2. 3. 4. 5. 6. B. - Stone Hill Contracting

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)
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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.
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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.
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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.
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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.
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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
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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
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contact names and phone numbers.
Quality Assurance-Quality Control 11330LOI
Submit testing procedures including performance ofthe equipment. END OF APPENDIX "A"
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