GEORGIA STATE FINANCING AND INVESTMENT COMMISSION
PROCUREMENT DIVISION
270 WASHINGTON STREET, SECOND FLOOR
ATLANTA, GEORGIA 30334
PHONE NUMBER: 404-463-5734 | FAX NUMBER: 404-463-5699
Mack C. Washington, Jr.
ADDENDUM ONE
April 17, 2013
Project Number: GDC 13-013
Project Name:
Dodge State prison Mechanical Auger Screen
THIS ADDENDUM IS BEING ISSUED TO INCORPORATE THE FOLLOWING
INFORMATION INTO THE REFERENCED PROJECT.
1)
Discard the original section 15010 and replace with new :
SECTION 15010
AUGER MONSTER® SYSTEM
SERIES AGE-285
SINGLE DRIVE-ELECTRIC 30005 GRINDER AND
ELECTRIC 285 MM AUGER
END OF ADDENDUM NUMBER ONE
SECTION 15010
AUGER MONSTER® SYSTEM
SERIES AGE-285
SINGLE DRIVE-ELECTRIC 30005 GRINDER AND
ELECTRIC 285 MM AUGER
PART 1
GENERAL
1.1 SUMMARY
A. This section of the specification describes the screenings removal equipment consisting of a
support system(s), grinder(s), auger(s), and motor controller(s). The equipment shall be
installed as shown on the plans, as recommended by the supplier, and in compliance with all
OSHA, local, state and federal codes and regulations.
B. The number of Auger Monster(s)® systems shall be (1) one . Each system shall include the
support system, grinder, auger, and motor controller.
C. The auger system shall be capable of processing 500 GPM with a minimum headloss of 12
inches at a downstream water level of 4 inches.
1.2 REFERENCES
A. Support system(s), grinder(s), and auger(s) materials of construction shall, as applicable, meet
the requirements of the following industry standards:
1. American Society for Testing and Materials (ASTM) A36: Standard Specification for
Carbon Steel Plate
2. American Society for Testing and Materials (ASTM) A536-84: Standard Specification for
Ferritic Ductile Iron Castings
3. American Iron and Steel Institute (AISI) 303 Stainless Steel
4. American Iron and Steel Institute (AISI) 304 Stainless Steel
5. American Iron and Steel Institute (AISI) 316 Stainless Steel
6. American Iron and Steel Institute (AISI) 4130 Heat Treated Alloy Steel
7. American Iron and Steel Institute (AISI) 4140 Heat Treated Hexagon Steel
8. Rockwell C
B. Motor controllers shall, as applicable, meet the requirements of the following Regulatory
Agencies.
1. National Electrical Manufacturer's Association (NEMA) Standards
2. National Electrical Code (NEC)
3. Underwriters Laboratory (UL and cUL)
DODGE STATE PRISON
15010 - 1
PART 1
GENERAL (Cont'd)
1.3 DOCUMENTS
A. Shop Drawing(s)
Supplier shall submit six (6) sets of shop drawings. Shop drawings shall include equipment
descriptions, specifications, dimensional and assembly drawings, parts lists, and job specific
drawings.
B. Operation and Maintenance Manuals
Supplier shall submit three (3) sets of Operation and Maintenance manuals prepared using best
commercial practices. The manuals shall include equipment descriptions, operating
instructions, drawings, troubleshooting techniques, a recommended maintenance schedule, and
the recommended lubricants.
1.4 QUALITY ASSURANCE
Qualified suppliers shall have a minimum five (5) years experience at manufacturing, support
systems, two (2) shafted grinding equipment, inclined augers and motor controls with a minimum
500 installations of similar equipment. Supplier shall provide a list of names and dates of
installations for verification by the Engineer or Owner's Representative.
Supplier shall provide the services of a factory-trained representative to check the installation and
to start-up each grinder, auger and controller. The factory representative shall have complete
knowledge of proper installation, operation, and maintenance of equipment supplied.
Representative shall inspect the final installation and supervise a start-up test of the equipment.
Each grinder, auger, and controller shall be factory tested to ensure satisfactory operation.
1.5 DELIVERY, STORAGE AND HANDLING
A. The equipment shall be packaged in containers constructed for normal shipping, handling and
storage.
B. The containers shall provide adequate protection for the equipment in a dry indoor
environment between +40°F (+4.5°C) and +100°F (+37.8°C) until time for installation.
1.6 IDENTIFICATION
Each unit of equipment shall be identified with a corrosion resistant nameplate, securely affixed in
a conspicuous place. Nameplate information shall include equipment model number, serial
number, supplier's name, and location.
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PART 2
PRODUCTS
2.1 MANUFACTURERS
A. Support system(s), grinder(s), auger(s), and motor controller(s) shall be in compliance with
these specifications and plans and shall be supplied by one of the following manufacturers:
1. JWC Environmental®: Auger Monster® system Model No. AGE1800-285
B. Manufacturers requesting to be selected as an approved equal shall submit certified
documentation showing compliance with these specifications a minimum of ten (10) days prior
to bid opening. Selected equipment manufacturers shall be added to the list of approved
manufacturers.
C. The manufacturer must certify that the unit can be returned for maintenance to the factory or a
local repair facility. The certification shall include a statement that there will be no charge for
repair labor.
2.2 SUPPORT SYSTEM(S)
A. GENERAL
1. A grinder and auger system support frame with adjustable mounting brackets shall be
provided for a 24 inch wide and a 72 inch deep channel.
2. An auger drive-end support shall be provided as required by the application. The drive end
support shall provide a method for pivoting the auger from the channel to perform simple
maintenance. Installations with transport lengths of the auger greater than 4000 mm (157
in) shall require additional supports.
3. A horizontal support shall be provided for mounting an ultrasonic sensor upstream from
the system support frame.
B. COMPONENTS
The support frame and additional supports shall be of welded square tube, angle, and plate
construction. The construction material shall be 304 stainless steel.
2.3 GRINDER(S)
A. GENERAL
1. Each grinder shall include cutters, spacers, shafts, bearings and seals, side rails, end
housings, covers, reducer, and motor.
2. The grinder shall be of two (2) shaft design and be capable of continuous operation,
processing wet or dry. Bar screens or single shaft devices utilizing a single rotating cutter
bar with stationary cutters shall not be acceptable. Grinders designed with cutter and
spacer cartridges rather than individual cutters and spacers shall not be acceptable.
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15010 - 3
PART 2
PRODUCTS (Cont'd)
2.3 GRINDER(S) (Cont'd)
A. GENERAL (Cont'd)
3. Two (2) shaft design shall consist of two (2) parallel shafts alternately stacked with
individual intermeshing cutters and spacers positioned on the shaft to form a helical
pattern. The two (2) shafts shall counter-rotate with the driven shaft operating at
approximately two-thirds (2/3) the speed of the drive shaft. Cutter diameters on the drive
and driven shafts shall be of equal diameter to ensure proper clean-out of the spacers.
B. COMPONENTS
1. Individual Cutters and Spacers
a. The cutting chamber shall be a nominal height of 18 inch .
b. Individual cutters and spacers shall be 4130 heat treated alloy steel, surface ground for
uniformity and through-hardened to a minimum 45-50 Rockwell C.
c. The inside configuration of both the individual cutters and the individual spacers shall
be hexagonal so as to fit the shafts with a total clearance not to exceed 0.015 inch (0.38
mm) across the flats to assure positive drive, minimize wear on the cutters.
d. Cutter configuration shall consist of individual eleven (11) tooth cam cutters on both
shafts. To maintain particle size, the height of the tooth shall not exceed 1/2 inch (13
mm) above the root diameter. Cutter to cutter root diameter overlap shall be not less
than 1/16 inch (1.6 mm) or greater than 1/4 inch (6 mm) to maintain the best possible
cutting efficiency while incurring the least amount of frictional losses. Clearance
between overlapping cutters of opposing shafts shall be no greater than 0.011 inches
(0.28 mm).
e. The cutters shall exert a minimum force at the tooth tip of 1,831 lb/hp (10,921 N/kW)
during momentary load peaks.
2. Shafts
a. Grinder drive and driven shafts shall be made of 4140 heat treated hexagon steel with a
tensile strength rating of not less than 149,000 psi (1,027 MPa).
b. Each hexagonal shaft shall measure a nominal two (2) inch (51 mm) across parallel
surfaces.
3. Intermediate Shaft Support
a. An intermediate shaft support shall be provided in the center of the cutter stack for
grinders with 40 inch (1,016 mm) cutter stack. Grinders with 50 inch (1270 mm) or 60
inch (1,524 mm) cutter stacks shall have two (2) intermediate shaft supports. No
support shall be required for required for grinders with 32 inch (813 mm) cutter stacks
and less.
DODGE STATE PRISON
15010 - 4
PART 2
PRODUCTS (Cont'd)
2.3 GRINDER(S) (Cont'd)
B. COMPONENTS (Cont'd)
3. Intermediate Shaft Support (Cont'd)
b. The intermediate shaft support shall provide additional support for heavier than normal
influent grinder demand loads and protection for the seal assemblies and retaining ring.
c. The intermediate shaft support shall be made of a cast 303 stainless steel collar and two
(2) bushings. The bushings shall act as bearings to allow free rotation of the shafts.
4. Shaft Bearings and Seals
a. The radial and axial loads of the cutter shafts shall be borne by sealed, oversized, deepgroove ball bearings at each end.
b. The bearings shall be protected by a combination of a replaceable and independent
tortuous path device and mechanical seals.
c. Face materials shall be of tungsten carbide.
d. O-rings shall be made of Buna-N elastomers.
e. Products requiring continuous or occasional lubrication or flushing shall not be
accepted.
f.
The mechanical seal shall be rated at 90 psi (620 kPa) continuous duty by the seal
supplier.
g. The bearings shall be housed in a replaceable cartridge that supports and aligns the
bearings and seals, as well as protects the shafts and end housings. The seal elements
shall be independent of the stack height; therefore cutter stack tightness shall not affect
seal performance. The seal elements shall maintain their factory set preload
independent of the cutter stack tightness.
h. Seals shall meet required pressure rating regardless of cutter stack fit. The seal
cartridge shall provide seal protection against axial loading on shafts and bearings
during shaft deflection.
i.
DODGE STATE PRISON
Each seal element shall be positively locked to its corresponding rotating or static
cartridge element. This positive lock on the seal elements is critical to long seal life in
applications where grit or other abrasive materials are present.
15010 - 5
PART 2
PRODUCTS (Cont'd)
2.3 GRINDER(S) (Cont'd)
B. COMPONENTS (Cont'd)
5. Side Rails
a. The inside profile of the side rails shall be concave to follow the radial arc of the
cutters.
b. Clearance between the major diameter of the cutter and the concave arc of the side rails
shall not to exceed 5/16 inch (7.9 mm).
c. The side rails shall have evenly spaced slots that increase flow and decrease head loss.
The slots shall only be built into the influent side of the side rail and, the effluent side
of the side rail shall be void of slots to allow for the maximum flow of the processed
effluent.
d. The side rails shall be cast of A536-84 ductile iron.
6. End Housings and Covers
a. Grinder end housings shall be of cast A536-84 ductile iron with a cast-in-place flow
deflector, designed to protect the bushings while guiding particles directly into the
cutting chamber.
b. Top covers shall be A536-84 ductile iron and bottom covers shall be A36 hot rolled
plates.
7. Reducer
a. The speed reducer shall be a grease-filled planetary-type reducer with a 500% shock
load capacity. The reduction ratio shall be 29:1.
b. The input shaft of the reducer shall be directly coupled to the motor using a two (2)
piece coupling, and the output shaft of the grinder shall be directly coupled with the
reducer using a two (2) piece coupling.
8. Motor
a. The motor shall be 5 hp (3.7 kW), TEFC, 1725 rpm, 230 volts, 1-phase, 60-Hz.
b. Motor service factor shall be 1.0, the efficiency factor not less than 85% at full load
and the power factor not less than 80% at full load.
c. Required Running Torque per Horsepower (kW):
At Momentary Load Peaks: 4,246 lbs-in/hp (643 Nm/kW)
DODGE STATE PRISON
15010 - 6
PART 2
PRODUCTS (Cont'd)
2.4 AUGER(S)
A. GENERAL
1. The auger(s) shall be comprised of a perforated screen segment, transport segment,
discharge segment, and drive segment with an internal rotating spiral.
2. Each auger shall be installed at an inclination of 35 degrees from horizontal immediately
downstream of the grinder.
3. The auger screen segment trough with a rotating spiral shall provide particle capture and
transport to the discharge segment outlet.
4. A wiper/brush shall be affixed to the outer edge of the spiral in the screen segment trough
to provide trough cleaning and particle transport. The wastewater shall be permitted to
pass through the screen segment and flow downstream.
5. Particles shall be washed both by the highly-agitated passing wastewater and by the
discharge of a spray wash system. Dewatering shall occur as the rotating spiral conveys
the washed screenings.
6. A spray wash assembly shall be provided to rinse the organic material from the processed
solids back into the waste stream. The spray wash system shall consist of a set of nozzles
proving a covering spray of water for cleaning the captured solids along with a set of
nozzles providing an impact spray to hold the solids against the screen trough for
transportability. A spray wash solenoid valve shall be automatically energized by the
system controller allowing wash water to spray into the screen segment whenever the auger
spiral is in operation. The spray wash solenoid shall be automatically de-energized,
stopping the flow of wash water whenever the auger spiral is stopped.
7. Starting of auger run cycles shall be initiated by signals from ultrasonic level sensors.
B. COMPONENTS
1. Auger Spiral
a. The 285 mm (11 ¼ in) spiral shall be made of high wear-resistant, alloy carbon steel.
b. The spiral shall have a groove designed into the outside diameter of the spiral for the
mounting of the brush. The groove shall securely position the brush so that constant
contact is maintained with the screen segment for the purpose of cleaning the
perforations and the free passage of soft organics and liquids. Spirals that mount the
brush to the face of the spiral shall not be acceptable.
c. The spiral shall have a welded drive plate for connection to the drive shaft.
d. The spiral tip speed shall not be more than 33 feet/minute (0.17 m/s).
e. The spiral transport speed shall not be more than 6.25 feet/minute (0.03 m/s).
DODGE STATE PRISON
15010 - 7
PART 2
PRODUCTS (Cont'd)
2.4 AUGER(S)
B. COMPONENTS (Cont'd)
2. Screen Segment
a. The screen segment trough shall be a replaceable, perforated 304 stainless steel
assembly. The perforated area of the segment shall be constructed of 14 ga sheet.
b. The screen trough perforations shall be 1/4 inch (6.4 mm) on a 5/16 inch (7.9 mm)
stagger for separation of the liquids from the solids. The sharp edges of the
perforations shall be removed.
3. Transport Segment
a. The transport segment shall be a 304 stainless steel assembly with inspection port(s).
The segments shall be constructed of 10 ga. Sheet.
b. The transport segment shall have stainless steel wear bars to support the rotating spiral.
4. Discharge Segment
a. The discharge segment shall be a 304 stainless steel assembly with an inspection port
and a full-width bottom discharge flange. The segment shall be constructed of 10 ga
sheet.
b. The discharge segment shall have a 304 stainless steel endplate for mounting the drive
segment.
5. Drive Segment
a. The drive segment shall be comprised of a drive shaft with welded drive plate, shaft
seal, drive adapter spool, speed reducer and electric motor.
b. The shaft seal shall consist of a packing housing; four (4) PTFE impregnated packing
cords, and adjustable packing ring.
c. The drive adapter spool shall be cast A536-84 ductile iron coated to inhibit corrosion.
d. The speed reducer shall have a reduction ratio of 160:1.
e. The electric motor shall be of 2.0 hp (1.5 kW), TEFC, 1725 rpm, 230 volt, 1-phase, 60Hz.
6. Spray Wash Assembly
a. The spray wash assembly shall consist of a one (1) inch spray wash manifold, solenoid
operated valve, manually operated ball-valve, and a remotely installed basket strainer.
b. The spray wash manifold shall be of 304 stainless steel pipes and fittings. The spray
nozzle shall consist of 40° “V” spray nozzles rated for 1.5 GPM @ 40 PSI and high
impact 50° spray nozzles rated for 1.0 GPM @ 40 PSI.
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15010 - 8
PART 2
PRODUCTS (Cont'd)
2.4 AUGER(S) (Cont’d)
B. COMPONENTS (Cont'd)
6. Spray Wash Assembly (Cont’d)
c. The solenoid valve shall be of bronze construction, fitted with an explosion proof
enclosure, housing a 120 VAC coil.
d. The manually operated ball valve shall be of 316 stainless steel and shall provide
adjustment for the spray wash water flow.
e. A one (1) inch NPT strainer shall be of SST material, with a 80 mesh 304 stainless
steel screen and a threaded drain.
f.
A one (1) inch NPT double back-flow preventer (not supplied by equipment
manufacturer) is recommended when using potable water for spray wash.
2.5 LEVEL SENSORS
A. GENERAL
1. The Auger Monster system shall be provided with upstream and downstream ultrasonic
level sensors.
2. The level sensors will initiate auger run cycles based on channel head differential and the
parameters set in the operator interface.
3. The PLC logic shall determine differential levels using signals from two (2) separatelymounted ultrasonic level sensors.
a. One (1) level sensor shall be installed upstream of the system and measure the
system’s upstream water level.
b. One (1) level sensor shall be installed downstream of the system and measure the
channel’s downstream water level.
c. The head in front (upstream) of the system shall be compared to the head behind
(downstream) of the system to determine the water level differential.
2.6 MOTOR CONTROLLER(S)
A. GENERAL
1. The controller shall provide independent control of the grinder, auger and spray wash
assembly.
2. Controller shall be the supplier's standard UL/cUL listed Model PC-2251D.
3. The controller shall be rated for 5 hp/3.7 kW and 2 hp/1.5 kW, 230 volts, 1-phase,
60-Hz.
DODGE STATE PRISON
15010 - 9
2.6 MOTOR CONTROLLER(S) (Cont'd)
B. OPERATION
1. The controller shall be equipped with a GRINDER ON-OFF/RESET-REMOTE three (3)
position selector switch.
a. In the OFF/RESET position the grinder shall not run.
b. In the ON position the grinder will run.
c. In the REMOTE position the grinder shall start and stop as controlled by a remotelylocated contact.
d. The grinder shall only be reset by switching the GRINDER ON-OFF/RESETREMOTE switch to the OFF/RESET position.
2. The controller shall be equipped with an AUGER ON/OFF/RESET-LEVEL three (3)
position selector switch.
a. In the OFF/RESET position the auger shall not run.
b. In the ON position the auger shall continuously initiate Auger Run Cycles.
c. In the LEVEL position, auger run cycles shall be initiated by the ultrasonic level
sensors or the Level Sensor Backup Timer. Auger Run Cycles in the LEVEL mode
shall only be enabled when the grinder is running.
d. The auger shall only be reset by switching the AUGER ON-OFF/RESET-LEVEL
switch to the OFF/RESET position.
3. The controller shall be equipped with a digital operator interface.
a. The operator interface shall display grinder and auger run times, elapsed times,
reversals, jams, motor overloads and over-temperature occurrences.
b. The operator interface shall display Fail, Service Reminder, and Operational Messages.
c. Operator interface function keys shall select the following displays: Date and Time,
Auger Run Cycle, Auger Start Time Interval, and System Monitor.
d. The Auger Cycle Run times, and Level Sensor Backup Timer shall be programmable.
Settings shall be entered at the operator interface using panel keys to initiate a desired
run sequence.
4. The controller shall be equipped with a programmable Level Sensor Backup Timer.
a. The Level Sensor Backup Timer shall initiate an auger run cycle if the ultrasonic
sensor fails to start an auger cycle within a preset interval of 1 to 999 minutes.
b. The Level Sensor Backup Timer shall run the system continually when the timer is set
to 0.
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15010 - 10
2.6 MOTOR CONTROLLER(S) (Cont'd)
C. COMPONENTS
1. Enclosure
a. Enclosures shall be NEMA 4X, 304 stainless steel construction and shall be suitable for
wall mounting. Doors shall have corrosion-resistant hinges and latches.
b. Enclosure shall house the control devices, relays, terminal blocks and reversing motor
starters.
2. Control Devices
a. Operator interface and pilot devices shall be mounted on the enclosure front panel door.
b. The controller shall have indicator lights for GRINDER RUN, AUGER RUN, and
common FAIL.
c. POWER ON, GRINDER JAMMED, AUGER JAMMED, GRINDER MOTOR
OVERLOAD, AUGER MOTOR OVERLOAD, GRINDER MOTOR OVERTEMP,
AUGER MOTOR OVERTEMP, LEVEL SENSOR 1 FAILED, LEVEL SENSOR 2
FAILED and HIGH LEVEL ALARM status messages shall be displayed on the operator
interface.
d. Control devices are mounted in the front panel of the enclosure. Indicator lights shall be
LED type pilot lights. Lights and the selector switches shall be heavy duty NEMA 4X
type.
e. Control transformer (if required) shall be protected by two (2) primary fuses and one (1)
secondary fuse. The 120 volt secondary shall have one (1) leg grounded.
f.
Relay contacts shall be included for GRINDER RUN, AUGER RUN, and common FAIL
signal outputs. The contacts shall be rated 10 ampere, 240 VAC, resistive load.
3. Motor Starters
a. Starters shall be a full-voltage reversing type with 120 volt operating coils.
b. Forward and reverse contactors on the starters shall have both mechanical and electrical
interlocks.
c. Overload relays (OL) shall be adjustable so that the range selected includes the full load
amperes (FLA) rating and service factor.
D. SAFETY FEATURES
1. When a grinder jam condition occurs in the grinder ON or REMOTE mode the controller shall
stop the grinder and reverse grinder rotation to clear the obstruction. If the jam is cleared, the
controller shall return the grinder to normal operation. Up to two (2) additional reversing
cycles (3 times total) may occur within 30 seconds before the controller de-energizes the
grinder motor and activates the grinder fail indicator and relay. The auger shall continue
operating during a grinder fail condition.
DODGE STATE PRISON
15010 - 11
2.6 MOTOR CONTROLLER(S) (Cont'd)
C. SAFETY FEATURES (Cont'd)
2. When an auger jam condition occurs in the auger ON or LEVEL modes the controller shall
stop the auger and reverse auger rotation to clear the obstruction. If the jam is cleared, the
controller shall return the auger to normal operation. One (1) additional auger reversal (2 times
total) may occur within 30 seconds before the controller de-energizes the auger motor and
activates the auger fail indicator and common fail relay. The grinder shall continue operating
during an auger fail condition.
3. If a power failure occurs while a grinder or auger is running, operation will resume running
when power is restored.
4. If a power failure occurs while the grinder or auger is in a fail condition the fail indicator shall
be reactivated when power is restored.
5. The controller shall provide overload protection for the motor through an overload relay
mounted directly on the grinder and auger starters.
6. The controller shall be equipped with a main power disconnect switch. Motor branch circuits
shall be short circuit protected.
7. Controller reset shall be from the local panel controls only.
PART 3
EXECUTION
3.1 INSTALLATION
Support system(s), grinder(s), auger(s), and motor controller(s) shall be installed in accordance
with the supplier’s installation instructions, and in compliance with all OSHA, local, state and
federal codes and regulations.
END OF SECTION
DODGE STATE PRISON
15010 - 12