: Clarifier 1: Replace Clarifier 2: Replace
ADDENDUM #3
Collection Launder: Remove & Replace With Tube Settler Launder System
Superstructure & Handrails: Clarifier 1: Repaint Clarifier 2: Repaint
Rotating Components: Clarifier 1: Replace Clarifier 2: Repaint

Radial Launders: Remove & Replace With Tube Settler Launder System
Drive Unit: Clarifier 1: Replace Clarifier 2: Replace
Center & Outlet Launder: Clarifier 1: Remove Clarifier 2: Remove Install Tube Settler Launder System
Handrail: Clarifier 1: Repaint Clarifier 2: Repaint
Radial Launders: Clarifier 1: Remove Clarifier 2: Remove Install Tube Settler Launder System Rake/Turbine Shaft: Clarifier 1: Replace Clarifier 2: Repaint
Superstructure: Clarifier 1: Repaint Clarifier 2: Repaint
Reaction Well: Clarifier 1: Repaint Clarifier 2: Repaint
ADDENDUM #3
Recirculation Drum: Clarifier 1: Repaint Clarifier 2: Repaint
Rotating Drum: Clarifier 1: Replace Clarifier 2 : Repaint
Rake Arms: Clarifier 1: Replace Clarifier 2: Repaint

Cone Scraper: Clarifier 1: Replace Clarifier 2: Repaint
ADDENDUM #3

1240 Addendum 3

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08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

American Society for Testing and Materials - Structural Steel Specifications

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 46 43 53 Solids Contact Clarifier Equipment

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 01 29 00 Payment Procedures

Issued as a part of ADDENDUM #3

08059580 Hot Springs Village Water Treatment Plant Expansion

Issued as a part of ADDENDUM #3

PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED)

08059580 Hot Springs Village Water Treatment Plant Expansion

Section 01 29 00 Payment Procedures

Issued as a part of ADDENDUM #3

INSPECTION REPORT FOR CLARIFIER MECHANISM

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

DBS Manuf. Rep:

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

1. The tank, internal components, and water were dirty.

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3

45 SouthWoods Parkway Atlanta, Georgia 30354 USA

Tel. 404-768-2131 www.dbsmfg.com

Issued as a part of ADDENDUM #3