OR-TEC HP 1000 SERIES

BELT PRESS

INDEX

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

1.2 DESCRIPTION OF WORK

1.3 QUALITY ASSURANCE

1.4 DOCUMENTATION

PART 2 - PRODUCTS & EQUIPMENT

2.1 ACCEPTABLE MANUFACTURERS

2.2 OPERATIVE CONDITIONS

2.3 EQUIPMENT SPECIFICATIONS

2.4 PRODUCT DESCRIPTION

2.5 MATERIALS

PART 3 - EXECUTION

3.1 INSTALLATION

3.2 TESTING AND INSPECTION

PART 4 - GENERAL TERMS AND CONDITIONS

4.1 PRICING TERMS

4.2 CLARIFICATIONS

PART 5 - DRAWINGS

All information included as part of the accompanying proposal shall remain the sole property of

OR-TEC, Inc. in conformance with the copyright laws and regulations of the United States.

This proposal may not be photocopied or faxed without the prior approval of OR-TEC, Inc.

The data herein is furnished on a restricted basis and is not to be used in any way

detrimental to the interest of OR-TEC, Inc.

PART 1 - GENERAL

1.1 RELATED DOCUMENTS:

1.1.1 Drawings and general provisions of contract, including General and Supplementary Conditions, and Division I Specifications apply to this section.

1.2 DESCRIPTION OF WORK:

1.2.1 Manufacture belt press complete with related accessories as indicated on the included drawings and specified herein.

1.3 QUALITY ASSURANCE:

1.3.1 Manufacturer: Shall furnish a fully functioning belt press as dictated by the accepted Scope of Supply. Manufacturer shall have produced similar process configurations for a period of at least (5) five years.

1.3.2 Manufacturer’s Services: A manufacturer=s representative for the equipment specified herein shall be present at the job site for a minimum of one (1) day, travel time excluded, for inspection of installation, certification of field testing, and adjustment. A second visit for a minimum of 1-1/2 days, travel time excluded, will be provided for polymer selection, training and reviewing the Operations Manual with appropriate personnel. Additional field service will be provided at a reasonable fee or at no charge, depending on the circumstances of the visit.

1.4 DOCUMENTATION:

1.4.1 Drawings: Shop drawings shall be submitted for the belt press and it’s associated components. Scaled dimension drawings, layout drawings, anchor and installation details, and details of major components will be included. Electrical and utility requirements will be described.

1.4.2 Product Data: Manufacturer’s technical data and installation instructions will be submitted along with pertinent data to substantiate material compliance with project requirements.

1.4.3 Operation and Maintenance Manuals: One (1) copy of installation and operational manuals complete with operation and maintenance instructions will be submitted including an arrangement drawing for layout/installation.

PART 2 - PRODUCTS & EQUIPMENT

2.1 ACCEPTABLE MANUFACTURERS:

2.1.1 All materials and components used in the manufacture of the belt press shall conform to and/or exceed specifications and quality standards.

2.1.2 All suppliers and manufacturers will be subject to compliance with the quality and utility requirements of OR-TEC, Inc. in the production of the HP 1000 Belt Press.

2.2 OPERATIVE CONDITIONS:

Waste Activated Sludge

Item

Requirements

Sludge Feed Rate

180 - 240 lbs. dry solids / hr

Sludge Feed Concentration

1-2%

Polymer Dosage

8 – 12 lbs. polymer / ton dry solids

Capture

93 – 95%

Final Cake

Min. 14 – 18%

2.3 EQUIPMENT SPECIFICATIONS

MODEL: HP 1000 Belt Press - 1.0 Meter

Construction

304 Stainless Steel

Length

6’ – 5”

Width

5’ – 3” including gear drive

Height

3’ – 9”

Weight

2,000 lbs.

Belt Wash

13 gallons/min. @ 80psi

Belt Length

172”

Belt Width

39”

2.4 PRODUCT DESCRIPTION

2.4.1 BELT PRESS:

1. The belt press shall be constructed of non-corrosive materials. The belt tracks by means of cone rollers. Sludge is introduced onto an upwardly sloping belt with dams on three sides comprising a sludge feed box.

2. The sludge feed box shall be sealed with polypropylene plastic skirting to prevent leakage of the sludge from the feed box. The sludge first travels on a sloping belt where de-watering occurs by gravity. This gravity de-watering is aided by a series of roll over ploughs and a dispersion roller. Next, the sludge travels through a pressing zone where the water is further removed by pressure. A doctor blade removes sludge from the belt by its scraping action against it. The belt continues on through a washing station where it is thoroughly cleaned prior to its returning to the de-watering zone.

3. All non-drive roller bearings are encased in stainless steel housings which are fitted into the roller end caps. Stainless steel snap rings hold the bearing location on the shaft. Seals fitted with a stainless steel spring provide protection from water and solids intrusion. All bearings are sealed and greased for life. (Rated life is 100,000 hours). The coned roller bearings, housed in nylon, are fitted as above. Drive roller bearings are fitted to stainless steel housings which, in turn, are fitted to the roller side plates. These bearings are sealed and greased for life as well. They are also self-aligning.

4. The belt is driven through a series of neoprene covered rolls by an adjustable variable speed drive. Speed is adjusted by means of a variable speed gear motor housed in a cast iron enclosure.

5. The belt wash station shall be equipped with a stainless steel spray bar containing stainless steel spray jets. The spray bar incorporates a hand-operated cleaning brush and contaminant discharge port to prevent clogging of the spray nozzles, thus eliminating the need to remove the spray bar for cleaning.

6. Wash water and pressate collection trays collect the wash water and pressate and deliver them to a drain. Collection trays are fabricated from stainless steel.

2.4.2 FLOCCULATION TANK:

1. A stainless steel flocculation tank with a minimum working capacity of 40 gallons will be provided. Sludge enters at the bottom of the tank and discharges near the top onto the belt press.

2. The flocculator is fitted with two (2) 4" reverse truss propellers. The propellers and shaft are made from stainless steel.

3. The tank will be fitted with internal deflectors which will eliminate dead areas.

4. The flocculator is driven by a variable speed gear motor.

2.5 MATERIALS:

2.5.1 BELT PRESS:

1. Support frame is constructed of tubular stainless steel with accurately machined positions for the roller frame assembly.

2. All trays, covers and guards are 304 stainless steel. The back, top and side covers are fabricated to ensure wash down of the press without having to strip the unit while, at the same time, preserving compliance with safety regulations regarding machine guards.

3. The roller frame plates shall be 304 stainless steel.

4. The drive roller shall have welded stainless steel end caps centered on a stainless steel machined shaft. The roller will be covered with neoprene rubber to 70 shore hardness. Bearing housings will be machined stainless steel fitted with self-aligning sealed bearings.

5. Idler rollers will have welded and machined stainless steel bearing and seal housings and machined stainless steel shafts with end slots for location on the roller frame plates. Adjustments are made by a machined stainless steel threaded bar through the shaft that is supported on the adjusting bracket fixed to the roller frame plates. Bearings are sealed and greased for life. Rollers are covered with neoprene rubber to 70 shore hardness.

6. Pressure rollers shall have welded and machined stainless steel bearings and seal housings along with machined stainless steel shafts with end slots for location on the roller frame plates. Adjustments are made by a machined stainless steel threaded bar through the shaft that is supported on the adjusting bracket fixed to the roller frame plates. Bearings are sealed and greased for life. Rollers are covered with neoprene rubber to 70 shore hardness.

7. Coned or tracking rollers will be machined nylon with bearing and seal end cones and shall have machined stainless steel shafts with end slots for location on the roller frame plates. The top roller is aligned by means of a threaded adjustment fixed to the end of the shaft. This adjustment is positioned with brackets fixed to the roller frame plates and secured by locking nuts. All related components are stainless steel. Bearings are sealed and greased for life. The horizontal section is supported by needle bearings.

8. The de-watering belt is made of woven polyester with stainless steel joiners connected by nylon coated stainless steel lacing.

9. Doctor blades are machined U.H.M.W. bolted to the stainless steel frame and adjusted by balanced weights at both ends of the frame to ensure that the blade rests firmly against the de-watering belt. The doctor blade frame is supported by adjustable stainless steel brackets located on the roller frame plates.

10. Drive motor: Type Lenze or Equal, 3/4 hp with 1-1/2" hollow shaft. Standard speed selection is 4-17 rpm. The gearbox is located on the drive roller and its bearing housing which are fixed on the roller frame plates.

Castings shall be machined, dipped in zinc enriched primer (one coat, min. DFT 1 mil.), assembled, degreased, spray painted with second coat of blue stainless steel impregnated water based paint (min. DFT 1.5 mil.). Primer and paint shall be by Haptic or approved equal.

11. The belt washing system is a self-cleaning, hand operated, 1-1/2" manifold system. It is manufactured from 304 stainless steel.

12. Gravity drainage area is sealed with polypropylene skirting.

13. Adjusters and fasteners are all stainless steel.

14. Ploughs are machined U.H.M.W. deflectors positioned across the gravity drainage zone. There are two (2) rows of deflectors to provide roll over of the sludge. The PVC roller is positioned directly after the deflectors to provide a gentle squeezing of the sludge for release of surplus water. A stainless steel frame holds the deflectors and roller. This frame is secured to side guards and can easily be removed.

2.5.2 FLOCCULATION TANK:

1. The tank and flocculator mount will be stainless steel.

2. An FNPT drain line shall be provided on the side of the tank.

3. Sludge will overflow onto the inlet chute from the tank.

2.5.3 FLOCCULATOR:

1. Flocculator shall be fabricated stainless steel, vertically mounted, with stub end shaft keyed to suite hollow shaft in the variable speed gear box. Gearbox type: Lenze or Equal, 0.5 hp, 50-245 RPM.

Paint specifications as above.

2.5.4 INLET CHUTE:

1. Inlet chute shall be stainless steel.

2 Inlet chute receives floc from 90 degrees around the circumference of the flocculation tank and fans it out across nearly the entire width of the belt. The chute is equipped with vanes or diverters.

2.5.5 SLUDGE PUMP:

1. Type: Progressive cavity . Duty: 400 - 2,400 gph

Positive displacement progressive cavity with a minimum of one stage. The pump will be compact and close-coupled in design (or bare shaft design directly connected to the specified drive). The gearbox will be sized for a minimum service factor or 1.5 and designed to absorb a maximum thrust load of no less than two times pump thrust load.

2. The pump design will allow the suction port to rotate in 90 degree increments perpendicular to the pump centerline. The pump casting will be cast iron with clean out ports on each side. The castings will be free of sand holes, blow holes and other such defects. A drain plug is located in the suction casting.

3. Suction and discharge flanges shall be raised face 150 lb. Flanges meeting ANSI B16.5 standards and casing shall be tapped to accept appropriate gages. The bearings will be sized to provide a minimum service life of 50,000 hours when operating at the rated capacity and head. The bearing housings are sealed with a double bearing seal on both sides of the cartridge housing. The housing is so designed that it can be removed without dismantling the pump or suction piping.

4. The rotor shall be AISI D-6 tool steel machined and hardened to 62-64 Hrc and treated for corrosion protection (316SS may be substituted for tool steel). To prolong service life, a non-porous fissure free coating is applied which diffuses deep into the base metal. Chrome plating is not acceptable due to hydrogen embrittlement of hardened metals.

5. The stator shall be vulcanized in a metal tube and have a shore hardness of 70. It shall be Buna N and will extend beyond the stator sleeves, forming a collar to prevent the material from contact with the metal stator sleeve.

6. Universal joints are the type that use an oversized hardened bolt and companion bushing assembly. These parts are hardened to 70 and 74 HRc respectively. The joint is so designed that only replacement of the bolts and bushing is required, not of the drive shaft or coupling rod. U joints are packed with high quality synthetic grease and are protected by an elastomeric sleeve secured by two stainless steel bands. This positive seal prevents the ingress of liquid into the joint area. The U joint is further equipped with a stainless steel cover to provide a guarantee of 10,000 operating hours. Each joint is designed to transmit the maximum torque at the maximum speed and at the maximum pressure rating of the pump.

7. The pump shaft is manufactured of solid chrome steel bar stock that is coated with a metalized surface exceeding 75 Hrc (Chrome plating is insufficient. Hollow drive shafts are not acceptable due to the settling of material in the area which affects rod movement, thus increasing wear on bearings and joints.)

8. The shaft also incorporates a plug-in arrangement that expedites disassembly and eases maintenance. This design allows quick replacement of the rotating assembly through the gland area without disturbing the suction piping or pump drive. Disassembly shall be front pull out design, allowing the rotor, both AU@ joints and the shaft to be removed as one unit.

9. The stuffing box is removable if modification is desired. It will be of

sufficient size and design to incorporate packing or mechanical seals as specified.

10. Construction materials for the casing can be cast iron. The shaft can be chrome alloy steel and the rotor tool steel, 62-64 Hrc.

11. Maximum operating speed of the pump shall be 240 rpm. Minimum motor size shall be 5 hp, 4 pole design. The unit is operated by a variable frequency drive within a range of 60 Hz. Motor shall have class F insulation and will be protected from high temperature damage by PTC thermistors in each motor phase winding. Service factor: 1.15.

12. The pump shall be close coupled to a gear reducer with a speed range of 56 - 558 RPM and a 5 hp, TEFC 1750 RPM, 3 phase, 60 hz, 230/460 V.

Paint specifications as above.

2.5.6 POLYMER DOSING SYSTEM:

1. OR-TEC BLEND 500P shall be a complete package that is capable of automatically pumping, metering, activating and feeding the emulsion polymer as a solution. The system will be manufactured with corrosion resistant material.

2. The system will include one emulsion polymer metering pump that is capable of pumping 1.83 gallons of emulsion per hour.

3. Dilution water will be controlled by a solenoid and regulated by a rotometer.

4. An activation, blending, mixing and retention system will be incorporated into the body of the unit. The point of injection of the emulsion polymer will be fitted with a Cormaic injector. This prevents contamination of the polymer feed line and also ensures precise metering of the chemical at a controlled head. The retention/mixing vessel provides sufficient retention with gentle mixing of the activated solution. The electrical requirement for the system is 120 vac.

2.5.7 DRY CAKE CONVEYOR:

1. Formed box style horizontal/elevating conveyor. Bed shall be 10' in length

2. Drive unit: 90 F.P.M. speed reducer roller drive. Frame will be constructed from stainless steel. Belt will be 12" wide and is 120# PIW USDA / FDA approved white PVC COS x FS with stainless steel lacing.

3. Drive shall be 2 H.P. TEFC motor with shaft mounted reducer.

4. Conveyor shall be supported on welded stainless steel square tube supports on 10' 0" centers.

5. Bearings shall be nickel plated.

2.5.8 WASH WATER PUMP:

1. Type: Jacuzzi centrifugal pump.

2. The pump shall be capable of delivering 18 gpm at 80 PSI. It shall be driven by a 2.0 hp motor at a maximum of 2,900 rpm.

3. Pump is painted with Sherwin Williams, JACBLUE#F75LT2 (GIT212F75). Surface preparation is by de-greasing. No primer is used. Finish is by spray painting one coat.

4. Inlet is 1 1/4" female NPT. Outlet is 1" female NPT.

2.5.9 CONTROL PANEL:

1. The control panel shall be a NEMA 12 enclosure and shall contain all electrical controls, wires, starters, terminals, relays, overloads, VFDs, fuses and labels required for operation of the belt press and ancillary equipment described herein.

2. The front of the control panel door shall include a main disconnect breaker switch (power on/off). In the off position all power to the control panel shall be off.

3. The front of the control panel door shall also include the following switching. All switch functions shall be clearly indicated by suitably engraved labels;

1. System on pushbutton/off pushbutton

2. System green/on and red/fault lights

3. Belt Press hand/off/auto switch

4. Belt Press green/running light

5. Belt Press red/fault light

6. Flocculator hand/off/auto switch

7. Flocculator green/running light

8. Flocculator red/fault light

9. Sludge Pump hand/off/auto switch

10. Sludge Pump green/running light

11. Sludge Pump red/fault light

12. Wash water pump hand/off/auto switch

13. Wash water pump green/running light

14. Wash water pump red/fault light

15. Conveyor hand/off/auto switch

16. Conveyor green/running light

17. Conveyor red/fault light

18. Polymer system hand/off/auto switch

19. Polymer system green/running light

20. Polymer system red/fault light

21. E-stop pushbutton

22. Hours running meter

23. Where applicable external speed pots/digital speed controllers will be fitted to the control panel door

4. The control panel emergency circuit shall immediately shut down all equipment and a red fault light will come on under the following conditions;

1. Pressing E-stop pushbutton on control panel

2. Pulling emergency pull cable surrounding belt press

3. Belt press limit switches being activated by belt tracking to a mis-aligned position

4. The unexpected de-energizing or overloading of any circuit within the control panel

2.5.10 BELT TRACKING:

1. Dewatering belt shall be automatically tracked by an Or-Tec ATS.

2. Sensors shall be spring loaded and contain mercury tilt switches.

3. Belt shall be moved by means of an electromechanical linear actuator.

4. System shall be controlled by proprietary Or-Tec software control device and housed in the control panel.

2.5.11 SKID:

1. All the above will be mounted, piped and wired on a stainless steel skid.

OPTIONS:

Op1. AUGER:

1. Type: Or-Tec. The dry cake auger shall be a screw auger with a stainless steel body

and 9” stainless steel screw

2. Gear Reducer: Lenze shaft mounted gear drive SAF67, 60RPM. Motor shall be wash down duty.

3. The auger shall be 10’ in length.

Op2. DRY CAKE PUMP:

1. The dry cake pump shall be a Progressive cavity, Inc, It is a positive displacement progressive cavity type with a minimum of two stages. The pump is of compact, close-coupled design (or bare shaft design directly connected to the appropriate drive). The gearbox shall be sized for a minimum service factor of 1.5.

2. The pumps design shall include a hopper type suction casing with an integral extension tube.

3. Discharge flanges will be raised face 125 lb. Flanges meeting ANSI B165 standards. Casing will be tapped to accept appropriate gages. The bearings shall be sized to provide a minimum service life of 50,000 hours when operating at the rated capacity and head. The housing is so designed that it can be removed without dismantling the pump or suction piping.

4. The rotor shall be AISI D-6 tool steel machined and hardened to 62-62 HRc and treated for corrosion protection. To prolong service life, a non-porous and fissure free coating is applied which diffuses deep into the base metal. (Chrome plating is not acceptable due to hydrogen embrittlement of hardened metals).

5. The stator shall be vulcanized in a metal tube and have a shore hardness of 70. The stator shall be Buna N and shall extend beyond the stator sleeve ends, forming a collar to prevent material from contact with the metal stator sleeve.

6. Universal joints are the type that use an oversized hardened bolt and companion bushing assembly. These parts are hardened to 70 and 74 HRc respectively. The joint is so designed that only replacement of the bolts and bushing is required, not of the drive shaft or coupling rod. U joints are packed with a high quality synthetic grease and are protected by an elastomeric sleeve secured by two stainless steel bands. This positive seal prevents the ingress of liquid into the joint area. The U joint is further equipped with a stainless steel cover to provide a guarantee of 10,000 operating hours. Each joint is designed to transmit the maximum torque at the maximum speed and at the maximum pressure rating of the pump.

7. The pump shaft is manufactured of solid chrome steel bar stock that is coated with a metalized surface exceeding 75 HRc (Chrome plating is insufficient. Hollow drive shafts are not acceptable due to the settling of material in the area which affects rod movement, thus increasing wear on bearings and joints.)

9. The stuffing box is removable if modification is desired. It will be of sufficient size and design to incorporate packing or mechanical seals as specified.

10. Maximum operating speed of the pump shall be 240 rpm. Minimum motor size shall be 5 hp, 4 pole design. Motor shall have class F insulation and will be protected from high temperature damage by PTC thermistors embedded in each motor phase winding. Motor shall have a service factor of 1.15.

11. The pump shall be close coupled to an adjustable gear reducer with a speed range of 44 - 281 rpm and 7.5 hp, TEFC, 1750 rpm, 3 phase, 60 hz, 230/460 V motor.

Paint specifications as above.

Op3. SLUDGE PUMP / DRY CAKE PUMP THERMISTOR:

1. A temperature sensor in a stainless steel protection sleeve shall be installed in the stator of the pump. This device shall continuously monitor the temperature in the stator and switch off the pump in the event of a rise in the stator temperature. This shall prevent the pump from dry-running.

Op4. SLUDGE FLOWMETER:

1. Sludge Flowmeter. Type: Magnetic Meter. Duty: 0 – 100gpm

2. Display: LCD Current Flow/Total Flow mounted on skid beside control panel.

3. Pipe size shall be 2”

4. Installed, mounted, piped and wired on skid between sludge pump and flocculation tank.

Op5. GRINDER:

1. The in-line grinder is designed to reduce organic solids from up to 4" into a fine slurry at a rate of 100-4000 GPH. The grinder shall be vertical in-line with inlet housing clean-outs, have a D6 air hardened too steel shear plate, (4) four tungsten carbide rotating cutters and a silicon carbide mechanical seal.

2. The grinder shall have a greased lubricated bearing frame designed for top pull out without disturbing the pipe connections. It will be close coupled to a fixed speed gear motor.

Op6. TRAILER:

1. The system is mounted in a dual axle Wells Cargo or equal trailer.

2. Outside dimensions: 20' -6" L x 8' W x 7' - 5" H

3. Inside dimensions: 20' L x 7'-6" W x 6'-8" H

4. One pair of rear entry doors and one curbside entry door

5. Mechanical equipment will be wired, piped and illuminated by fluorescent

lights.

6. Provided with heater.

7. Two (2) 6' awnings.

8. Aluminum diamond plate on the inside floors and wheel wells.

9. Insulated, washable interior and exterior walls.

PART 3 - EXECUTION

3.1 INSTALLATION

3.1.1 General: Install belt press and associated components as shown on the plans

and in accordance with manufacturer=s instructions.

3.2 TESTING AND INSPECTION

3.2.1 General: Notify Owner and Engineer in writing when the installation is complete and ready for testing and start up.

3.2.2 Inspect components for proper installation, wiring and piping.

3.2.3 After sludge is available, operate all components and check for proper operation. Make necessary adjustments.

PART 4 - GENERAL TERMS AND CONDITIONS

4.1 PRICING TERMS:

4.1.1 Prices and estimated shipping dates are based upon the receipt of a Purchase Order or at least a letter of intent within 60 days from the proposal date. If not received, approval drawing schedules and shipping dates are subject to adjustment at that time.

Weights given are estimated and are provided as an aid in determining handling and construction costs.

4.1.2 The following terms of payment shall apply to the purchase of the equipment, unless alternate terms are otherwise agreed upon with

OR-TEC, Inc.:

Condition Amount of Invoice Terms

Receipt of Order 50% of Total Price Upon Receipt

Delivery of Equipment 40% of Total Price Upon Receipt

Start Up of Equipment 10% of Total Price Net 30 days

All invoices are due and payable as specified. Purchaser shall be obligated to pay said invoices even if the Purchaser is not paid by the Owner, provided the reason such nonpayment is unrelated to the performance of OR-TEC, Inc.

Warranty and service policies are limited to equipment supplied by OR-TEC, Inc. Equipment that is not integral to OR-TEC, Inc. is subject to warranty and service policies of the respective manufacturer.

4.2 CLARIFICATIONS:

4.2.1 Unless specifically mentioned in this proposal for inclusion with the proposed agreement, the aforementioned price DOES NOT INCLUDE:

Spare parts

Electrical motors, devices, controls, wiring (other than outlined)

Piping, valves, fittings, hangers or supports (other than outlined)

Equipment erection or field welding

Concrete work, grout or sealant

Polymer or any other chemical

Lubricating oil or grease

4.2.2 Seller shall use reasonable efforts to meet specified drawing schedules and shipment dates, but such dates are estimates provided only to serve as a guide to the Contractor, and not guaranteed. No liability, direct or indirect, is assumed by OR-TEC, Inc., for failure to ship on such dates. Contractor agrees to expedite issuance of the written purchase order and approval of drawings.

4.2.3 Seller retains the title and right of repossession to the equipment until the full purchase price has been paid. Purchaser will not encumber nor permit other to encumber said equipment by any liens or security instruments until the full purchase price has been paid.

4.2.4 Contractor agrees not to back charge for labor, materials or other such costs unless previously approved in writing by an authorized employee of seller.