Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356

de Medelln Technical Specifications Dewatered Sludge

Storage Silos

SECTION 11356

DEWATERED SLUDGE STORAGE SILOS

PART 1 GENERAL

1.1 SUMMARY

1.1.1 The work in this section includes the design, fabrication, and furnishing, packaging,
delivery and installation of 4 dewatered sludge storage silos, including push floor
mechanisms, instrumentation and control equipment. Locate the equipment as
shown in the Dewatering Building. The dewatered sludge storage silos equipment
shall be manufactured complete with all components, drives, motors, ancillary items
and supports. The work includes attachment bolts, anchor bolts, local controls, local
control panels including motor feeding and protection, all wiring within each unit and
from the units to the local control panel, shop testing, shop painting, training of
operating personnel, supervision of installation, installation, commissioning,
performance tests and all necessary appurtenances required for a complete
installation and satisfactory operation.

1.1.2 Furnish the following:

Four (4) rectangular dewatered sludge (cake) storage concrete silos, including the
access hatches, ventilation connections, the push floor systems, support structures
including beams and columns, access ladders, hand railing and other related
accessories as shown, specified and required.

One (1) push floor mechanism for each silo to recover cake from the storage silos
and direct it to the silo discharge/truck loading conveyors.

Eight slide gates at the discharge of silo discharge conveyors to direct the dewatered
sludge to the cake hauling trucks. Each silo discharge conveyor will be equipped with
two slide gates.

Control and automation equipment.

Spare parts and special tools required to assemble and maintain the push floor
mechanism and related equipment.

Equipment's identification and specification plates.

Miscellaneous items, such as nuts and bolts, wedges, anchors, fillers, sealants,
gaskets, supports and all other material for proper installation and operation of the
equipment.

Design, Fabrication and Furnishing of Major Equipment Page 1 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

1.1.3 Related Work Specified in Other Sections Includes:

1. General Requirements
2. Section 05035 - Galvanizing
3. Section 05120 - Structural Steel
4. Section 05500 - Metals Fabrications
5. Section 05531 - Metal Floor Gratings and Plate
6. Section 09900 - Painting
7. Section 11355 - Centrifuge Equipment
8. Section 13310 - Instrumentation and Field Buses
9. Section 13320 - Instrumentation Control Panels and Panel Instruments
10. Section 14552 - Screw Conveyors
11. Section 15010 - Basic Mechanical Requirements
12. Section 15055 - Basic Piping Materials and Methods
13. Section 15074 - Steel Pipe and Fitting
14. Section 15076 - Stainless Steel Pipe and Fitting
15. Section 15080 - Miscellaneous Pipe and Fittings
16. Section 15100 - Valves
17. Section 16150 - Electric Motors
18. HTA-4-SP-16-009 - Technical Specifications for the design, supply,
installation, evidence and putting into use of equipment of electrical system,
including the Adjustable Frequency Drives

1.2 REFERENCES

1.2.1 Codes and standards referred to in this Section are:

National Building Code

American Welding Society (AWS)

ASTM A 283 Standard specification for low and intermediate tensile strength
carbon steel plates shapes and bars.

ASTM A 285

ASTM A 106

AISI 316L

ASTM A 36/A 36M - Specification for Carbon Structural Steel

ANSI 820.1-1976 - Safety Standards for Conveyors and Relate Equipment

Design, Fabrication and Furnishing of Major Equipment Page 2 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

1.3 SYSTEM DESCRIPTION

1.3.1 General: Design the sludge cake storage silos equipment to fit the space, piping and
structural arrangements shown. If any changes, relocations or additions to the
equipment, piping or structural facilities are required to accommodate the sludge
cake storage silos equipment to be provided, accomplish such work at no addition to
the contract price.

1.3.2 The dewatered sludge storage silos shall be specifically designed to operate as an
integral part of the Screw Conveyor System.

1.3.3 Design Stresses: Design all parts of the equipment to be amply proportioned for all
stresses which may occur during fabrication, shipment, erection and intermittent or
continuous operation in accordance with this section, and the section on equipment
design of the General Requirements.

1.4 DESIGN REQUIREMENTS:

1.4.1 Each storage silo shall be rectangular in design and manufactured to store, in
normal operation, 194 m3 of dewatered sludge. Each silo shall be equipped with a
push floor mechanism. The push floor mechanisms shall be designed with a sliding
frame, activated by a hydraulic unit and designed to prevent bridging of the cakes in
the silos.

The silos shall be designed to withstand the overall internal and external loads
without warping. The silos shall be watertight and airtight and be designed to
withstand a minimal negative pressure of -0,25 kPa in relation to atmospheric
pressure.

1.4.2 Furnish the storage silos with push floor mechanisms in accordance with the
following operating conditions:

1. Sludge Cake Characteristics:

Item Centrifuge Dewatered Sludge

Cake
Dry solids content of the cake:
Average, percent 28
Variations, percent 25 to 35
Cake density for volumetric 1,0 - 1,2
design, metric tons/m3
pH 6,5 - 8,5

2. Sludge Type: The sludge will consist of anaerobically digested and

dewatered sludge.

Design, Fabrication and Furnishing of Major Equipment Page 3 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

3. Storage Silo: Each storage silo shall conform to the following design criteria:

Type vertical, rectangular concrete silo

Lay-out interior, self-supporting
Capacity, m3 194
L x W x H, meter 5,7 x 6,2 x 5,5
Height of support Submit for approval
Construction fully enclosed, watertight

Push floor mechanisms: Each push floor mechanism shall conform to the following
design criteria:

Flow rate Capacity 40 metric tons/hour of cake

maximum cake volume of storage
silo
Power of hydraulic unit Submit power calculations for
approval.
Construction rigid and watertight

The push floor shall consist of sliding frame with opposed cylinders installed inside
the storage silo, on the bottom, perpendicular to the extraction screws.

Extraction Screws: Each extraction screw shall conform to the following design
criteria:

Type single screw, it shafted, no

intermediate supports front
drive
Lay-out Helical gear box motor, two
external outlets
Flow rate, metric tons/hour 40
Maximum screw deflection mm 6
Construction fully enclosed, watertight

1.5 SUBMITTALS

1.5.1 General: Provide all submittals, including the following, as specified in the General
Requirements.

1. Shop Drawings: Submit shop drawings, including physical and erection

drawings of the concrete storage silos, push floor mechanisms, silo support
structures and related control equipment, wiring diagrams, schematic control
diagrams, structural design calculations, and complete description of the control
systems and equipment operating characteristics.

Design, Fabrication and Furnishing of Major Equipment Page 4 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

2. Submit technical specifications sheets for the materials including, among

other things, the manufacturing process, chemical composition, mechanical
properties, detailed thermal treatment and the type of surface protection for every
group of parts including the concrete roof, the concrete walls and the bottom of the
silos, the drive shafts, the sliding frames and the screws.

3. Submit complete specifications sheets for all electrical, mechanical and

hydraulic devices and components such as speed reducers, electric motors,
couplings, anti-friction bearings, gears, chains, pumps, jacks, hydraulic piping, joints,
supports and other accessories.

4. Submit hydraulic schematics and calculations, adjustment values of the

hydraulic components and operating sequences.

5. Submit complete technical specifications sheets for all control and automation
equipment.

6. Submit drawings showing the distribution on the support structure of the static
and dynamic loads of the silos.

7. Installation Information: Provide all information required for installation of the

equipment including all erection drawings and written installation instructions.

8. Storage Instructions: Submit storage instructions for the equipment for use by
the las Empresas.

9. Catalog data on Mechanical and Electrical components.

10. Electrical elementary diagrams, internal connection diagrams, external

interconnection diagrams and a complete description of the control system.

11. Local control panel layout drawings.

12. Manufacturer's certified performance and material records for quality

control.

13. Certification of welders qualifications, welding procedures and quality

assurance for welders (e. g. AWS D9.1) for approval.

14. Operating and maintenance information.

15. Recommended spare parts and tools lists.

16. Painting procedure.

1.5.2 Operation and Maintenance: Submit operation and maintenance manuals for the
equipment.

Design, Fabrication and Furnishing of Major Equipment Page 5 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

1.6 QUALlTY ASSURANCE

1.6.1 Design, fabricate and assemble the sludge storage silos and push floor mechanism
equipment in accordance with the latest modern engineering and shop
practices. The Specifications include requirements for materials of construction,
coatings, linings and various structural and mechanical components. Design and
manufacture sludge storage silos including push floor mechanism equipment to
operate as an integral part of the Screw Conveyor System.

1.6.2 Experience: Each prospective bidder for the furnishing of the storage silos including
push floor mechanism equipment shall provide references for at least two full-scale
sludge storage silos including push floor mechanism systems that have been
operating anywhere in the world for at least five years at the time of bid on the
municipal water or wastewater dewatered sludge. Each of the two referenced
systems shall meet or exceed the design and operating conditions as specified
above.

1.7 DELlVERY AND HANDLING

1.7.1 Deliver, in accordance with the General Requirements and as directed by Las
Empresas, all products and materials to the site designated by las Empresas.

Off-Ioad the equipment.

1.8 SPARE PARTS

1.8.1 General: AII spare parts shall be carefully labeled and packaged to prevent damage
or deterioration during storage and transportation. Provide the following spare parts:

1. One (1) extraction screw, without trough, complete with drive train (motor,
speed reducer and chain drive), anti-friction bearings and packing gaskets for
screws.

2. Three (3) complete hydraulic jacks complete with connections and

accessories for the extraction mechanisms.

3. Three (3) sets of packing for the openings in the silo walls for the extraction
mechanism.

4. Two lights of each type. One push-button and switch off each type.

5. Ten (10) cartridges for the hydraulic units' inlet filter.

6. Special Tools: Furnish a complete set of special wrenches and other special
tools sufficient for the removal, dismantling, reassembly, and maintaining of the
equipment. Manufacture tools of forged steel, case hardened, and full finished.
Furnish the set in a metal tool case with a handle and provision for padlocking.

7. One (1) set of bearings.

Design, Fabrication and Furnishing of Major Equipment Page 6 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Storage Silos: The furnishing of each of the four (4) storage silos shall include but
not be restricted to the following items:

1. The concrete roof, roof reinforcement structure, access hatch, ventilation

connections and other related accessories.

2. The rectangular concrete sections forming the vertical wall, reinforcement,

flanges for the push floor mechanism and other related accessories.

3. The concrete bottom.

4. The silos shall be designed to withstand the overall internal and external
loads without warping.

2.1.2 Roof: The roof of the storage silo shall be fixed, flat and rectangular.

1. The roof of the storage silo shall be reinforced by a structure installed inside
the silo and constructed using only beams.

2. The roof and its structure shall be designed to withstand the overall static and
dynamic loads including concentrated loads for local maintenance of the equipment
and an additional mini mal load of 2,4 kPa distributed evenly.

3. The storage silos roof and roof openings shall be watertight and shall be
subject to a testing by sprinkling with a hose while checking the inside for leakage.
Leaks shall be repaired at no additional cost.

4. The roof of the silo shall be equipped with the following openings, couplings
and accessories:

a. Two (2) flanged rectangular openings. These openings shall be

designed to match the feed chutes of dewatering centrifuge and a belt
conveyor. In case the adjacent sludge storage silo is out of operation
the centrifuge can be further operated with a dewatered sludge outlet
to a belt conveyor which conveys the sludge to the adjacent sludge
silo. The opening for the belt conveyor shall be used also as an access
hatch and equipped with double heavy-duty hinges, hinged protection
screen which can be padlocked, accessories and an air tight cover
from stainless steel 316L.

b. Air intake and exhaust connections (see Section Ventilation and Odor
Control) of the silo's gas exhausts system with insect screen.

c. Two (2) coupling with clamp for the ultrasonic level detector per tank
(one standby).
Design, Fabrication and Furnishing of Major Equipment Page 7 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

d. One (1) circular opening 100 mm in diameter for high level indicator, in
case sonic level detector goes out of order.

5. AII the openings and couplings shall be airtight and equipped with black nitrile
continuous gaskets.

6. The taps and clamps of circular openings shall be made of stainless steel
AISI A 316L with better mechanical and corrosion resistance.

7. Nuts and bolts shall be made of 316L stainless steel with a minimum
diameter of 13 mm. Submit respective calculation for approval.

2.1.3 Vertical Wall: The vertical wall of the storage silo and its related fasteners and
reinforcements shall be constructed of concrete.

1. The taps and clamps of circular openings shall be made of stainless steel
AISI A 316L with better mechanical and corrosion resistance.

2. The wall shall be sufficiently rigid to withstand external loads and internal
pressures without warping.

3. The vertical wall shall be equipped, at the base, with three (3) openings with
steel clamps allowing for the installation of the hydraulic push elements of the
extraction mechanism.

4. The size of the opening, and the exact dimensions and positioning of the
clamps shall depend on the extraction mechanism.

2.1.4 Bottom: The bottom of the silo shall be constructed of concrete.

1. The bottom of the silo shall be leveled to offer a flat, even surface which will
encourage extraction.

2. The bottom shall be equipped with one (1) rectangular opening with mounting
frames for the extraction screws.

3. The continuous mounting frame shall be fixed to the bottom of the silo around
the entire opening and shall allow for a perfectly sealed joint between the screw
trough and the bottom.

4. The frame shall be constructed from structural sections of ASTM A572 Grade
80 or better steel in terms of structural and corrosion resistance properties with the
prior approval of las Empresas.

2.1.5 Push Floor Mechanism:

Design, Fabrication and Furnishing of Major Equipment Page 8 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

1. General: Each storage silo shall be equipped with a push floor mechanism to
prevent the bridging of cakes in the silos, to control cake transfer and to even out the
feed into the extraction screws.

a. The components of the 4 push floor mechanisms with 3 push elements

at each mechanism shall be of heavy duty design and able to withstand
without warping the pressure exerted by the cakes when they fill the
maximum volume of the silo.

b. The 3 push elements of each push floor mechanism consisting of

special profiles with guiding beam and 2 mm casing made in stainless
steel 316L, guiding elements and front cylinder brackets, 3 cylinder
counter bearings, 3 special gasket units with adjustable stuffing box, 3
double acting hydraulic cylinder with rear cylinder bracket

c. The supply of each extraction mechanism shall include but not be

restricted to:

1) the sliding frame

2) the hydraulic jacks;

3) the hydraulic unit;

4) the hydraulic circuit;

5) all other materials required for adequate installation and

operation of mechanism.

d. The hydraulic equipment shall be certified ANSI/NFPA for a maximum

operating pressure of 20 MPa including the jacks, the pipes and tubing,
the valves, the joints, the adapters and all other related equipment.

2. Sliding Frame: The frame shall be special in shape with the long and short
axes of such a dimension as to sweep the total bottom surface of the storage silo.

a. The stroke and the speed of the frame shall be adjusted so as to feed
continuously and completely transfer the cakes to the extraction
screws.

b. The jacks' mounting bearers shall be constructed of 316L stainless

steel pipes.

c. The frame shall be attached to the mounting bearers and shall be held
and guided by sliders attached to the bottom of the silo.

d. The frame, the sliders, the fasteners, the packing joints and other
related parts shall be constructed of sheets and structural sections of

Design, Fabrication and Furnishing of Major Equipment Page 9 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

stainless steel 316L in terms of structural and corrosion resistance

properties as approved by las Empresas

e. The mounting bearers shall be sealed to the wall of the silo using
packing joints bolted to the fastening clamps of the vertical wall.

3. Hydraulic Jacks: The four (4) hydraulic jacks shall be two-way with end of
stroke shock absorption, manufactured according to ANSI/NFPA standards.

a. The walls of the jack shall be a single piece, with sufficient inner
diameter for the piston to move freely. The jack shall be equipped with
scrapers designed to remove dirt and abrasives from the piston shaft.
The jack shaft shall be designed for easy removal of the piston and the
shaft and for easy gasket replacement.

b. Each piston shall be a single piece of cast or forged steel. Each piston
shaft shall be made of alloyed steel, and without welds. The external
surface of each piston shaft shall be chrome plated to resist corrosion.
Submit chrome plating procedure for approval. A gasket shall prevent
oil from leaking beyond the piston and its shaft.

c. The jacks shall include all fastening accessories, nuts and bolts and
other related parts.

d. The hydraulic jacks shall be fastened to the ends of the mounting

bearers and shall be located outside the silo.

e. The cylinders shaft is firmly attached to the silo's support structure, as

specified in the plans. The jacks' fasteners shall be made of the same
kind of steel as the sliding frame.

f. The jacks shall be fed by a complete hydraulic unit located at the silo's
base.

4. Hydraulic Unit: The hydraulic shall include, among other things, a motor, a
pump, flexible tubing, an oil tank (min. 100 l), oil leakage compartment and all related
equipment to power hydraulically driven equipment. Submit design calculations for
approval. The hydraulic unit shall be equipped with, among other things: air/oil cooler
with internal cycle, pressure gauges at the pump discharge, safety valves for
overpressure, oil level and oil temperature; check valves, ball valves on the main
piping at the hydraulic unit's inflow and discharge, oil level, pressure and
temperature control and all related equipment. The hydraulic unit shall be also
designed to actuate the 2 hydraulic sludge outlet slide gates at both discharges of 1
screw conveyor.

a. Oil Tank: The oil tank shall have sufficient capacity and be composed of
internal baffles with a lateral maintenance port. At the factory, all
Design, Fabrication and Furnishing of Major Equipment Page 10 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

interior and exterior surfaces of the tank shall be coated against

corrosion according to the manufacturer's recommendations as
approved by las Empresas.

The oil tank shall be equipped with, among other things: a vacuum
valve (to prevent excess internal pressure due to vacuum), a filler cap
with a sieve, a level indicator and safety cut-off switches with alarm for
overpressure, oil level and oil temperature, an intake filter with metal
separator and clogging cut-off switch and other related equipment like
oil drainage and cleaning opening.

The motor and pump assembly shall be installed on the tank in a

compact and safe manner and shall be easy to disassemble.

b. Motor: The motor shall be chosen to provide the power required by the
pump at maximum load in continuous operation. Submit motor data for
approval.

The motor shall be of the following type: totally enclosed fan cooled
(TEFC) induction motor with squirrel cage, insulation class F, IP 55 for
outdoor installation, service factor of 1,15 and designed to operate on
480 V/3 ph/60-Hz.

The motor shall satisfy the requirements of section titled "Electric

Motors".

c. Pump: The pump shall have variable discharge with a manually

adjustable range of operating pressures and shall be designed to
supply on a continuous basis the total feed volume of the jacks at the
operating pressure corresponding to the silo's maximum loading
conditions.

5. Hydraulic Circuit: The hydraulic circuit shall include the rigid piping and
flexible tubing, the valves, the tube couplings and adapters, the supports, the
anchorings and all related fasteners.

The rigid hydraulic pipes shall be made from type 316L stainless steel. The thickness
of the pipes shall be determined in relation to the maximum operating pressure, in
accordance with ANSI/ASME code 831.3 - Pressure Piping.

Flexible tubing shall be used locally to connect the equipment to the hydraulic circuit.
The flexible tubing shall be chosen and designed to withstand the maximum
operating pressure.

Both the piping and tubing shall be attached and installed adequately in such a way
as to prevent superfluous lengths and to make the maintenance and replacement of
hydraulic components easier.

2.2 EXTRACTION SCREWS

Design, Fabrication and Furnishing of Major Equipment Page 11 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

2.2.1 Each storage silo shall be equipped with one (1) or more extraction screws designed
to transfer the stored sludge cakes.

The extraction screws shall be sized and designed to prevent bridging and to allow
for an even and continuous transfer of the cakes under all operating conditions of the
silo and the screws.

The supply of each screw shall include, without being restricted to, the following
items:

the drive mechanism

the screw

the trough

the drains and drain piping

all other materials required for the proper installation and operation of the screw

1. Drive Mechanism: Each extraction screw shall be equipped with a drive

mechanism which includes a motor, speed reducer, and any other equipment
required for the proper operation of the loaded screw. Submit calculations for
approval.

To make maintenance easier, the components of the drive mechanism and their
layout shall be identical.

a. Electric Motors: Provide motors meeting the requirements of the

Section headed "Electric Motors" and designed for 480 V/3ph/60-Hz, IP
55 for outdoor installation. The motor shall be pole-changing.

b. Speed Reducer: The design of the reducer shall be linear, mounted

horizontally on legs and composed of solid horizontal shafts and multi-
stage helical gears. Selection of the reducer shall aim to maximize the
speed ratio for a service factor of at least 1,5.

The reducer shall be designed to operate continuously within a range of

50 percent to 115 percent of its rated input speed, without any
reduction in the life expectancy of its components.

In order to make oil changes easier, the speed reducer's oil drain shall
be equipped with rigid extension piping equipped with a ball valve and
a cap.

2. Screw: The screw shall have a single spiral mounted on a shaft.

Design, Fabrication and Furnishing of Major Equipment Page 12 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

The spiral of the screw shall be designed in a way to discharge the sludge either to
sludge outlet 1 or 2. After rehabilitation of railways the sludge shall be conveyed with
chain conveyors to the railway cars.

The screw shall be cut at the beginning of the discharge opening in order to make
discharging the cakes easier.

At the head of the extraction screw, a section of spiral with an inverted tread shall be
installed, beyond the discharge point, to prevent any accumulation of cakes.

The shaft of the screw shall be composed of a main hollow section made from
seamless tubes of ASTM A 106, Grade C or better steel equipped at both ends with
a section of annealed AISI, 1045 or better steel shaft.

The shaft of the screw shall be of sufficient capacity to withstand the torque and
loads transmitted to the screw and it shall be designed such that the maximum
deflection is no more than 4 mm between supports.

The screw shall be installed to operate under axial traction when transporting
material.

The screw shall be designed to minimize the clearance between the spiral and the
bottom of the silo in order to prevent bridging.

The screw shall be supported, without intermediate support, by two (2) spherical
roller bearings located outside the transport trough.

The roller bearings shall be equipped with chicane joints and tightener couplings.

The bearings shall be equipped with grease points and have a life of at least 100.000
hours according to AFBMA B-10.

In order to prevent leakage of any liquids or cakes, packing gaskets with grease
points and replaceable carbon fiber packing shall be required where the shaft goes
through the trough.

The wing diameter of the screw shall be at least 450 mm and the strength of the wing
at least 8 mm.

3. Trough: The extraction screw's trough shall have a straight section.

The trough sections located in the loading area under the silo shall be connected by
welding to the steel frame inside the concrete opening, without any bolted joints.

The screw trough shall be attached to the bottom of the silo with a reinforcement
frame.

Design, Fabrication and Furnishing of Major Equipment Page 13 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

The trough support shall be attached to the silo's reinforcement frame using AISI
316L stainless steel bolts and shall be equipped with a continuous, black nitrile
gasket.

The trough shall be equipped with 2 rectangular discharge openings located as,
specified in the plans.

The wall thickness of steel trough shall be at least 6 mm. The front plates shall have
a thickness of at least 10 mm.

4. Discharge Chutes: Each of the extraction screws shall be equipped with a

discharge chute designed to discharge the cakes efficiently into truck.

The chutes shall be designed to eliminate any sections where cakes accumulate and
to discharge the cakes efficiently.

Each chute shall be constructed by mechanical assembly and welding of A36 or

better steel plates with a minimum thickness of 6 mm thick.

Each chute shall be designed to be assembled and installed using bolted joints from
stainless steel 316L equipped with a continuous, black nitrile gasket.

A hydraulic actuated slide 500 x 500 shall be considered in each sludge outlet chute.

5. Drains and Drain Piping: Drains shall be installed at both ends of the trough
in order to allow liquids to drains to the floor drainage system.

The drain shall be equipped with a sieve and a removable sealing cap.

A ball valve with a rated diameter of 25 mm shall be installed on the side of the drain
to allow for clean-up using wash water.

2.3 PAINTING

2.3.1 General: AII parts and equipment shall be completely prepared and painted in the
shop according to the paint systems described below and as specified in Section
09900 - Painting.

Touch-up of all the equipment shall be performed on-site and shall include surface
preparation, as well as base and finishing coats according to the systems described
below.

Unless otherwise indicated, galvanized, aluminum and stainless steel surfaces shall
not be painted. Similarly, machined surfaces, course shafts, bearings, specifications
plates, identification plates, grease points and moving parts shall not be painted
unless indicated otherwise. These surfaces shall be masked adequately to prevent
them from being painted.

Design, Fabrication and Furnishing of Major Equipment Page 14 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

Surfaces to be painted shall be dry, clean, free of forms materials, scumming, mortar
spatters and drips, dust, non-adhesive particles, welding spatters, oil, grease and
any other foreign materials.

Application methods for each type of paint shall follow manufacturers'

recommendations as approved by las Empresas.

The Contractor shall submit for the approval of las Empresas the manufacturers'
detailed specifications for each type of paint, the results of surface state and
preparation checks as well as the methods and standards used. Colors shall be
submitted for approval.

2.3.2 The Contractor shall ensure that each paint system is perfectly compatible with each
type of covering specified.

Type I Paint System

a. Surfaces Affected: Metal surfaces which come into contact with the
cakes, such as the extraction screws, the interior surfaces of storage
silos, of extraction screw troughs, of discharge chutes, of extraction
mechanisms and of other components shall be prepared, then painted
with primer and finish coats in the shop and touched-up on-site
according to the type I paint system.

b. Preparing Surfaces In the Shop: Metal surfaces shall be prepared by

white quality abrasive-blasting.

c. Preparing Surfaces On-Site (Touch-Ups): Metal surfaces shall be

prepared using the manual tool cleaning method (BNQ-3700-972)
followed by a solvent cleaning (BNQ-3700-971).

d. Primer For Interior Metal Surfaces: Two (2) coats of polyamide-epoxy-

resin-based primer:

Thickness of each wet coat: 93 microns

Thickness of each dry coat: 50 microns

Type: Epoxy primer

e. Finish For Interior Metal Surfaces: Two (2) coats of epoxy-resin-based

finish modified by catalysis with hardening fluorocarbons:

Thickness of each wet coat: 125 microns

Thickness of each dry coat: 63 microns

Type: Fluorocarbon-modified epoxy-resin

Design, Fabrication and Furnishing of Major Equipment Page 15 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

2.3.3 Type II Paint System

1. Surfaces Affected: Exterior metal surfaces, such as the extraction

mechanisms, of screw troughs, of discharge hoppers, of screw drive supports and of
other components shall be prepared, then painted with primer and finish coats in the
shop and touched-up on-site according to the Type II paint system.

2. Preparing Surfaces in the Shop: Metal surfaces shall be prepared by white

quality abrasive-blasting.

3. Preparing Surfaces On-Site (Touch-Up): Metal surfaces shall be prepared

using the manual tool cleaning method followed by a solvent cleaning. Submit
procedures for approval.

4. Primer for Exterior Metal Surfaces:

5. One (1) coat of catalysis-hardening epoxy-based zinc phosphate primer,

standard ONGC 1-G P-165:

a. Thickness of each wet coat: 110 to 170 microns

b. Thickness of each dry coat: 50 to 75 microns

6. One (1) coat of epoxy-based primer with a high covering rating, standard
ONGC 1-GP-153:

a. Thickness of wet coat: 160 to 250 microns

b. Thickness of dry coat: 125 to 200 microns

7. Finish for Exterior Metal Surfaces: One (1) coat of epoxy-resin-based finish,
standard ONGC 1-GP-146:

a. Thickness of wet coat: 84 to 112 microns

b. Thickness of dry coat: 40 to 50 microns

2.4 CONTROL AND AUTOMATION

2.4.1 General

At each silo a local panel shall be installed for power supply and control of the
hydraulic motor, the four 3 push floors, the screw conveyor with the two hydraulic
outlet gates.

Power and control part shall be in different sections.

The principal layout can be seen at the single line diagram and at the control
overview.
Design, Fabrication and Furnishing of Major Equipment Page 16 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

The automatic function to optimize the sludge extraction shall be done by a PLC.

The basic function for maintenance, repair and to secure an emergency operation
shall be possible without the PLC and with hard wired selector switches and push
buttons including main status and failure indication lamps.

A graphical display with virtual touch buttons shall shown detailed information and
performs manual and auto operation.

For remote operation a push button panel shall be provided with key selector switch
for preselection forward, reverse and push buttons open, close and emergency stop
(close) status and failure indication lamps

2.4.2 The control panels shall include all controls either locally or remotely to start, stop,
and operate the equipment, provide detection of malfunctions and shut down the
equipment should malfunctions occur. The control panel shall incorporate all features
required for proper operation of the equipment. Control philosophy shall be fail-safe
operation. I.e. all controls and instruments shall fail in an alarm situation, the screw
outlet gates with the push floor shall close in case of power failure. The control shall
be designed so that the equipment cannot operate unless the control is energized,
nor can they operate with any defective control.

2.4.3 The control panel shall be based on a powerful programmable logic controller PLC in
accordance with electrical specifications.

2.4.4 All the control and monitoring sub-systems and components shall be sourced from
one expert supplier to ensure proven effectiveness and reliable integration.

2.4.5 Each specific control panel shall be factory tested saving time on installation and
commissioning on site.

2.4.6 The data exchange with the plants control system shall be in accordance with
Section 13310. Field bus interfaces for communications with COP (process
controller) shall be considered. The signals shall be transmitted in a bi-directional
way between COP and equipment as stated in section 13310 Instrumentation and
Fieldbuses.

Communications Interface:

Outgoing: programmable

Incoming: programmable

Additional general fault signal as dry contact including buzzer and warning light.

2.4.7 Furnish dewatered sludge storage silo system and appurtenances with the controls
and control panels listed below required for the proper control and operation of the
dewatered sludge storage silos, including push floor mechanism in conjunction with
the Screw Conveyor System, as described whether or not such components have

Design, Fabrication and Furnishing of Major Equipment Page 17 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

been specifically shown or specified. Manufacturer the control equipment to meet the
requirements specified in Section 13320.

2.4.8 The system operation, monitoring and control requirements are as described below.
Note that portion of control description noted "DCS" refers the plant computer based
Distributed Control System. The equipment under the section "At Each Push Floor
Conveyor Control Panel" and "At Hydraulic Unit Control Panel" is to be furnished
with the equipment. Provide all appropriate sensing devices and contact points for
connection to the DCS and for the signaling of all fault conditions. Provide
pushbuttons, selector switches and indicating lights in accordance with section in
electrical specifications.

1. Push Floor Extraction Conveyor

a. Control Panels

1) For each Push Floor Extraction Conveyor provide two local

control panels constructed by the Push Floor Extraction
Conveyor Manufacture. One panel is for the control of the
extraction mechanism with control of hydraulic actuated
sludge outlet valve and the other for the hydraulic unit.
Provide the panels in a NEMA 4 enclosure. The electro-
mechanical elements of the hydraulic units are to be wired
and connected to the control panels of the extraction
mechanism. The interconnecting cables between the two
panels are to be routed in conduits. Wire the panels for 120
VAC and 24 VDC input.

Provide a support equipped with vibration dampers to absorb

any vibrations caused by the operation of the pump's motor.

b. At Each Push Floor Extraction Conveyor Control Panel

The following principal operation functions shall be possible with

hardwired or soft push buttons or selector switches

1) Hand/OFF key operated Selector Switch

Hand Position - Unit controlled locally Off Position - Unit is

inoperable

2) Extension/OFF/Retraction Selector Switch

Extension Position }

Retraction Position } Conveyor Positions

Off Position - Conveyor is OFF line

Design, Fabrication and Furnishing of Major Equipment Page 18 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

3) Emergency Stop Pushbutton

4) Stop Pushbutton

5) Start Pushbutton

Hardwired indication lamps or at graphical display shall be in

principal

6) ON/OFF Indicating Lights Extraction Conveyor

7) ON/OFF Indicating Lights Hydraulic Unit

8) Fault Reset Pushbutton

9) The following Fault Indication Lights:

Hydraulic Unit High Oil Temperature

Hydraulic Unit Low Oil Level

Low Oil Pressure in Hydraulic Jack's Main Feed Line

High Oil Pressure when Conveyor is in Extracted

Position

High Oil Pressure when Conveyor is in Retracted

Position

Malfunction of drive train.

c. At Hydraulic Unit Control Cabinets: Its face shall include, without being
restricted to, the following equipment:

1) One (1) key switch, with three holding positions,

LOCAL/SERVICE/REMOTE (Iocal/off-line/remote)

2) One (1) lever selector, with three positions,

EXTENSION/HORS/RETRACTION (extended/off -
line/retracted)

3) One (1) red mushroom-head (emergency stop) push-button

4) One (1) black (acknowledgment) momentary-contact push-

button

5) One (1) green momentary-contact push-button

Design, Fabrication and Furnishing of Major Equipment Page 19 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

6) One (1) red (OFF) momentary-contact pushbutton

7) One (1) green indicator light to signal UNITE (hydraulic unit

operating)

8) One (1) green indicator light to signal (extraction mechanism

operating)

9) The red (blinking) indicator lights required to signal the

following abnormal conditions:

Low oil level

High oil temperature

Low pressure - main feed line

High pressure - extended

High pressure - retracted

Malfunction

Note: Alarm indicator lights shall blink until acknowledged,

and then remain on until the normal situation return. All other
electrical and electronic components which may be required
to control the operation of the hydraulic unit and the
extraction mechanism.

d. TO DCS

1) All Alarm and Status indications for hydraulic aggregate,

push floors, screw and screw gates

e. As part of the Conveyor Control Panel, provide a programmable logic

controller to execute the demands and interlocks required for the
operation and protection of the hydraulic unit, hydraulic slide gate and
conveyor. The controller will be composed of a base with the
necessary outputs and inputs, one (1) central processing unit (CPU),
one (1) 120 V AC power supply, and the communication card to the
DCS.

The cabinet shall also include the terminals and terminals required to
connect the control cables. AII electro-mechanical, elements of the
hydraulic unit shall be wired and connected in the workshop to the
control cabinet of the extraction mechanism. The cables if necessary
oil resistant shall be routed in conduits.

The cabinet shall be wired for 120 VAC and 24 VDC input.
Design, Fabrication and Furnishing of Major Equipment Page 20 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

Extraction Screws: Each of the two (2) push floor extraction screws shall be
equipped with a speed detection device to signal any failure of the drive train.

2.4.9 The controls shall include the necessary components to allow for proper operation of
the equipment. (See single line diagram)

One (1) main switch panel for every equipment, internally pre-wired, to house the
necessary controllers, contactors, terminal blocks, control transformer, fuses, relays,
indicator lamps, pushbuttons, etc. The panel shall be located adjacent to the
hydraulic unit.

2.4.10 The above switch panels shall be wall mounted type internally pre-wired to terminal
strips and shall include the following items:

a. Disconnect switch with indicator

b. Hand/Off/Auto selector switch

c. Contacts for remote control

d. PLC for automatic operation

e. Contacts for Ultrasonic level controllers

f. Start pushbutton

g. Reset pushbutton

h. Indicating lamps for:

Ready for operation

Thermal fault

Running and hand operator

Emergency stop

Power loss

Failed operation

2.4.11 Access into the panel shall be through a door complete with a mechanically
interlocked isolating switch that renders the internal circuits safe, unless they are
covered with insulated shrouds or of safe low voltage levels.

The control panel shall be fitted with a thermostatically controlled anti-condensation

heater.
Design, Fabrication and Furnishing of Major Equipment Page 21 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

2.4.12 The panel shall include any additional controls, indications or alarms considered
necessary for safe operation and protection of the equipment and for interface with
remote control.

Each motor starter shall be equipped with the following minimum content of control
and protection equipment:

a. Short circuit protection

b. Thermal overload relay having inherent single phase protection. Direct

online starter, NEMA AC3 category, with soft starter if requested

The control circuit shall be 120 volts, A. C. provided from its own transformer and
MCBs, the secondary connections shall be earthed on the side.

A Lamp Test pushbutton shall be provided on the control panel door a necessary
relays to illuminate all door mounted indicating lamps when the button is pressed.

Two (2) Emergency Stop pushbuttons of the twist to reset pattern shall be provided
on the relevant equipment.

2.4.13 With the selection and the installation of the electrical equipment great importance is
to be attached to the contact protection.

Open parts are to be covered in an appropriate way and be protected from

coincidental affecting.

Safety devices, time delay relays must be safely operated with inserted cover.

All drives are to be secured individually with fuse switches. Disturbances of the
drives are to be indicated at the control panel separately. Each motor receives an
automatic circuit breaker. All bimetal relays receive a restarting barrier.

The control transformer is to be over-dimensioned with 50 % and secured with

automats or circuit breakers.

2.5 ELECTRIC MOTORS

2.5.1 General: Furnish motors, horizontal shaft, 480-volt, 3-phase, 3-wire, totally enclosed,
squirrel-cage induction motors, suitable for operation at 480 volts, 3-phase, 60 hertz,
IP 55. Submit calculation for approval. Provide motors meeting the requirements of
Section 16150 Electric Motors. Overload protection for motor cutoff in the event of
mechanical overload by means of a torque support shall be considered.

PART 3 EXECUTION

3.1 INSTALLATION

Design, Fabrication and Furnishing of Major Equipment Page 22 of 24

Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

3.1.1 Installation and assembly of the equipment shall be in accordance with the drawings
and with the manufacturers installation instruction manual. The contractor shall
furnish all bolts, shims, tools and other devices necessary for installing the
dewatered sludge storage silos equipment. The manufacturers representative
familiar with the equipment shall supervise the handling, installation, start-up and
testing of the equipment.

3.1.2 After the system is installed and prior to start-up, complete clean up of the dewatered
sludge storage silos area of any accumulated construction debris shall be done. Any
damage to the equipment during initial start-up due to foreign objects left in the areas
shall be corrected at the contractors expense.

3.2 SHOP TESTS

3.2.1 Each dewatered sludge storage silo equipment shall be assembled and tested
before shipping. The owner reserves the right to have a representative present
during the factory testing. Testing shall include a simulation of an operation and
automations and normal hand modes. Safety features shall also be tested.

3.2.2 Completely shop assembles the dewatered sludge storage silos equipment, test and
adjust prior to shipment. The shop test will consist of running the mechanism through
a minimum of one complete cycle to ensure proper operation of the equipment.

3.3 FIELD TESTS

3.3.1 Tests: After installation of the dewatered sludge storage silos equipment, control
equipment and all appurtenances, supervise a field running test, under actual
operating conditions as specified in the General Requirements. Tests will be of
sufficient duration to show that the equipment works properly, operates at the
specified speeds, has necessary clearances, operates without overheating of any
parts and in all other respects meets all requirements of the Specifications.

1. Supervise field testing to include checking the operation of the warning and
drive shut-down circuitry. The test will include increasing the loading to test
the mechanical overload protection system.

2. Submit complete test procedures for approval prior to testing; however,

accomplish testing with the machine in operation.

3. Furnish all labor, materials, and test apparatus necessary for supervising the
above tests.

4. Correct any defects in the equipment or failure to meet the requirements of

the Specifications properly.

3.3.2 Controls: Ensure that the tests also demonstrate that the equipment operates as
specified with its control system.

3.3.3 Field testing shall be conducted by an experienced field test engineer and will be
witnessed by the owner. Before initially energizing the motors, the contractor shall
have successfully tested all the control, monitoring, and protective circuits. This
Design, Fabrication and Furnishing of Major Equipment Page 23 of 24
Empresas Pblicas Planta de Tratamiento de Aguas Residuales Bello Section 11356
de Medelln Technical Specifications Dewatered Sludge
Storage Silos

thorough electrical checkout procedure shall have followed a detailed step-by-step

approved test plan. The motor units undergoing tests should also be checked at this
time.

3.3.4 Tests will be of sufficient duration to show that the equipment operates properly at
the specified speeds, has necessary clearances, operates without overheating of any
parts and in all other respects meets all requirements of the specifications.

3.4 TRAINING

Subjects of instruction for training shall include the following:

- Startup procedures

- Shutdown procedures

- Troubleshooting

- Operating adjustments for performance optimization

- Preventive maintenance

- Maintenance procedures

- Emergency procedures

- Record keeping

- Mechanical unit function and description

While conducting operational instruction and training, the Contractor shall perform, at
his expense, all materials to produce guaranteed performance.

Other requirements for training shall be as described in the General Requirements.

END OF SECTION

Design, Fabrication and Furnishing of Major Equipment Page 24 of 24