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BIOSOLIDS TRANSFER PUMPS

The pumps(s) shall be a simplex* two-stage semi-positive displacement slurry type pump specifically designed for applications transferring biosolids and slurries in wastewater treatment facilities. Being named in this specification does not preclude the manufacturer from meeting the technical specifications without exception.

*substitute duplex or triplex, if for 6" or 8" specification, respectively

 

PART 1 - GENERAL REQUIREMENTS

1.01 QUALITY ASSURANCE

A. All of the pump and accessory materials shall be designed to withstand the stresses and corrosion encountered in the installation, operation, and hostile environment associated with a wastewater treatment facility. The non-pump accessory components provided - motor, vacuum and / or pressure switch assemblies, variable frequency drives, disconnects, and valves - shall be provided by a manufacturer incorporating the most recent technology.

B. The pump manufacturer shall have a minimum of 10 years experience in application and services for this type of semi-positive displacement slurry pump, a minimum of 5 years manufacturing experience, and 10 years operating installations that are similar in nature.

C. Certified pump performance curves shall be provided with the submittal as verification of the specified capacity and in compliance with the specified total dynamic head as per the system head requirements in the installed operation of the pumps.

D. No exceptions in the specification will be acceptable or allowed. The castings foundry shall furnish a notarized certificate for the pump castings material of Class 65 ductile iron compliance. The notarized certificate shall be included with the submittal from the pump supplier and shall be dated at the time the submittal is provided.

1.02 WARRANTY AND GUARANTEE

A. The manufacturer’s standard warranty shall be in effect from start-up and for a period of 24 months thereafter. The guarantee shall be concurrent with the manufacturer’s warranty period and be UNCONDITIONAL for the 24-month period. Written confirmation of the UNCONDITIONAL guarantee shall be provided to the contractor along with the scope of proposal during the bidding process and with the subsequent submittals. Failure to provide such written confirmation shall be cause for rejection of the submitted pump(s). A 24-month warranty against manufacturer's defects in materials and workmanship is not an acceptable alternative.

1.03 APPROVED MANUFACTURER

A. DIADISK® Pump - Waste Tecnology Group, Inc.

B. Engineer approved equal - Approval required 30 days prior to bid date.

1.04 APPLICABLE SECTIONS

A. Submittals - Secton No.

B. Electrical - Section No.

 

PART 2 - PUMP PRODUCT

2.01 CHARACTERISTICS

A. The pump shall not emit any pumpage or odor to the atmosphere, and sealing shall be by a diaphragm per each stage. Sealing with packing, mechanical seals, and flush liquids shall not be required.

B. A dry start-up or extended periods of dry operation shall not cause damage to the pump. Dry priming is up to 7 feet, wet priming is up to 14 feet, and operating vacuum / lift is up to 25 feet. Entrained gas and air shall have only a minor effect on the pumping capacity due to the pump’s elevated linear flow pattern.

C. Operating capacities and heads, with the standard 70 durometer disks, shall be from 0 to 250 GPM and pressures from 0 to 45 PSIG.

D. The pump shall operate in either shaft rotational direction without any piping changes or modifications to the pump. Belted and sheaved drivers shall be mounted on either side, or on top of the pump, as referenced in the drawings.

E. The pump shall pass semi-hard solids up to 1 inch in diameter, and there shall be no adverse effects or blockage due to long stringy solids.

F. The pump shall exhibit minimum pulsation while maintaining a maximum solids suspension. Turbulence and shear factors shall be minimal.

2.02 DESIGN AND CONSTRUCTION

A. The castings – dampener bodies, upper and lower suction elbows, suction casing, intermediate casing, discharge casing, center and end pedestals – shall be high tensile strength Class 65 (65,000 PSI tensile) ductile iron. The drive cams shall be high tensile heat treated cast aluminum. All castings shall be machined to within .002 inches tolerance for a minimum of cumulative tolerance deficits. The Class 65 ductile iron shall insure all components provide the maximum resistance to abrasion and corrosion. No grades or classes of cast iron will be an acceptable alternative to Class 65 ductile iron.

B. The suction casing and intermediate casing shall have machined seats for optimum disk contact. The intermediate casing and discharge casing areas in contact with the diaphragms shall be machined concentric to the casing disk seats for minimum stresses and maximum concentricity of the disk/diaphragm/drive cam assembly. Confirmation of the casings’ design construction and machined concentricity shall be by written certification and included with the submittals. “Hand polishing” in lieu of raised seats and machined surfaces is not acceptable.

C. The eccentric rotation of each drive cam assembly shall be independently supported by its own bearing assembly included with the center pedestal, and each end pedestal shall include a bearing assembly. The four drive shaft bearing assemblies shall be self-aligning, sealed, greased for life, and designed for both axial and radial forces. The drive cam bearings shall be SKF for heavy-duty radial loading, double sealed, and greased for life.

D. The disks shall be nominal 70 durometer blended neoprene compound hand laid and molded. The disk and its high tensile strength aluminum insert shall be a special homogeneous bonded mold to maintain continuity and concentricity. The strength, reliability, and integrity of the disks shall be further enhanced by four plies of ballistic nylon molded into the blended neoprene compound. The blended neoprene compound, aluminum insert, and 4-ply ballistic nylon shall be mechanically locked to resist any rupture or fatigue during normal operation.

E. The diaphragms shall be nominal 70 durometer hand laid and molded neoprene. The central body of the diaphragm shall be a “C” cup configuration that enhances the pumping action, limits fatigue, and supports the lateral movement of the drive cams. Molded into the diaphragm shall be a 2-ply ballistic nylon that provides additional support to the durability and integrity of the diaphragm and resists any rupture of the neoprene.

F. The pump shaft shall be high tensile strength, ground and polished 1.375" diameter, 416 stainless steel. The eccentric cam lobes and drive rods shall be hardened 420 stainless steel.

Pump RPM shall not be the governing factor for longevity affecting the reliability and integrity of the rotating assembly. The rotating assembly, including the shaft, shaft bearings, drive cam bearings, diaphragms, and disks, shall be designed to operate at 750 RPM and shall be superior to lower RPM pumps that do not incorporate the same quality, design, and materials. Pumps not compatible with and certified for 750 RPM are not acceptable.

G. The suction and discharge flanges shall be 4" ANSI 150# FF flanges. The suction inlet to the pump shall consist of a 2-piece suction elbow that allows suction piping to the pump from 180 degrees in 45 degree increments. The upper suction elbow shall be a "slip" fit flanged connection to the lower flanged suction elbow to accommodate final piping and alignment. The lower suction elbow shall provide quick and easy access to the clack valve, suction casing, and suction disk. A single piece suction elbow is not acceptable.

H. The clack valve shall be a special elastomer material with 2 plies of heavy nylon mesh to provide added strength and durability. The stainless steel clack valve plate shall have a full port 4" diameter opening (12.56 sq. inches) to assist the inlet flow pattern and eliminate blockage at the inlet to the suction casing. The clack valve plate shall have a machined chamfer opening to facilitate contact and prevent damage to the clack valve. The clack valve shall not seal against the suction elbow.

I. The suction and discharge hydraulic dampener assemblies shall be 3-piece construction. The dampener body shall be either 4" x 4" for 4" piping, or 6" x 4" eccentric reducer/increaser type for 6" piping. The dampener bodies shall mount on the 4" upper suction elbow flange and the 4" discharge flange. All of the mounting flanges shall be ANSI 150# FF flanges. The carbon steel 8" dampener tube shall provide a total of 1300 cubic inches of dampening, support long runs of suction or discharge piping, and vacuums up to 22" Hg (25'). The dampener tube shall be secured by 304 stainless steel tie rods and sealed top and bottom by gasketing. The carbon steel dampener cap shall have 2 each .75" drilled and tapped connections. One of the connections shall be dedicated to the pressure gauge/air nozzle/isolation valves assembly. The other connection shall be dedicated to the diaphragm/pressure or vacuum switch/isolation valve assembly. Each component of the 3-piece dampener shall be serviceable and replaceable.

J. The pump discharge casing shall have a drilled and tapped sludge sample port and a sample port assembly consisting of piping and valving. The sample port shall have a dual purpose as an air release from the pump casing during priming and start-up when the pump is under a lift condition and when the discharge piping does not allow for an air evacuation.

K. The pedestal and shaft shroud, belt and sheave guard, and all miscellaneous hardware, i.e., bolts, nuts, washers, and lockwashers shall be 304 stainless steel.

L. The pump and motor base shall be 304 stainless steel tube. The motor base portion shall be self-supporting and without undue stresses transmitted to the pump base. Motor base supports that are cantilevered off of the pump base are not acceptable. All exposed tube openings shall be capped.

M. The internal pump flange gaskets shall be of an elastomer compound material with a 40% memory retention under 65# of torque. The gaskets shall not take a set that allows the bolts and nuts to change their torque rating that will allow leakage at higher pressures.

N. The pump castings and dampener tube with cap are the only pump components that shall require external surface protection. These pump components and all machined surfaces shall be coated with DuPont TGIC polyester industrial 3 mil powder coat. Stainless steel surfaces, i.e., pump and motor mounting base, pedestal and shaft shroud, belt and sheave guard, and miscellaneous hardware shall not receive an external surface protection. Any of these stainless steel items coated by the pump manufacturer shall be replaced by the pump manufacturer at their expense.

O. (Duplex Pump only) The pump shall be the duplex configuration consisting of two each 4 inch pumps operating in parallel. Each pump shall have a motor mount, motor, and pulsation dampeners and be a duplicate of the other pump. The duplex configuration shall be complete with a suction header (6" True Y and 6" diaphragm isolation valves) and discharge header (4" 45° elbows and spacers, 6" diaphragm isolation valves, and 6" True Y). All fittings shall be ductile iron. The diaphragm isolation valves shall be ductile iron construction. Each motor shall include a NEMA 4 disconnect. The duplex pump configuration shall provide redundant operation features. In the event a mechanical or electrical upset occurs or maintenance is required, one pumping unit shall be isolated from the other. The system shall continue to operate at a reduced capacity until the second pump is returned to service. Any pump system that does not provide for redundant, non-interrupted service is not acceptable.

O. (Triplex Pump only - please contact Fluid Tech Group for Triplex specification.)

 

2.03 OPERATING CONDITIONS

1. Pump ID Numbers
2. Quantity
3. Sludge Type
4. Solids Percent--------------------------to
5. Suction Lift-------------------------------feet maximum
6. Design Capacity----------------------- to GPM
7. Design TDH-----------------------------to feet

The pump manufacturer shall determine the pump speed required to meet the operating capacity parameters as specified, and per the system head curve. The motor shall be non-overloading throughout the entire range of operation and in accordance with the sludge solids and viscosity.

2.04 MOTOR

A. The motor shall be U.S. Electric, or approved equal, with TEFC hostile duty enclosure and Inverter Duty rated.

B. The nominal motor speed shall be 1200 RPM or 1800 RPM - 3/60 - 230/460 volt - Class F insulation - 1.15 service factor.

C. The motor and pump sheave shall each be 2-groove with taper bushing, and two belts shall drive the pump.

D. The motor shall be mounted on a sliding motor base with dual alignment features to accurately align the drive and driven sheaves.

2.05 GAUGES

A. The gauges shall be Weksler (Ashcroft), or approved equal. Each gauge assembly shall consist of a compound 30" Hg vacuum - 60 PSI, glycerine filled, 4" stainless steel gauge, and an isolation ball valve. One pressure gauge/isolation valve assembly shall be mounted on each suction and discharge dampener cap.

2.06 SENSORS

A. Vacuum and/or pressure switches shall be Weksler (Ashcroft), or approved equal, Model Number WP424BX06500 – 60 PSI. The isolation diaphragms shall be Weksler (Ashcroft) Model D19-7, glycerine filled, stainless steel construction, flushing connection, and factory assembled with the pressure switch. The sensor assembly shall include an isolation ball valve and shall be mounted independently of the gauge assembly, but on the same dampener cap.

2.07 SPARE PARTS

A. The 24-month UNCONDITIONAL warranty and guarantee preclude the procurement of excess spare parts with this contract. The recommended spare parts are: 1 each suction disk and 1 each suction casing gasket, and 1 each clack valve and 1 each clack valve gasket. All spare parts shall be available for shipment with 24 hours of notification.

 

PART 3 - EXECUTION

3.01 MANUFACTURER’S SERVICES:

A. The pump manufacturer shall inspect the installation prior to start-up and shall instruct the contractor on start-up procedures. During the same time period, the pump manufacturer shall instruct the plant personnel in the start-up, operation, and maintenance of the pump.

B. The pump manufacturer and on-site engineer shall inspect the entire piping system hydraulics prior to start-up.

C. The contractor, on-site engineer, and owner shall witness the start-up and subsequent tests to verify the pump performance in accordance with the intent of the specification.

D. The pump manufacturer shall prepare and submit a report detailing the start-up results and any recommendations concerning pump operations.

END OF SECTION

 

INSTALLATION · OPERATION · MAINTENANCE

The DIADISK® Pump is a semi-positive displacement pump that is specifically designed for biosolids transfer services. The DIADISK® Pump is self-priming, employs a linear non-turbulent flow pattern, and maintains soft and stringy solids in suspension.

SPECIAL INSTALLATION INSTRUCTIONS:

• Attach the suction and discharge hydraulic pulsation dampeners #104 or #106 to the DIADISK® Pump.
• Place a pipe support under each pulsation dampener.
• Do not subject the DIADISK® Pump to any pipe loading or pipe misalignment.

INSTALLATION:

• The pump is shipped as a completely assembled unit except for the hydraulic pulsation dampeners and any component accessories such as, pressure gauge/switches.
• Suction and discharge hydraulic pulsation dampeners are to be securely attached to the pump after the pump has been set on the pump has been set on the pump pad.
• Preliminary piping is to be installed on the discharge side of the pump after the pump has been leveled, and prior to the pump being anchored to the pump pad.
• The discharge piping and pump discharge shall be aligned and the discharge piping supported before connecting the discharge piping to the pump.
• The pump suction has a piping adjustment feature whereby the upper suction elbow can be adjusted to compensate for minor piping misalignment.
• Suction piping shall be installed from the pump suction to the suction source after the pump suction piping has been supported.
• At no time shall piping stress be transmitted to the pump.
• The pump should not be situated between existing piping and pulled together with flange bolts. This procedure could damage the lower suction elbow to suction casing connection.
• Shim the pump base to the pump pad and grout in place. The pump grouting is to be leveled to the top of the pump base foundation and extend under the pump base foundation.
• Tighten the anchor bolts, complete the electrical connections, install the fittings on the top of the hydraulic pulsation dampeners (if applicable), and the pump installation is complete.

NOTE: Piping and fitting sizes affect the hydraulics of the application and must be sized for the specific application. Suction and discharge piping must be 4" minimum although 6" is preferred. Wye connections for the discharge fittings are more preferable than “T” connections.

CAUTION: Do not remove the pedestal shroud or belt guard unless the motor is disconnected or locked out. Never operate the pump without the pedestal shroud and belt guard in place.

CAUTION: If the pump is to be flushed at any time, only flush from the suction side and do not exceed 55 PSIG.

OPERATION:

• Be sure all valves in the suction and discharge piping are fully open.
• Do not operate in line with a positive displacement pump.
• The pump will through flow from the suction through the discharge, but it will not backflow from the discharge through the suction.
• The pump is self-priming and can be started dry up to an 8 foot lift.
• It is normally not necessary to prime the pump. While the pump is running, small amounts of air in the system can be evacuated through the valve and sludge sample port assembly at the discharge flange.
• The pump and motor sheaves were aligned and the belts tensioned prior to shipment.
• Follow the motor electrical schematic for the correct voltage when connecting the motor to the power source.
• The motor and pump can rotate either clockwise or counter clockwise. No motor rotation adjustment is necessary.
• Both suction and discharge hydraulic pulsation dampeners have compound liquid-filled gauges. Note the gauge readings prior to start-up and watch the gauges during start-up.
• If the suction gauge drops below 15 inches Hg vacuum or the discharge gauge rises above 45 PSIG, shut the pump off.
• Excessive vacuum or pressure means that the line is not open on the suction and/or discharge side of the pump.
• After the pump has been started and while it is operating, re-charge the discharge hydraulic pulsation dampener if air was evacuated during start-up. Only small amounts in short bursts should be added.
• Once the preceding has been completed, the pump should not exhibit vibration or noise.

OPERATION CHECKS:

• Low solids percentage sludge applications and/or air entrained applications may produce a slight ticking sound as the disk contacts the casing seat. This is due to the limitation of the “cushioning” effect of the sludge. The slight ticking sound does not affect the pump.
• If the pump exhibits excessive noise and/or excessive vibration, or liquid will not pass through the pump, first check the suction and discharge gauges, and visually verify that the pump shaft is turning.
• Shut off pump.
• Double-check all suction and discharge valves to assure that they are completely open to enable the flow to enter and exit the pump.
• The compound gauges provided with the dampeners #104 or #106 display inches of mercury for lift conditions and pounds for positive head and discharge readings.

The formula for converting pounds to feet is 2.31 feet per pound. For example, 5 lb x 2.31 = 11.5 feet of positive head, or 11.5 feet of discharge pressure.

The formula for determining lift conditions is 1 inch of mercury equals 1.1 feet of lift. For example, 10 inches x 1.1 = 11 feet of lift.

• If the application has a flooded suction, the pressure gauge on the suction side should display a positive reading equal to the height of the liquid on the suction side.
• If a lift condition exists, the suction gauge should display a reading in inches equivalent to the application. Allow adequate time for material to reach pump at 10 feet of lift or less. Pump needs to be primed to initiate higher lift conditions. Once pump is primed, a 26 ft. lift can be achieved. If pressure readings remain at zero or do not reach required parameters for the application, an air leak on the suction side is usually present. Valves and fittings should be checked first, but the air leak must be located and eliminated for any pump to function during a lift condition.

NOTE: If a blockage has occurred at the suction clack valve area #119, this will not show on the suction pressure gauge.

TO CHECK FOR BLOCKAGE:

• Disconnect or lock out power source – close valves to isolate pump.
• Remove upper suction elbow #107
• Remove lower suction elbow #108
• Remove clack valve plate #120
• Remove clack valve #119
• Save all stainless steel hardware for reassembly.

At this point, any blockages will have been revealed or be visible in the suction casing. Remove blockage and reassemble making sure the clack valve #119 opens into the pump side with the reinforced side facing into pump and the chamfered edge of the clack valve plate against the clack valve to reduce wear. Gasket is placed between clack valve plate #120 and lower suction elbow #108. The four (4) aluminum spacers found in the clack valve must be reused to assure proper alignment. The upper suction elbow #107 with gaskets is designed to be installed last to simplify realignment.

DAMAGE TO SUCTION DISK IS SUSPECTED DUE TO REDUCED FLOW, EXCESSIVE VIBRATION, OR LOUD NOISES:

• Begin by checking for blockages as described above, then:
• Remove suction casing #101 by removing the ten (10) stainless steel bolts with lockwashers connecting it to intermediate casing #102. Four (4) bolts are through bolts located toward the suction side (1/2" x 3-1/2") and six (6) are case-screw-in (1/2"x 2-1/4") located toward discharge.
• Remove suction gasket #130 located between #101 and #102 (which can be reused if in good condition).
• Remove suction disk #121, which is right-hand thread (like bolts and nuts). If suction disk is torn or severely damaged, loosening can be difficult. To aid in removal it is recommended to cut flat area of disk completely off (about 2-1/2" to 3" from outer edge) and use a large channel lock wrench around remaining hub to loosen. Be careful not to damage diaphragm #125 located above suction disk.
• Before installing new suction disk, check discharge disk #123 for damage. Normally the suction disk absorbs the most abuse and the discharge disk is fine.

The suction and discharge disks are from different molds. Both are marked on the top side of the disk. Please assure both are properly located before replacing.

• When installing new suction disk, apply liberal amounts of anti-seize or grease lubricant to the threads of suction drive rod #122. Also apply a liberal amount of grease lubricant on the disk in the area that contacts (touches) the diaphragm. This has been done during initial assembly and aids in the removal of the disks. Tighten disk, which is right-hand thread, by hand until resistance is strong. Reattach suction casing #101 (with gasket #130), clack valve assembly, and suction elbows as described previously.

REPLACING DISCHARGE DISK #123 OR SUCTION DIAPHRAGM #125:

• Disconnect power source and isolate pump.
• Disconnect suction and discharge piping from pump.
• Remove belt guard #137 and pedestal shroud #136.
• Loosen motor tension and remove belts.
• Remove suction elbows #107 and #108 along with clack valve assembly #120 and #119 as previously described.
• Remove pump from frame.
• Remove suction casing #101 and suction disc #121 as previously described.
• Remove six (6) bolts through intermediate casing #102 and four (4) allen-head bolts in pedestals closest to the suction side of the pump. These four (4) allen-head bolts are 1/2" x 5" while the remaining four (4) allen-head bolts closest to the discharge are 1/2" x 1-3/4".
• Remove intermediate casting #102.
• Remove discharge gasket #131 (can be reused if in good condition). Save all hardware for reassembly. Discharge disk #123 and suction diaphragm #125 can now be removed and replaced.

Both diaphragms #125 and #127 are identical and interchangeable, but the disks are not interchangeable. When replacing either diaphragm, the lettering and numbers molded into the diaphragm are located against the drive cams #112 and #113. When replacing either diaphragm retainer #126 or #128, the flat surface is up, facing the pedestals #109.

REPLACING THE DISCHARGE DIAPHRAGM #127:

Follow above procedure regarding discharge disk or suction diaphragm, then:

• Remove four (4) remaining allen-head bolts from pedestal assembly.
• Lift off complete pedestal assembly which exposes discharge diaphragm #127 and retaining ring #128.
• Replace diaphragm, re-install the retaining ring, and reassemble the pump. Be sure to replace all gaskets and apply grease to drive rods and disks as previously described. Tighten all bolts to 65 lb. of torque.

MAINTENANCE:

The DIADISK Pump requires minimal maintenance. If parts are required, they can be shipped in 24 hours from the manufacturer.

• Power should always be disconnected before checking or working on pump.
• Pump should always be run with guards in place.
• Check belt tensioning every six months.
• Check gauge pressures. Different pressure readings than normal operating conditions could indicate blockage is developing or disks need to be replaced.
• There are four (4) each shaft bearings. The bearings are sealed, greased for life. DO NOT lubricate the bearings.
• There are two (2) each drive cam bearings. The bearings are greased and sealed for life. The bearings DO NOT require lubrication.
• The hydraulic pulsation dampeners may require re-charging on a semi-annual basis. While the pump is operating, add small amounts of air in short bursts through the air nozzle on the top of the hydraulic pulsation dampener. Normally, 3 to 4 short bursts, 2 to 3 seconds duration, will re-charge the hydraulic pulsation dampener.
• Follow maintenance schedule for motor as provided.

NOTE: Long-term storage (beyond six weeks) requires the belt and sheave guard to be removed and the belt tension relieved. Loosen the four bolts through the motor feet and use the dual adjustable sliding motor mount to remove the pressure/tension from the belts, motor bearings, and pump bearings. Reverse this procedure and re-align the sheave prior to placing the pump in full-time operation/service.

The DIADISK Pump is furnished with the most comprehensive Warranty and Guarantee in the wastewater industry. The manufacturer’s standard warranty shall be in effect from start-up and for a period of 24 months thereafter. The Guarantee shall be concurrent with the manufacturer’s warranty period and be UNCONDITIONAL for the 24-month period.