TYPICAL SPECIFICATION

SECTION XXXXJetMix™ Vortex Mixing System

1.0 GENERAL

1.1 SCOPE OF SUPPLY

1.2 RELATED SPECIFICATION SECTIONS

MotorsPipingElectrical Controls

1.3 GENERAL DESCRIPTION

1.3.1 The mixing system for each Digester shall be a JetMix Vortex Mixing System Evoqua Water Technologies. The system shall consist of __ fixed mixing nozzles, and __ dry pit horizontal recirculation pump for the anaerobic digester tank. The equipment shall be located as shown in the plans. The equipment shall be provided as a complete system by the mixing system manufacturer. Each equipment item shall be constructed as hereinafter specified.

1.3.2 The mixing system shall be designed to create a rotating toroidal pattern. The pattern shall also include a helical flow pattern following the surface of the toroid, rising along the tank wall and descending in the middle of the tank to effectively sweep solids from the center of the tank. Zone mixing either horizontal only, or vertical only will not be acceptable, as an approved alternate to toroidal mixing.

1.3.3 The design base manufacturer for the mixing system is JetMix by Evoqua Water Technologies Alternate manufacturer is subject to demonstration of compliance to these specifications, and in accordance with the contractor’s sole obligation to accommodate any design modifications required for associated equipment.

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1.4 QUALITY ASSURANCE

1.4.1 All mixing system equipment furnished under this section shall be of a design and manufacture that has been used in similar applications, and shall be demonstrated to the satisfaction of the owner that the quality is equal to equipment made by that manufacturer specifically named herein. Manufacturers shall provide evidence of at least five (5) installations in which identically sized and arranged equipment has been providing satisfactory performance for a minimum of five (5) years in a similar application. No consideration will be given to alternate mixing systems that have not been commercially available for five (5) years.

1.4.2 To insure a consistent high standard of quality, the manufacturer of this mixing system shall comply with all of the requirements of these specifications and only accepted by the final approval of the owner’s engineer. Showing full compliance with this requirement is mandatory.

1.4.3 All system components and appurtenances shall be furnished by the mixing system manufacturer to insure compatibility and integrity of the individual components, and provide the specified warranty for all components. The mixing system manufacturer shall accept unit responsibility for the system, including all components and accessories.

1.4.4 Alternate manufacturers that cannot comply with all paragraphs 1.4.1, 1.4.2, and 1.4.3 above, must post a 250% performance bond (based on total cost of mixing system) with the engineer, in the name of the owner, prior to bidding or any post bid submittal process for approval. Failure to post the performance bond automatically disqualifies the manufacturer.

1.5 WARRANTY AND GUARANTEE

1.5.1 The equipment shall be warranted to be free from defects in material or workmanship for a period of one year from the date of beneficial use or acceptance of the equipment, whichever comes first. All parts and/or repairs shall be made by the system supplier at no cost to the owner.

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2.0 MECHANICAL DESIGN

2.1 MIXING NOZZLES

2.1.1 The mixing nozzles shall be cast of ASTM A532 class II, Type C Chrome iron with a minimum hardness of 450/550 Brinell throughout the entire nozzle wall. The nozzle shall be sandblasted in accordance with SSPC-SP6. The coating system shall be Tnemec Series 69 Hi-Build Epoxoline. The prime coat shall have a minimum DFT of 3 – 5 mils and intermediate and finish coat shall be applied with a DFT of 5+ mils each for a total coating DFT of 13 – 16 mils.

2.1.2 The nozzles shall be designed to discharge at an angle 5° below horizontal. The nozzle construction shall be of an eccentric design to create a downward force to enhance the sweeping pattern across the tank floor, preventing solids buildup. Concentric nozzle barrels with simple elbows are not considered equal. The nozzle orifice shall be selected by the mixing system supplier to provide the proper system performance.

2.1.3 The nozzle shall have a 6 inch diameter, van Stone or slip style, flanged connection allowing an adjustment in alignment of 360 degrees. The alignment of the nozzle shall be as directed by the mixing system manufacturer. Quick disconnect or Victaulic type couplings will not be acceptable as an alternate to flanged connections.

2.1.4 The nozzle shall incorporate flow control vanes to reduce nozzle turbulence and improve discharge pattern. A 12” taper length is not considered equal to flow control vanes. The absence of vanes shall require a straight taper length of a minimum of ten pipe diameters.

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2.1.5 Externally case hardened or heat treated nozzles are not equal to cast hardened metal and will not be approved. To be considered as an approved alternate a glass lined nozzle manufacturer must submit a third party certification of “pin hole free” surfaces throughout the nozzle surface. Also an on-site high voltage test shall be performed on the contact surfaces of all the finished nozzles using a high voltage test to identify any discontinuities in the glass contact surfaces. The tester shall have an accuracy of + 1% such that the voltage at the test probe is 1000V. The tester shall have an up to date valid calibration record. Nozzles having any discontinuities in the glass contact surfaces shall be rejected by the field inspector and replaced by the manufacturer at no cost to the owner. Certification, test procedure and manufacture of the high voltage testing unit shall be submitted to the Engineer and approved prior to bidding.

3.0 MIXING/RECIRCULATION PUMP

3.1 GENERAL

3.1.1 The recirculating pump shall be part of the scope of supply of the mixing system manufacturer. The pump performance, design and operating characteristics shall be the responsibility of the mixing system manufacturer. The pump shall be designed to prevent nozzle clogging in the specified application.

3.1.2 Suction and discharge flanges shall meet ANSI 150 class bolting.

3.1.3 Pumps shall be sized to meet the following design criteria:

Fluid ____ Solids concentr. ____ %Temp ____ °F Disch. Size ____ in.Suction Size ____ in.

Capacity ____ gpmTDH 40 ft

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3.2 PUMP DESIGN

3.2.0 The basic design shall be a horizontal end suction clog-free, chopper-type pump, utilizing a centrifugal chopper impeller. The overall pump design shall combine high efficiency, low required NPSH, and the ability to chop or condition scum, rags or other fibrous material without plugging. Design basis is the Wemco ChopFlow pump.

3.2.2 The casing shall be of semi-concentric design, with the first half of the circumference being cylindrical beginning after the pump outlet, and the remaining circumference spiraling outward to the 150 lb. flanged center line discharge.

3.2.3 The hydraulic design of the impeller shall combine the action of a semi-open centrifugal impeller with the action of a fixed blade to chop and/or condition the incoming solid materials.

3.2.3.1 The front of the impeller shall have hardened, spiraled vanes that completely wrap around the center of rotation, pulling material into the cutting area and assuring positive and complete chopping action. The single piece removable and replaceable cutting bar shall extend completely across the cutting vanes of the impeller.

3.2.3.2 The reverse side of the impeller shall include pump-out vanes, each with two cutting slots and a centered labyrinth to prevent any material from reaching the seal area, whether the pump is running or not. The cutting slots shall function integrally with replaceable cutter teeth mounted on the backplate.

3.2.3.3 The impeller/cutter bar clearance shall be externally adjustable by means of adjustment screws. Each adjusting screw shall incorporate a mechanism for positively advancing , positively retracting and positively locking the position of the chopper impeller, so that the necessary running clearances between the chopper impeller and cutter bar can be maintained for optimum chopping capability. This clearance adjustment shall be accomplished without loosening any pump mounting bolts, moving pump flanges or feet, and without the need to dismantle any portion of the pump.

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3.2.4 The backplate shall be a separate component part, and shall not be integral to the bearing frame and allow removal of the pump components from above the casing. The backplate shall be sealed to the bearing frame with “0” rings that so that it can be moved axially for external adjustment of impeller-to bar clearance.

3.2.4.1 The backplate shall incorporate the raised face portion of the seal labyrinth to engage the machined grooves in the rotating impeller, and shall incorporate 4 independent, replaceable cutter teeth that engage with cutting slots in the back of the impeller.

3.2.4.2 In order to maintain optimum running clearances between the rear cutting slots on the back of the impeller and replaceable cutter teeth, the clearances between these components shall be externally adjustable by means of adjustment screws. Each adjusting screw shall incorporate a mechanism for positively advancing, positively retracting and positively locking the position of the backplate, so that the necessary running clearances between the replaceable cutter teeth and cutter slots can be maintained for optimum chopping capability. This clearance adjustment shall be accomplished without loosening any pump mounting bolts, moving pump flanges or feet, and without the need to dismantle any portion of the pump.

3.2.4.3 The 4 individual cutting teeth in the backplate shall be attached to the backplate with screws, so that they can be independently and easily replaced, without the need to replace the entire backplate for renewal of the cutting surfaces.

3.3 MECHANICAL

3.3.1 Casing: The pump casing will be constructed of ASTM A536 ductile iron with all water passages to be smooth and fee of blowholes and imperfections for good flow characteristics.

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3.3.2 Impeller: Impeller: Shall be semi-open type with pump out vanes to reduce seal area pressure. Chopping of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar at the intake openings, with a set clearance between the impeller and cutter bar of .010” to .015”. Impeller shall be ASTM A148 cast alloy steel case hardened to Rockwell C60 and dynamically balanced. The impeller shall be threaded to the shaft and shall have no axial adjustments and no set screws.

3.3.3 Cutter Bar: Shall be recessed in to the pump bowl, and shall extend diametrically across the entire funnel shaped pump suction opening. Cutter bar shall be ASTM 514 Grade A (TI alloy) steel hardened to Rockwell C60.

3.3.4 Replaceable cutting teeth: 4 independent, replaceable cutting teeth shall be bolted into the backplate and shall engage and intermesh with the cutting slots machined into the back of the impeller, reducing and removing materials from the mechanical seal/packing area. Replaceable cutters shall be ASTM 514 Grade A (TI alloy) steel case hardened to minimum Rockwell C60.

3.3.5 Pump Shafting: The pump shaft and impeller shall be supported by standard AFBMA series bearings. Shafting shall be ANSl 4140 heat treated steel, with a diameter of sufficient size to minimize any deflection during solids chopping.

3.3.6 Bearings: Shaft thrust in both directions shall be taken up by to back-to-back mounted single-row angular contact ball bearings. Bearings shall be rated with a minimum B-l0 bearing life of 100,000 hours.

3.3.7 Bearing Housing: Shall be ASTM A536 ductile cast iron, and machined with piloted bearing fits for concentricity of all components. Bearing housing shall be oil bath lubricated with ISO Grade 46 turbine oil and a side mounted sight glass to provide a permanently lubricated assembly. Viton double lip seals are installed to provide sealing at each end of the bearing housing.

3.3.8 Seal: Pump stuffing box shall be designed for maximum flexibility in allowing shaft seal with a flushless mechanical Seal system specifically designed to require no seal flush, through elimination of the stuffing box. The seal shall be made of ANSl 316 stainless steel and shall be cartridge type with Viton 0-rings and silicon carbide or tungsten carbide seal faces. The cartridge seal shall be pre-assembled and pre-tested so that no seal settings or adjustments are required. Any springs used to push the seal faces together must be shielded from the fluid to be pumped.

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3.3.9 Inlet manifold: The pump assembly shall be mounted horizontally with 150 lb. standard inlet flange, clean out and mounting feet. The suction spool shall be manufactured of ductile cast iron ASTM A536 and shall include a cast casing clean out of ductile iron ASTM A536. The mounting feet shall be cast integral to the suction spool piece.

3.3.10 Coupling: Bearing housing design shall be designed for the motor to be connected to the pump by means of a constant speed, v-belt drive. The belts and sheaves shall be properly selected for the speed and torque requirements of the pump.

3.3.11 Base: Pump manufacturer shall provide a common pump and motor base constructed of a minimum 3/8 inch thick fabricated steel, suitably reinforced to support the full weight of the pump, motor, drive belts, sheaves and guard.

3.3.12 Drive Guard: An approved fiberglass or thermoplastic coupling guard shall be provided to safely enclose the v-belt drive components in accordance with OSHA regulations. If metal guards are furnished, they shall be of all 316 stainless steel construction with suitable lifting eyes and handles to aid in removal.

3.3.13 Motor: Motor shall be TEFC type, for 3 Phase, 60 Cycle, 230/460 Volt service M, and shall be connected to the pump by the drive method specified. All motors shall be of nationally known manufacture and shall conform to NEMA standards and specifications.

3.4 COMPONENT ACCESSORIES

3.4.1 Suction and Discharge gauges: Suction and discharge piping pressure gauges shall be supplied and mounted in close proximity to the recirculating pump. The gauge construction shall be all-welded with an integral 316L stainless steel sealed diaphragm and 316L stainless steel parts. The discharge gauge should have a range of 0.0 to 60 psi and the suction gauge should have a range of -30 to +30 psi.

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4.0 EXECUTION

4.1 EXAMINATION

4.1.1 Contractor shall offload equipment at installation site using equipment of sufficient size and design to prevent injury or damage. Immediately after offloading, contractor shall inspect the complete mixing system and appurtenances for shipping damage or missing parts. Any damage or discrepancy shall be noted in a written claim with shipper prior to accepting delivery. Validate all station serial numbers and parts lists with shipping documentation. Notify the manufacturer’s representative of any unacceptable conditions noted with shipper.

4.2 INSTALLATION

4.2.1 Install, level, align, and lubricate mixing system as indicated on project drawings. Installation must be in accordance with written instructions supplied by the manufacturer at time of delivery.

4.2.2 All piping connections are to be tight and leak free. Fasteners at all pipe connections must be tight. Install pipe with supports and thrust blocks to prevent strain and vibration on system piping. Install and secure all service lines as required.

4.2.3 Check motor and control data plates for compatibility to site voltage. Install and test the station ground prior to connecting line voltage to station control panel.

4.2.4 Prior to applying electrical power to any motors or control equipment, check all wiring for tight connection. Verify that protective devices (fuses and circuit breakers) conform to project design documents. Manually operate circuit breakers and switches to ensure operation without binding. Open all circuit breakers and disconnects before connecting utility power. Verify line voltage, phase sequence and ground before actual startup.

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4.3 FIELD QUALITY CONTROL

4.3.1. OPERATIONAL AND PERFORMANCE TEST

4.3.1.1 Prior to acceptance by owner, an operational test of all pumps, drives, nozzles and control systems shall be conducted to determine if the installed equipment meets the purpose and intent of the specifications. Tests shall demonstrate that all equipment is electrically, mechanically, structurally, and otherwise acceptable; it is safe and in optimum working condition; and conforms to the specified operating characteristics.

4.3.1.2 After construction debris and foreign material has been removed from the tank and piping, contractor shall supply adequate water volume to operate pump and mixing nozzles. Contractor shall observe and record operation of pumps, suction and discharge gauge readings, ampere draw, and pump controls. Check all equipment and control systems. Note any undue noise, vibration or other operational problems.

4.3.2 MANUFACTURERS’ STARTUP SERVICES

4.3.2.1 Coordinate station startup with manufacturers’ technical representative. The representative or factory service technician will inspect the completed installation before the tank is filled. He will correct or supervise correction of defects or malfunctions and check nozzle alignment. The technical representative shall also be present when the equipment is initially operated to check on the performance.

4.3.2.2 The manufacturer’s technical representative shall provide training of plant personnel on site including classroom and hands on instruction for one day. The training shall cover proper operation and maintenance procedures.

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4.3.3 WARRANTY AND GUARANTEE

4.3.3.1 Equipment Manufacturer shall furnish its standard warranty against defects in material and workmanship for the Mixing Equipment provided under this section. Equipment Manufacturer shall warrant the Jet Mixing Equipment through the earlier of: Eighteen (18) months from delivery of the equipment or Twelve (12) months from initial operation of the Jet Mixing Equipment. The Jet Mixing Nozzles shall be warranted through the earlier of: One Hundred Twenty Six (126) months from delivery of the Nozzles, or One Hundred Twenty (120) months from initial operation of the Nozzles.

4.3.3.2 The mixing system shall be designed to resuspend solids from a quiescent condition that can last for periods of six months duration. The resultant mixture shall have a uniform concentration with the solids content varying by no more than ±10%.

END OF SECTION

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