C 03/14/14 DIVISION 11 SECTION 11330 ELECTRIC GRINDERS PART 1. GENERAL 1.01 SUMMARY A. This Section specifies the requirements for sewage electric grinders and motor controllers. 1.02 DESIGN AND PERFORMANCE REQUIREMENTS A. Design and performance of components and methods specified herein shall comply with all applicable Federal, State and Local laws, ordinances, regulations and codes, and with the latest industry standards including those ofthe entities listed below: l. American Society for Testing and Materials (ASTM) A 36: Standard Specification for Carbon Steel Plate 2. American Society for Testing and Materials (ASTM) A 536-84: Standard Specification for Ferritic Ductile Iron Castings 3. American Iron and Steel Institute (AlSI) 303 Stainless Steel 4. American Iron and Steel Institute (AlSI) 304 Stainless Steel 5. 6. American Iron and Steel Institute (AISI) 4130 Heat Treated Alloy Steel 7. RockwellC B. American Iron and Steel Institute (AISI) 4140 Heat Treated Hexagon Steel Design and performance requirements ofelectric grinders shall be as specified in the Schedules shown on the Contract Drawings. 1.03 QUALITY ASSURANCE A. Qualifications 1. B. Manufacturer shall have 10 years experience at manufacturing, support systems, two shafted grinding equipment and motor controls with a minimum of 100 installations with similar equipment, as evidenced by a list of names and dates of installations. Regulatory Requirements: Motor controllers shall, as applicable, meet the requirements ofthe following regulatory agencies: l. National Electrical Manufacturer's Association (NEMA) Standards 2. National Electrical Code (NEC) 3. Underwriters Laboratory (UL) 446 11330 - 1 1.04 DELIVERY, STORAGE. AND HANDLING A. Deliver grinder and components in factory-fabricated protective packaging. B. Handle grinder and components carefully to prevent breaking, denting and scoring. C. Store grinder and components in clean, dry spaces and protect them from weather. 1.05 SPARE PARTS A. Furnish to the Authority the following spare parts: One (1) JWC Environmental, Muffm Monster 30005-0008 open channel grinder and motor or approved equal. 1. a. 2. B. The following items are excluded: Support System, Rails, Bypass Basket, Motor Controller One (1), 150 linear foot, JWC Environmental, Muffm Monster 30005 multi conductor electrical feeder cable or approved equal. Coordinate extra material delivery with the Engineer. Deliver materials in a container or pallet to Port Newark, Building 260, Maintenance garage. 1.06 IDENTIFICATION E4ch unit of equipment shaH be identified with a corrosion resistant nameplate. securely affixed in a conspicuous place. Nameplate infonnation shall include equipment tag number. equipment model number. serial number, supplier's name. and location. A. 1.07 SUBMITTALS See Appendix "A" for submittal requirements. PART 2. PRODUCTS 2.01 MANUFACTURERS Subject to compliance with requirements of this Section, grinders and motor controllers shall be products of the following manufacturers, or approved equal: A. 1. JWC Environmental·: Muffin Monster· Model No.30005-0008. 2. Approved equal. B. Obtain from the manufacturer written certification that the unit can be returned for maintenance to the factory or a local repair facUity. 2.02 SUPPORT SYSTEMS A. General I. Furnish and install custom wallmount frame of suitable dimension and strength to support grinder in place and direct flows toward cutters. The wallmount frame shall be of stainless steel Type 316 construction and frrmly anchored to the pit wall. 447 11330 - 2 2. Include an overflow bar rack to assure screening upon possible failure of grinder. 3. Install a guide rail system to pennit easy removal of grinder for maintenance. There shaH be no necessity for personnel to enter the pit. 4. Include an aluminum basket strainer for installation in the channel frame to ensure continued screening when the grinder is removed for maintenance or inspection. 2.03 GRJNDERS A. General I. Grinders shall include cutters, spacers, shafts, bearings and seals, side rails, end housings, covers, reducer, and motor. 2. Grinders shall be of two-shaft design and be capable of continuous operation, processing wet or dty. Bar screens or single-shaft devices utilizing a single rotating cutter bar with stationary cutters will not be acceptable. Grinders designed with cutter and spacer cartridges rather than individual cutters and spacers, will not be acceptable. 3. Two-shaft design shall consist oftwo parallel shafts alternately stacked with individual intenneshing cutters and spacers positioned on the shaft to fonn a helical pattern. The two shafts shall counter-rotate with the driven shaft operating at approximately two-thirds (2/3) the speed of the drive shaft. B. Components Individual Cutters and Spacers I. a. Individual cutters and spacers shall be AISI 8620 heat treated alloy steel, surface ground for unifonnity and through-hardened to a minimum 60-65 Rockwell C. b. The inside configuration of both the individual cutters and the individual spacers shall be hexagonal to fit the shafts with a total clearance not to exceed 0.015 inch across the flats. c. Cutter configuration shall consist of 11 tooth cam cutters. To maintain particle size, the height of the tooth shall not exceed 1/2 inch above the root diameter. Cutter to cutter root diameter overlap shall be not less than 1/16 inch or greater than 114 inch. d. The cutters shall exert a minimum force at the tooth tip of2,050 Ibs.lhp during momentary load peaks. Shafts 2. a. Grinder drive and driven shafts shall be made ofAISI 4140 heat treated hexagon steel with a tensile strength rating of not less than 149,000 psi. b. Each hexagonal shaft shan measure a nominal 2 inches across paraJlel surfaces. 3. Intennediate Shaft Support a. Include an intermediate shaft support in the center ofthe cutter stack for all grinders with 40 inch cutter stacks. Grinders with 50 inch or 60 inch cutter stacks shall have two intermediate shaft supports. 448 b. 4. The intennediate shaft support shall be made of a cast AISI 303 stainless steel collar and two bushings. The bushings shall act as bearings to allow the free rotation ofthe shafts. Shaft Bearings and Seals a. The radial and axial loads of the cutter shafts shall be borne by sealed, oversized, deep-groove 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 to tungsten carbide. d. O-rings shall be made of Buna-N elastomers. e. Components requiring continuous or occasional lubrication or flushing are not acceptable. f. The mechanical seal shall be rated at 90 psi continuous. g. The bearings shan be housed in a replaceable cartridge that supports and aligns the bearings and seals, as wen as protects the shafts and end housings. The seal elements shall be independent of the stack height, so cutter stack tightness does not affect seal perfonnance. The seal elements shan 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. Each seal element shall be positively locked to its corresponding rotating or static cartridge element. Side Rails 5. a. The inside profile ofthe cutter side rails shall be concave to follow the radial arc of the cutters. b. Clearance between the major diameter ofthe cutters and the concave arc ofthe side rails shall not exceed 5/16 inch. c. The side rails shall have evenly-spaced slots that increase flow and decrease head loss. d. The side rails shall be cast of ASTM A 536 ductile iron. 6. End Housings and Covers a. Grinder end housings shall be of cast ASTM A 536 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 ASTM A 536 ductile iron and bottom covers shall be ASTM A 36 hot rolled plates. 7. Reducer a. The speed reduCer shall be a grease-filled planetary-type of reducer with a 500010 shock load capacity. The reduction ratio shall be 29:1. 449 11330 - 4 b. S. The input shaft of the reducer shall be directly coupled to the motor using a three-piece coupling. and the output shaft of the reducer shall be directly coupled with the grinder using a two-piece coupling. Motor a. The motor shall be 5 hp, Totally Enclosed Non-Ventilated (TENV) Explosion proof(XP), 1,770 rpm, 20S/4S0 volt, 3 phase, 60 Hz. b. Motor service factor shall be LI5, the efficiency factor not less than 91.0% at full load and tbe power factor not less than 76% at full load. Required Running Torque per Horsepower 9. a. At Momentary Load Peaks: 4,756 in-Ibs/hp. 2.04 MOTOR CONTROLLERS A. General I. The control1er shall provide independent control of the grinder. 2. Controller shaH be the grinder manufacturer's standard UL listed model (JWC Environmental Model PC2200, or approved equal). 3. The controller shall be rated for 5 hp, 208/480 volts, 3 phase, 60Hz. B. Operation The controller shall be equipped with a GRINDER ON-OFFIRESET-AUTO three (3) position selector switch. 1. C. a. In the OFFIRESET mode the grinder shall not run. In the ON mode the grinder will run. b. In the AUTO mode the grinder shall start and stop as controlled by a remotely located dry contact. c. The grinder shall only be reset by switching the GRINDER ON-OFFIRESET· AUTO switch to the OFFIRESET position. Safety Features I. When a grinder jam condition occurs in the grinder ON or AUTO mode the controller shall stop the grinder, then reverse the 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. 2. If a power failure occurs while a grinder is running. operation shall resume wben power is restored. 3. If a power failure occurs while the grinder is in a fail condition the fail indicator shall reactivate when power is restored. 4. The controller shall provide overload protection for the motor through an overload relay mounted directly on the grinder starter. 5. Ensure short-circuit protection by having a properly-sized circuit breaker or fuses. 450 11330·5 6. Controller reset shall be from the local panel controls only. Components D. l. Enclosure a. Enclosures shall be NEMA 4X stainless steel, and shall be suitable for wall mounting. Doors shall have hinges and corrosion-resistant latches. b. Enclosure shall house the control devices, relays, terminal blocks and reversing motor starters. 2. Control Devices a. Pilot devices shall be mounted on the enclosure front panel door. b. The controller shall have indicator lights for POWER ON, RUN, and FAIL. c. Indicator lights shall be LED pilot lights. Lamps and the selector switches shall be heavy duty NEMA 4X type. d. Control transformer shall be protected by two primary fuses and one secondary fuse. The 120 volt secondary shall have one leg grounded. e. Relay contacts shall be included for GRINDER RUN and FAIL signal outputs. The contacts shall be rated 2 amp, 240 V AC, resistive load. 3. Motor Starter a. Starter 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 FLA (full load amperes) rating and service factor. 2.05 SOURCE QUALITY CONTROL A. PART 3. Each grinder and controller shall be factory tested to ensure operation that meets specified requirements. EXECUTION 3.01 EXAMINATION A. Notify the Engineer at least 48 hours in advance of making the required tests, so that arrangements may be made for his presence to witness the tests. B. Furnish and install necessary equipment, instruments, hardware, temporary piping, vents, drains, and include necessary personnel required to perform all tests. C. Repair or replace any portion of the system installed under this Section that is damaged as a result of test operations at no cost to the Authority. D. Where piping installed under this Section is connected to any existing system, such furnished and installed piping shaH be isolated from the existing system during the performance of the required field tests, unless otherwise directed by the Engineer. 11330 - 6 451 E. The Contractor shan exercise all precautions necessary to prevent damaging and endangering existing installations and equipment. Any such installations and equipment that becomes damaged shall be restored or replaced by the Contractor to the satisfaction ofthe Engineer at no additional cost to the Authority. F. Arrange for equipment to be started up and tested by the grinder manufacturer and witnessed by the Engineer. G. Grinders and motor controllers shall be installed in accordance with the manufacturer's installation instructions, and in compliance with all OSHA, local, state, and federal codes and regulations. 3.02 FIELD QUALITY CONTROL A. Engage the services of a factory-trained representative of the grinder manufacturer to check the installation and to start-up each grinder and controller. The factory representative shall have complete knowledge of proper installation, operation, and maintenance of the furnished and installed equipment. Representative shall inspect the fmal installation and supervise a start-up test of the equipment. Furnish to the Engineer a written start-up report and checklist for each installation. 3.03 START UP AND TRAlNlNG A. The manufacturer's representatives shall provide two (2), eight-hour training sessions for up to 12 ofthe Authority's personnel per training session. END OF SECTION 11330 -7 452 SECTION 11330 ELECTRIC GRINDERS APPENDIX "Alf SUBMITTALS Submit the following in accordance with the requirements of "Shop Drawings, Catalog Cuts and Samples" of Division I - GENERAL PROVISIONS: Shop Drawings Shop drawings shall include equipment descriptions, specifications, dimensional and 11330AOI assembly drawings, parts lists, and shall be lift station specific. I I 330A02 General arrangement drawing that illustrates the layout ofthe equipment, principal dimensions and other related data including descriptive literature, electrical control drawings including sequence of operation, point-to-point wiring diagrams, control panel layouts, etc. catalog cut sheets for individual components and drive motor data. Manuals, WarranteeslGuarantees 11330101 Submit 4 set(s) of Operation and Maintenance manuals. The manuals shall include equipment descriptions, operating instructions, drawings, troubleshooting techniques, a recommended maintenance schedule, and the recommended lubricants. Qualifications Submit evidence ofmanufacturer experience in the form of an installation list with 11330KOI contact names and phone numbers. Quality Assurance-Quality Control 11330LOI Submit testing procedures including performance ofthe equipment. END OF APPENDIX "A" 11330 - 8 453
© Copyright 2025 ExpyDoc