Empresas Públicas Planta de Tratamiento de Aguas Residuales Bello Section 11323

de Medellín Technical Specifications Grit Handling Equipment

SECTION 11323

GRIT HANDLING EQUIPMENT

PART 1 GENERAL

1.1 SUMMARY
1.1.1 The work in this section includes the design, fabrication, furnishing, assembly,
testing, packaging, delivery, supervision of installation, and installation of eight (8)
grit washers, and one (1) complete automatically operated container handling
system with four (4) lifting trolleys and three (3) transverse trolleys as well as
eighteen (18) containers a 7 m³ including instrumentation and control equipment
meeting the requirements for NEC Class I, Group D, Division 1, explosion-proof
equipment and wiring. Locate the equipment as shown in drawings for the Grit
Treatment Building. The grit handling equipment shall be manufactured complete
with all components, drives, motors, ancillary items and supports. The work includes
attachment bolts, anchor bolts, controls, electric control panels, all wiring within each
unit and from the units to the control panels, shop testing, shop painting, training of
operating personnel, commissioning, performance tests and all necessary
appurtenances required for a complete installation and satisfactory operation.
1.1.2 Related Work Specified in Other Sections Includes:
1. Section 01000 - 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 11329 - Grit Removal Tank Equipment
8. Section 13310 – Instrumentación y buses de campo
9. Section 13330 – Controladores Lógicos Programables PLC
10. Section 13340 – Sistema de Control Distribuido DCS
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
1.1.3 System Responsibility: It is mandatory that a single manufacturer-supplier regularly
engaged in the design, manufacture, assembly and production of grit washers and
container handling equipment of the type specified have complete responsibility for
the system design, furnishing, coordination, assembly, installation and installation
supervision, commissioning and testing of all equipment specified in this section. It
is also intended that the manufacturer-supplier make all adjustments, alterations,
replacements and tests specified and required for a complete, satisfactory, and
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trouble free operating installation in accordance with the Specifications and as

approved by the Owner.

1.2 REFERENCES
1.2.1 Codes and standards referred to in this Section are:
1. AGMA 6034-B92 "Enclosed Cylindrical Worm Gear Speed Reducers and
Gear motors"
2. AGMA 908-B89 "Factors for Determining the Pitting Resistance and Bending
Strength of Spur, Helical and Herringbone Gear Teeth"
3. ASTM A 36 / A36M - Specification for Carbon Structural Steel
4. ASTM A 240 - Specification for Heat Resisting Chromium and Chromium
Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels
5. ANSI B105.1
6. NEMA Design C
7. AISI 1045
8. NEC Class I, Group D – National Electrical Code
9. OSHA - Occupational Safety and Health Administration
10. ASTM - A167
11. AISC - American Institute of Steel Construction
12. AISI 316L
13. ASTM A153
14. ASTM A385
15. ASTM 8633
16. NBS Handbook 44
17. ANSI 820.1-1976 - Safety Standards for Conveyors and Relate Equipment
18. CEMA Class C-5
19. AISC - American Institute of Steel Construction - Manual of Steel
Construction
20. DIN 30720 - Containers for multi-bucket system vehicles; sizes, materials,
performance

1.3 SYSTEM DESCRIPTION GRIT WASHER

1.3.1 General: Design the grit removal equipment to fit the space, piping and structural
arrangements shown.
1.3.2 Design: Design the grit washer operating parameters, i.e., pool area, weir length,
screw peed, submergence, and slope, to avoid build-up of fine grit in the classifier
tank and which will cause grit of the desired size to be lost.
1.3.3 Design the grit washer of the inclined screw type to wash, classify and dewater grit
from the cyclone separators by moving the-grit up the sloping bottom and depositing
the grit into the container. Submit calculations demonstrating compliance with the
following:
1. Furnish grit separation equipment meeting the requirements of Section 11329
“Grit Removal Tank Equipment”, to discharge to the grit washer.
2. Provide a capacity sufficient to handle not less than 100 percent of the
discharge from the grit separation equipment, and capable of processing a
minimum of 1,5 tons/hour of grit.
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3. Design the grit separation/grit washing system to guarantee a capture of 95

percent of the grit of grain size 0,20 mm or larger.
1.3.4 The grit washer shall be designed for optimal separation and washout of
contaminated grit trap material combined in one plant. Designs with separate
separation and washing units or preceding screening units are not permitted.
1.3.5 After solids separation the organic particles are washed out in the bottom part of the
tank by means of a grit fluidized bed. The wash water shall be added across the
entire wash zone cross section. A specific design shall eliminate clogging or
blockage at the wash water addition point. In order to achieve constant washing
results, the system shall work with an uniform, constant upflow velocity in the wash
zone. Washout shall be supported by a slowly running stirrer, which ensures
separation of the lighter organic particles from the dense mineral particles.
1.3.6 Organic material shall be additionally removed via a separate automatically actuated
organics discharge located above the grit fluidized bed.
1.3.7 The washed grit shall be removed and at the same time dewatered by a sturdy grit
transport screw supported on both ends in a trough. A special arrangement of the
screw flights shall guarantee plug-free operation.
1.3.8 Main characteristic plant features:
- Grit Washer feeding by means of pump,
- No additional screening shall take place upstream of the Grit Washer. The
plant must be able to handle mineral grain sizes up to 30 mm.
- The grit/water mix shall centrally flow into the Grit Washer.
- Grit classification and washing shall take place in one tank, i.e. preceding
longitudinal grit traps are not permitted.
- The surface overflow rate (incl. wash water) shall be < 25 m/h.
- The Grit Washer shall be equipped with an overflow weir on the outside.
- The overflow weir load shall be < 15 m²/h.
- The combined addition of water and air, or fixed bed plants is not permitted.
- The Grit Washer shall have a separate organics discharge of DN 100.
- The Grit Washer must remain in full function (wash and discharge grit) even
during feeding from the grit trap.
- The grit removal screw must be a stainless steel screw 316L supported on
both ends.
- The grit removal screw trough shall not have guide bars or plastic shells.
- The Grit Washer shall be acid treated in a pickling bath and passivated.
- The complete Grit Washer and the stirrer must be made of 316L stainless steel
material.
1.3.9 A wash water connection with rising pipe for washing of grit within the grit washer
shall be foreseen. The wash water connection shall be completely mounted to the
grit washer comprising one 1” dead closed solenoid valve for automatic wash water
addition incl. hoses, manual ball valves for wash water regulation, T-irons and fixing
materials. Provide a low pressure switch down stream of the solenoid valve.
1.3.10 The design shall allow an easily maintenance and cleaning access for the different
components. The inspection hatches shall be of the quick-release type and shall be
installed at suitable locations to facilitate routine inspection. Provide adequate

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sealing around the aperture when the hatch is closed. Consider hinges to facilitate
the inspection.
1.3.11 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 SYSTEM DESCRIPTION – CONTAINER HANDLING SYSTEM

1.4.1 General: Design the container transport trolley equipment to fit the space, piping and
structural arrangements shown.
1.4.2 Container handling system with 12 parking berths, 4 loading berths and 2 lorry -
offload/upload berths for containers shall be designed to move the grit containers of
8 grit washers. The plant consists of 4 lifting trolleys and 3 motor driven transverse
trolleys with sufficient space to receive one container a 7 m³.
1.4.3 Each berth shall be equipped with a proximity switch in order to determine whether a
container is placed in the berth. Weighing devices and ultrasonic level sensors at the
filling berth shall observe the level and the weight in the containers during filling
procedure.
1.4.4 The lifting trolley platform shall be equipped with a hydraulic lifting system and an
electrical driving system. As running wheels flanged rim wheels shall be used.
1.4.5 The container shall be driven by the lifting trolley. In order to place the lifting truck
directly underneath the container, the lifting trolley shall be equipped with an
electronically controlled carriage by frequency converters combined with a laser
range finder. The platform operated by means of lifting cylinders shall raise the
container. Afterwards the container shall be moved with the lifting trolley to its new
location.
1.4.6 In order to be able to move the container in longitudinal direction the lifting trolley
needs a transverse trolley, into which it drives if necessary. The transverse trolley
shall consist of a stable sectional steel framework, which shall be moved by four
running wheels on the track rails. The positioning shall be made as with the lifting
trolley by a laser range finder. The electrical cable supply shall be made by a cable
dragging line.
1.4.7 The lifting and the transverse trolley shall be connected by power track chains with
cables.
1.4.8 The full container shall then be moved into a lorry loading berth. Provide the lorry
loading berths with container guides and stoppers. After this an empty container
shall be transferred into the filling berth.
1.4.9 The container transport trolleys shall run on railway tracks. Additionally 2 proximity
switches per each transport trolley to determine the positioning of the transport
trolley shall be considered.
1.4.10 The trolleys shall be driven by gear box motor worm type. The speed shall be
adjustable by frequency inverters. The platform of the lifting trolley shall be lifted by a
hydraulic power system. The power supply for the trolley shall be realized by a
spring driven cable reel. Cable trays and power track chain shall be included.

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1.4.11 The container handling system shall include an appliance for setting down and
centering from sturdy structural steelwork to setting off the containers at the parking
berths and lorry - offload/upload berths. The lorry - offload/upload berths shall have
in addition centering angles as steel sheet construction.

1.5 SUBMITTALS
1.5.1 General: Provide all submittals, including the following, as specified in the General
Requirements.
1.5.2 Shop Drawings: Submit shop drawings including physical drawings of the
equipment, including all mechanical calculations.
1.5.3 The submittals shall include:
1. Installation details and instructions,
2. Motor descriptions and performance characteristics,
3. Gear reducer descriptions and performance characteristics,
4. Calculations for the motors and gear reducers demonstrating their suitability
for the specified service,
5. Catalog data on Mechanical and Electrical components,
6. Electrical elementary diagrams, internal connection diagrams, external
interconnection diagrams and a complete description of the control system,
7. Local control panel layout drawings,
8. Documentation of the PLC application program. Documentation of the VFD
configuration. Description of the signals and configuration parameters for
communication, supervision and operation from DCS,
9. Manufacturer's certified performance and material records for quality control,
10. Certification of welders’ qualifications, welding procedures and quality
assurance for welders (e. g. AWS D9.1) for approval,
11. Operating and maintenance information,
12. Recommended spare parts and tools lists,
13. Painting procedure.
1.5.4 Quality Control Submittal: Submit manufacturer's certified performance and materials
records.
1.5.5 Operation and Maintenance: Submit operation and maintenance manuals for the
grit handling equipment.
1.5.6 Installation Information: Provide all information required for installation of the
equipment including all erection drawings.
1.5.7 Storage Instructions: Submit storage instructions for the equipment for use by the
Owner.
1.5.8 QUALlTY ASSURANCE
1.5.9 The equipment furnished under this Specification shall be designed and
manufactured by a Company who shall demonstrate to the satisfaction of The
Owner, that the Company complies with the experience criteria as specified in the
Bid Documents.”

1.6 DELlVERY, STORAGE AND HANDLING

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1.6.1 Deliver, in accordance with the Bidder Documents, the General Requirements and
as directed by the Owner, all products and materials to the storage site. Off-Ioad the
equipment

1.7 SPARE PARTS

1.7.1 All spare parts shall be interchangeable for a manufacturer’s Product of the same
size and model. Furnish the following spare parts:
1. One (1) bearing set for each type
2. One (1) set of wear bars for each grit washer
3. One (1) motor for each type of equipment
4. One (1) speed reducer and one (1) set of speed reducer seals for each size
5. Twenty (20) m power track chains
6. Four (4) proximity switches for the container handling system.
7. Fifty (50) sheer pins of each size

For each PLC type used in the PCC panels

8. One (1) CPU module
9. One (1) Communication module
10. One (1) Power supply module
11. One (1) DI module
12. One (1) DO module
13. One (1) AI module
14. One (1) AO module
15. One (1) PTC input module

PART 2 PRODUCTS

2.1 GRIT WASHER

2.1.1 Materials, Dimensions and Technical Data. Furnish material utilized in the
construction of the grit washer equipment conforming to the following standards:

- Feed with grit/water mix: 25 l/s

- Maximum possible solids amount: 1,5 t/h

- Reduction of organics to: 3 % loss on ignition

- Guaranteed separation efficiency of: 95%

- for grit of grain size: 0,20 mm

- Surface overflow rate: 22 m/h

- Maximum handleable mineral grain size: 30 mm

- Wash water demand: approx. 5 m³/h

Material of all components in contact with medium shall be 316L stainless steel, acid-
treated in a pickling bath (except fittings, drives, bearings).
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2.1.2 Construction. Grit washer, equipped with all components such as stirrer (if
necessarily) for mixing of the water/grit mixture as well as all required installations for
an optimal and fully automatic operation of the equipment.
2.1.3 Trough. The Trough shall be a self-supporting construction, totally enclosed and
shall have a bolted cover on top of the trough and conveyor screw. The inspection
cover shall be easily opened. Within the range of the overflow and the grit outlet
chute an easily accessible inspection opening shall be considered. At the bottom of
the trough a 50 mm drainage connection with ball valve shall be installed. The fixing
and supporting material shall be made of stainless steel 316L.
The inlet into the trough is to be arranged in such a way that no turbulences occur
and an optimal separation of the settling and floating material is ensured.
2.1.4 Trough Screw. The screw trough with double bearings shall end above the container
(7 m³ containers on container trolleys). The trough shall be equipped with a
replaceable wear strip from ceramic or special steel. The screw discharge takes
place as a function of the supplied sand quantity, which is determined over a
pressure sensor to be provided. The screw discharge ends centrically over the
container with a pipe bend. A flexible hose shall be fastened at the pipe bend to
distribute the dewatered grit within the container.
2.1.5 Construct the grit washer so that maintenance can be performed without draining the
grit settling tank.
2.1.6 Provide the tank with a water connection as required and a solenoid valve
compatible with the area classification, which shall activate when motor is activated.
2.1.7 Design the screw such that there is sufficient clearance between the tank and the
screw so that a built-up layer of grit will provide a bed for the screw, minimizing tank
wear.
2.1.8 Lubrication. For the lubricating of the bearing lubricating nipples in well accessible
places shall be arranged. A reliable shaft sealing over radial shaft seals shall avoid a
leakage within the range of the drive unit.

2.2 CONTAINER HANDLING SYSTEM

2.2.1 Materials, Dimensions and Technical Data. Furnish material utilized in the
construction of the container handling equipment conforming to the following
standards:

- Maximum load: 20 t

- Materials lifting trolley: mild steel, galvanized bearings

- Materials transverse trolley: mild steel, galvanized bearings

- Four (4) container positioning devices in hot dip galvanized steel

- Three (3) power track chain with cable with lay - down trough and fixing
materials

- Eighteen (18) container positioning switches in hot dip galvanized steel

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- Eighteen (18). level sensors with support column and fixing materials in hot dip
galvanized steel

- Railway track: approx. 180 m (360 m rails). See drawings.

- Material railway: hot dip galvanized mild steel and painted complete with fixing
materials and leveling plates to overcome planarity tolerances of +- 20 mm of
the concrete base

- Material setting down and centering appliance: hot dip galvanized steel

- Material centering angles: hot dip galvanized steel

- Thickness centering angles: 12 mm

- Side length centering angles: 200 mm

- Fixing materials, anchor bolts: hot dip galvanized mild steel

- Motor protection grade: IP 54 meeting the requirements for NEC Class I, Group
D, Division 1, explosion-proof equipment and wiring.
2.2.2 Centering Angles. Steel sheets shall be welded to an approx. 75° angle construction
with a side length of approx. 200 mm and with stable bracing between the sides.
2.2.3 Safety Devices

1. Light barriers / Wire mesh fence: As the trolleys are moving fully automatic, the
access to the building has to be restricted. In case of people entering the area of
the container handling system the operation has to be stopped. The detection of
personnel shall be done by installation of light barriers or a wire-mesh fence at
each access way.

2. Traffic light device: During a container transport procedure the traffic light at the
lorry - offload/upload berth indicates "red" and the roll gate shall not be opened.
If a container reached the lorry - offload/upload berth the traffic light switches to
"green" and the roll gate opens.

3. Warning signals: Each container shifting procedure shall be indicated by a

visible and acoustic warning signal.

4. Rail stoppers shall be provided at the end of rails. Rail way drainage must be
considered.

2.3 CONTAINER
2.3.1 Materials, Dimensions and Technical Data. Furnish material utilized in the
construction of the containers conforming to the following standards:
- Bottom plate length: 2.200 mm
- Bottom plate width: 1.600 mm
- Overall length: 3.380 mm
- Overall width: 1.900 mm
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- Overall height: 1.465 mm

- Wall metal sheet thickness: 4 mm
- Metal sheet thickness of bottom plate: 7 mm
- Volume: 7 m³
- Weight: 760 kg
- Material: hot dip galvanized mild steel and painted
2.3.2 Construction.

1. The containers shall be stackable and designed asymmetric according to DIN

30720 type OB 10 and shall match to the container lifting system of the trucks.
The hanging up pins shall be welded.

2. The container shall be waterproof with continuous welding seams. The upper
frameworks shall be from steel channel with strengthened corners. A drainage
with blind cap sunk in container side wall (not outstanding over the side wall)
shall be provided.

2.4 CENTRAL AND LOCAL CONTROL PANELS

2.4.1 The equipment shall be controlled by its own PCC Central Control Panel. PCC
panels have to be furnished according to HTA-4-SP-16-009 – Especificaciones
Eléctricas.
2.4.2 The Central Control Panel shall have connectivity to the DCS; refer to section 13340
“Sistema de control distribuido DCS”. Provide the lists of Input / Output registers,
addresses and values ranges of the variables and parameters that shall be
transmitted to and from the DCS using fieldbus or network links. Provide necessary
device description files for PCC-DCS integration. Each station shall be configured
with a communication bus integrating all station PCCs to the DCS.
2.4.3 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 Local 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 control shall be designed so that the equipment cannot operate unless the
control is energized, nor can they operate with any defective control.
2.4.4 The PCC Central Control Panel shall be based on a powerful programmable logic
controller PLC in accordance with Section 13330 in electrical tender specifications.
2.4.5 All the control and monitoring sub-systems and components shall be sourced from
one expert supplier to ensure proven effectiveness and reliable integration.
2.4.6 Each specific PCC Central Control Panel with PLC shall be factory tested saving
time on installation and commissioning on site.
2.4.7 The data exchange with the plant’s 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 “Instrumentación y
buses de campo ” and in Section 13340 “ Sistema de Control Distribuido DCS”.

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2.4.8 The PCC shall have general fault signal for each equipment, as dry contact outputs
to be wired to DCS. Digital inputs shall be provided to shut down the machines from
DCS.

2.5 OPERATIONS AND CONTROL GRIT WASHER

2.5.1 The screw of the grit washer shall be impulse-pause operated in dependence of the
fed amount of grit, which is measured by a pressure probe.
2.5.2 Grit level measurement shall be carried out by means of a hydrostatic pressure
probe.
2.5.3 The control shall be realized by 4 independent PLC’s (one PLC for two grit washers)
as stand alone units. Each PLC shall be connected to the DCS by a bus connection
(see Section 13310). All status and failure indications shall be transmitted to the
DCS. In case of DCS mode the PLC receives some interlocking from the DCS. The
MCC with the power supply shall be located in the MCC room. The control
switchboard shall be located in the control room. The discharge of organic material
shall be automated. An explosion proof panel (NEC Class I, Group D, Division 1)
shall be located near the mechanical equipment to perform manual operation.

2.6 OPERATIONS AND CONTROL CONTAINER HANDLING SYSTEM

2.6.1 The control procedure shall be fully automatic with accurate positioning of the
containers at the individual container berth. The control shall be as follows:

- Detection of the full/empty condition of the containers at the individual berths by

the ultrasonic level meters.

- Detection of containers at the individual berths (containers available/missing) by

contact proximity switches or similar.

- Shifting the containers from the delivering place to the individual supply or filling
place,

- Detection of the weight of the containers at the filling berths to shift the
containers and for statistics

- Automatic exchange of the full containers by empty containers at the filling

places during fulfillment.

- Provision of the filled containers at the pick up place if these is not occupied.

- Alerting over PLC, if given number of berths (in the control as process variable
freely selectable) is occupied with full containers.

- With closed roller gate the lorry - offload/upload berths will not be selected by
the container control, but it takes place only a container exchange between the
loading and filling berths within the container transport station.

- Interruption of the container transport procedure through the light barrier or

opened door in the wire mesh fence, the restart can only be done by the
operator.
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- Interruption of the container transport procedure through release of the safety

strips at the trolleys

- With beginning of the container transport procedure release of the audible and
visible alarm. The visible alarm remains for the duration of the procedure in
operation.

- Open the roller gates only (odor control) whether a container reached a lorry -
offload/upload berth.

- The drive to the lorry - offload/upload berth shall be interlocked if the door is not
fully open (volt free contact).

- The drive to and from lorry - offload/upload berth shall be done only on request
(pushbuttons at the lorry - offload/upload berth).

- The system shall generally work as a stand alone unit with some interlocking to
and from the DCS.
The MCC with the power supply shall be located in the MCC room. The control
switchboard shall be located in the control room. A movable explosion proof panel
shall make it possible to operate the individual drives from local and without the PLC
(for maintenance and repair works).
2.6.2 In the control of the container transport station following contacts shall be
considered:

- 2 pieces of door contacts at the doors of the fence

- 2 pieces of gate contacts at the roller gates

2.6.3 Except the fully automatic operation the following further operations are to be
realized:

- Half automatic pre-selection container X from A to B

- Manual control by visual control over portable tableau

- Execution of the container transport operation by hand in the case of power

failure or fault

- The control shall be realized by a powerful PLC and a hot standby unit which
can take over the control in case of break down of the first unit. The PLC’s shall
be connected to the DCS via a bus connection (see Section 13310). All status
and failure indications shall be transmitted to the DCS.

2.7 ELECTRIC MOTORS

2.7.1 General: Furnish screen motors, horizontal shaft, 480-volt, 3-phase, 3-wire, totally
enclosed, NEC Class 1, Group D, Division 1 explosion-proof squirrel-cage induction
motors, suitable for operation at 480 volts, 3-phase, 60 hertz. Submit calculation for
approval. Provide motors meeting the requirements of Section 16150 Electric

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Motors. Overload protection for motor cutoff in the event of mechanical overload by
means of a torque support shall be considered.

2.8 SHOP TESTS

2.1.1 The grit handling equipment shall be assembled and tested before shipping. The
equipment shall be factory tested to certify its mechanical characteristics over the
entire performance range, as specified. The Owner reserves the right to have a
representative present during the factory testing.
2.1.2 The container handling system shall be assembled and tested before shipping. The
equipment shall be factory tested by means of simulations to certify its mechanical
characteristics over the entire performance range, as specified. The Owner reserves
the right to have a representative present during the factory testing.
2.1.3 The equipment shall be tested in the manufacturer's shop with its own electric panels
and motors to demonstrate the proper operation of all components and the
mechanical performance. Submit details of test procedures and test equipment and
instruments for approval.
2.1.4 Testing shall include a simulation of an operation and automations and normal hand
modes. Safety features shall also be tested.
2.1.5 Tests shall include manufacturer’s standard tests; current standard test procedures
according to ANSI, ASME, IEEE, NEMA, DIN, ISO for component equipment; and
specific tests listed herein.
2.1.6 Provide testing to demonstrate that no overheating of bearings, motors, or other
components occurs.
2.1.7 Test the unit for vibration.
2.1.8 All start/stop sequences and all safety and alarm systems shall be tested in
automatic and hand modes. The entire system of all motors, accessories and local
panels shall be demonstrated to the witnessing Engineers as an operating system.
Verifications test, including but not limited to:
- Manual and Automatic start and synchronizing sequence tests.
- Manual and Automatic load control at different loads
- Function of all safety systems
- Alarm trip functions tests.
- Measurements at different loads:
• Voltage
• Current
• Capacity m³/h
• Velocity m/s
2.1.9 The fieldbus interface for DCS supervision has to be tested
2.1.10 The reports shall be prepared by the Manufacturer and shall present complete
performance and characteristic curves showing capacity and kW inputs.
2.1.11 Test results of the motors and package functional tests shall be included in the
Operations & Maintenance Manual.

PART 3 EXECUTION
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de Medellín Technical Specifications Grit Handling Equipment

3.1 INSTALLATION
3.1.1 Installation and assembly of the equipment shall be in accordance with the drawings
and with the manufacturer’s installation instruction manual. The Contractor shall
furnish all bolts, shims, tools and other devices necessary for installing the grit
handling equipment. The manufacturer’s representative shall supervise the
handling, installation, start-up and testing of the equipment.
3.1.2 Support systems shall not be attached to handrails, process piping, or mechanical
equipment.
3.1.3 Make sure that the dimensional tolerances of the floor and buildings are according to
manufacturer instructions.
3.1.4 Anchoring of the supports: the Contractor shall consider the manufacturer’s
documentation of the mechanical type of dowels.
3.1.5 Electric motors and operators shall be installed in accordance with the
manufacturer's written instructions.
3.1.6 After the system is installed and prior to start-up, complete clean up of the grit
handling area of any accumulated construction debris shall be done. The Contractor
is responsible to correct any damage to the equipment during initial start-up due to
foreign objects left in the areas.

3.2 FIELD TESTS

3.2.1 Inspections: Inspect equipment after initial test run for defects and rectify in
accordance with manufacturer’s instructions.
3.2.2 Tests: After installation of the grit handling equipment, container handling system
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. Furnish all labor,
materials, and test apparatus necessary for supervising the above tests.
3.2.3 Field tests must demonstrate that the units can operate successfully, individually and
together in parallel, and that they will continue to operate satisfactorily under varying
loads.
3.2.4 Tests will be of sufficient duration to show that the equipment operates properly at
the specified rates, has necessary clearances, operates without overheating of any
parts and in all other respects meets all requirements of the specifications.
3.2.5 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
3.2.6 All malfunction devices and alarms shall be field tested and adjusted. The entire
system shall be field tested under operational conditions specified herein.
3.2.7 Test the communication of each PLC to the DCS. All read/write operations of
configured registers for status, commands and failures shall be tested. Demonstrate
that the equipment operates as specified with its control system, and that the DCS
COP can read/write the specified registers.
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Empresas Públicas Planta de Tratamiento de Aguas Residuales Bello Section 11323
de Medellín Technical Specifications Grit Handling Equipment

3.2.8 Controls: Ensure that the tests also demonstrate that the equipment operates as
specified with its control system. Ensure that the communication to the DCS works
as specified and that all listed variables to be transmitted to and from the DCS are
sent and received correctly.
3.2.9 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
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.
3.2.10 Final Acceptance Test (Demonstration) Run: Provide the Final Acceptance Test Run
of the equipment performed by the manufacturer's service representatives in the
presence of the Owner. Perform the Final Acceptance Test Run in conjunction with
the DCS, using waste water. Simulate and demonstrate that all performance
requirements are satisfied and that the alarm and shut down functions operate
satisfactorily.

3.3 TRAINING
3.3.1 Subjects of instruction for training shall include the following:
1. Startup procedures
2. Shutdown procedures
3. Troubleshooting
4. Operating adjustments for performance optimization
5. Preventive maintenance
6. Maintenance procedures
7. Emergency procedures
8. Record keeping
9. Mechanical unit function and description
3.3.2 Other requirements for training shall be as described in the General Requirements.

END OF SECTION

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