SECTION 11192

PRIMARY CLARIFIER MECHANISM

PART 1
1.1

GENERAL

SCOPE OF WORK

Furnish, install and test one (1) circular scraper type primary clarifier mechanism including all
ancillary items and equipment as shown in the Drawings and as specified herein to provide a
fully functioning system.
It is the responsibility of the Contractor and equipment manufacturer to verify scum and influent
pipe connection locations and influent column size.
1.2

SUBMITTALS

A.

Provide submittals in accordance with Section 01330 and Section 11000.

B.

In addition to the items required under Section 01330 and Section 11000, the following
shall also be provided.
1.

Manufacturers hydraulic calculations for the sludge removal arm, identifying the
number, size, spacing of blades, and the arms cross sectional area along its entire
length.

2.

Weights and loads transmitted to equipment supports.

1.3

REFERENCES

A.

Industry standard references shall be noted, as applicable, in this specification and shall
be considered a part of this specification. This section references the latest revision of
the following documents. They are a part of this section as specified and modified.
Reference
ANSI/AGMA 6001-D97
ANSI/AGMA 2000- A88
ANSI/AGMA-2001-D04
ANSI/AGMA-6034-B92
(R1999)
ANSI/AGMA 2004-B89
(R2000)
ANSI/AGMA 6019-E89
(R1995)
ASTM A36M-03a

Title
Design and Selection of Components for Enclosed
Gear Drives
Gear classification And Inspection Handbook
Fundamental Rating Factors and Calculation
Methods for Involute Spur and Helical Gear Teeth
Practice for Enclosed Cylindrical Wormgear Speed
Reducers and Gearmotors
Gear Materials and Heat Treatment Manual
Gearmotors Using Spur, Helical, Herringbone,
Straight Bevel, or Spiral Bevel Gears
Standard Specification for Carbon Structural Steel
11192 - 1

Reference
ASTM A48/A48M-03
ASTM A536-84(1999)e1
ASTM E18-03

AISI 8620

Title
Standard Specification for Gray Iron Castings
Standard Specification for Ductile Iron Castings
Standard Test Methods for Rockwell Hardness and
Rockwell Superficial Hardness of Metallic Materials
Standard Specification for Copper-Base Alloy
Centrifugal Castings
Standard for Gearmotor, Shaft Mounted and Screw
Conveyor Drives
Alloy Steel

AISI 4150

Alloy Steel

ASTM B271-96
ANSI/AGMA 6109-A00

B.

STRUCTURAL STEEL AND WELDS

All structural steel used for equipment fabrication shall conform to the requirements of the
Standard Specifications for Steel for Bridges and Buildings and ASTM A36. All welding shall
conform to the latest standards of the American Welding Society.
C.

STRUCTURAL DESIGN

All steel structural components shall be so designed that the stresses developed under the
specified conditions will not exceed the allowable stresses defined by the latest AISC standards
and the aforementioned standards.
D.

DISCREPANCIES

Any discrepancies between the referenced specifications and this section should be brought to
the immediate attention of the Engineer. In case of a conflict between the requirements of this
section and those of the referenced specifications, the requirements of this section shall prevail.
1.4

QUALITY ASSURANCE

A.

MANUFACTURERS EXPERIENCE

Manufacturer shall be one who has been regularly engaged in the business specified herein for at
least 5 years with a registered P.E. on staff full-time. The equipment and all ancillaries shall be
designed, supplied and warranted as a unit item by a single manufacturer or vendor.
B.

WARRANTY

As specified in Section 11000.

11192 - 2

1.5

EQUIPMENT SCHEDULE

Item
Location
Sludge and scum collector with drive, motor, Primary Clarifier 1
scum baffle, weir

Equipment Number
COL 2101

1.6

SERVICE CONDITIONS

A.

Fluid temperature is expected to range from 35 to 75 degrees Fahrenheit.

B.

The equipment will be installed outdoors at a wastewater treatment plant in Durango,

Colorado at an elevation of approximately 6,470 feet above mean sea level. All
equipment furnished under this Section shall be suitable for outdoor installation.

C.

The drive unit shall be designed for continuous (24-hours per day) service.

PART 2
2.1

PRODUCTS

ACCEPTABLE PRODUCTS

Reference to a manufacturer's name and model number or catalog number is for the purpose of
establishing the standard of quality and general configuration desired. Acceptable clarifier
equipment manufacturers include:
A.

Walker Process Equipment,

B.

Envirex/Evoqua Water Technologies, LLC,

C.

WesTech Engineering Inc.,

D.

Engineer-approved equal.

2.2

GENERAL

The Primary Clarifier tank equipment shall include, but not be limited to the following:
Walkway/Bridge with handrails that extend from the perimeter of the tank to a platform at the
center of the tank. Center drive assembly with torque control, variable frequency motor and
controls. Center pier which functions as an influent pipe, feed-well, sludge removal rake arms
with blades, scum skimmer, scum baffles, scum trough, and effluent weir. The equipment shall
be suitable for use in the gravity separation of primary solids from wastewater influent.
2.3

DESIGN AND PERFORMANCE REQUIREMENTS

Each tank shall be designed and operable for the conditions listed in the following table:
Criteria
Internal diameter, feet

Value
70

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Criteria
Value
Side-water depth, feet
9.25
Minimum freeboard above high water level, feet
1
Influent column, minimum inside diameter, inches
24
Minimum continuous running torque applied at output of the drive unit, footlbs.
30,000
Minimum peak torque applied at output of the drive unit, foot-lbs.
60,000
Influent diffusion well
Diameter, feet
12
Depth below water surface, feet
3.5
Scum gates, qty
6
Maximum inlet flow, mgd (peak hour flow)
6.08
Minimum inlet flow, mgd
1.62
Maximum Total Suspended Solids Loading, ppd (maximum month)
5,577
Maximum influent head-loss at peak hour flow, inches
3
Maximum tip speed of sludge collection, feet per minute
10
Maximum drive unit motor output, horsepower
0.75
2.4

MATERIALS OF CONSTRUCTION

A.

GENERAL

Except where specifically indicated otherwise, all plates and structural members designated for
submerged service shall have a minimum thickness of 1/4". Stainless steel anchor bolts, with
necessary hex nuts and washers, shall be provided for all parts of the Clarifier mechanism to be
secured to the tank. All fasteners for the mechanism shall be ASTM A 325 high strength and Grade
5 for secondary connections, for submerged fastening hardware see the Materials table in paragraph
2.4C. Provide and install 304 stainless steel bolts for all handrails.
B.

GALVANIZING

All steel portions of the clarifier, including influent structure, drive cage, sludge collector
mechanism, skimmers, scum trough, walkway structure, and supports shall be hot dip galvanized
after fabrication and prior to shipping to the job site in accordance with the requirements of
Section 05910.
C.

MATERIALS

Component
Center column
Steel plate
Structural steel shapes
Steel tube

Material
ASTM A36M-03a
ASTM A36M-03a
ASTM A36M-03a
ASTM A36M-03a

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Component
Material
Main spur gear
Ductile iron
ASTM A536, 120-90-02
Cast iron
ASTM A48, Class 40
Forged steel
AISI 4150
Worm Gear and Shaft
AISI 8620
Ball Bearings
AISI E52100 Grade 50
Effluent troughs
Concrete (existing)
Effluent weirs
FRP, see Section 2.5
Scum baffle
FRP, see Section 2.5
Scum baffle/trough supports
FRP, see Section 2.5
Submerged fastening hardware including anchor
Type 304 stainless steel
bolts
Wiper blades
Neoprene
2.5

SCUM BAFFLE, WEIR PLATES, AND SCUM SYSTEM SUPPORT

A.

GENERAL

Fiberglass reinforced polyester resin; compression molded in matched metal die molds; provide
all required lap plates, cover plates, and support brackets. Plates fabricated from cut plate stock
with cut edges, notches, etc., will not be accepted.
B.

FIBERGLASS LAMINATE CONSTRUCTION

Sheet Molding Compound (SMC) for use in wastewater treatment systems.

C.

MATERIALS

Glass content of laminate; 20 percent plus/minus 3 percent by weight; resin fillers: 40 percent
plus/minus 2 percent of resin mixture.
1.

Final laminate thickness: Plus/minus 10 percent of nominal specified thickness.

2.

Tensile strength (ASTM D638-03): 14,000 psi.

3.

Flexural strength (ASTM D790-03): 25,000 psi.

4.

Flexural modulus (ASTM D790-03): 1,000,000 psi.

5.

Impact, notched, Izod (ASTM D256-03): 15 ft-lb/in.

6.

Barcol hardness (resin-rich surface) (ASTM D2583-95(2001)e1): 40 minimum,

average.

7.

Water absorption (ASTM D570-98): 0.2 percent at 24 hrs.

8.

Coefficient of thermal expansion, average (ASTM D696-03): 0.0000105in/in/degree F.

11192 - 5

9.
10.

D.

E.

Test coupons prepared in accordance with ASTM D618-00.

Chemical resistance: Comply with ANSI/AWWA F102-02, Type II
Classification.

CONSTRUCTION
1.

1/4 inch nominal thickness

2.

Color: White

3.

Length: Nominal 5 feet long.

4.

Mounting holes: 4 each, 2 1/2 inches square at 12 inches on center to provide a

minimum 2 inches vertical or horizontal adjustment.

5.

Mounting: -inch diameter stainless steel anchor bolts and 5 inch square
fiberglass cover plates to prevent short circuiting of water.

6.

Ends secured with 6 by 12 inch high lap plates to allow for horizontal expansion.

7.

Provide stainless steel anchor bolts.

8.

Support dimensions shall be as recommended by manufacturer and as supported

by structural calculations.

ASSEMBLY HARDWARE
1.

Stainless steel, ISS Type 304.

2.

Provide hook anchors, -inch by 6 inches by 2 inches.

2.6

EQUIPMENT

A.

INFLUENT PIER

The central influent pier shall be designed to support the drive mechanism, the sludge collection
mechanism, utility piping, access bridge and walkway. No vertical thrust load shall be placed on
any bearing that is underwater. All drive gears shall be located above water level and all gearing
shall be completely enclosed and oil lubricated. The drive cage, sludge collector arms, and
associated supports shall be designed to safely carry all loads and stresses associated with the
application of 110-percent of the peak design torque specified. PC spec, quotes, docs
B.

INFLUENT STRUCTURE
1.

The tank influent structure shall consist of the center column and the influent
diffusion/ flocculation well.

2.

The center column shall be a hollow steel cylinder with its base flanged for fixing
to the concrete floor of the tank. Its top shall also be flanged and stiffened for

11192 - 6

supporting the sludge collection mechanism, the drive mechanism, and the Access
Bridge.

C.

3.

The influent well shall be supported from the drive cage and shall rotate with it.

4.

Ports shall be provided for discharging the wastewater influent from the center
column into the influent diffusion well.

5.

Adjustable baffle gates shall be provided at the periphery of influent diffusion well.

6.

The top of the ports in the influent pier and the top of the gates in the diffusion
well shall be above the tank's maximum water surface elevation. Removable,
shallow gates shall also be provided on the influent well extending above the
maximum water surface elevation to allow scum removal. The gates shall be
designed for manual operation from the bridge.

DRIVE CAGE

Torque shall be transmitted from the drive unit to the rotating components of the mechanism by
a drive cage. The drive cage shall encompass the center column and shall be fabricated of
structural, steel shapes of sufficient strength to transmit and/or carry not less than 110 percent of
the specified peak design torque without undue deflection. The drive cage shall be bolted to the
main gear which shall rotate the cage. The drive cage shall be provided with connections for two
rake arms which shall rotate with the cage.
D.

SLUDGE COLLECTOR MECHANISM

1.

The sludge collector shall consist of two rotating fabricated steel truss rake arms,
with steel scraper blades and adjustable stainless steel squeegees. Each rake arm
shall be located parallel to the tank bottom. The steel rake arms shall be designed
to sweep the entire tank bottom clean twice with every revolution. This slowly
revolving mechanism shall collect the sludge from the tank bottom and transport
it to the sludge hopper. The complete sludge collection mechanism shall be
capable of handling the maximum total suspended solids loading as specified in
the performance requirement section.

2.

Adjustable tie rods shall support the sludge rake arms. Structural design of
adjustable tie rods shall be in accordance with AISC latest edition. Tie rods shall be
HDG.

3.

The fabricated steel rake arms shall be rigidly connected and supported by the
drive cage. They shall be three-dimensional structural steel trusses to hold the
rake arms in alignment in a vertical and horizontal plane.

4.

Sludge collectors shall be designed for balanced torque load on the center column
with no submerged bearings. The sludge collector shall be designed to operate
continuously or intermittently at a peripheral speed no more than 10 feet per
minute. The steel scraper blades shall be spaced along the rake arm to provide for
uniform sludge removal. The steel scraper blades shall be fabricated of 3/16-inch
thick steel plate. The rake arms shall be adjustable at the drive cage.

11192 - 7

E.

5.

The rake arms shall be designed to meet AISC specifications when twice the
continuous torque of the drive unit is applied as a uniform load to both arms.

6.

The adjustable squeegees shall be fabricated from stainless steel. They shall be
fastened to the rake blades with stainless steel fasteners.

7.

Except where specifically indicated otherwise, all plate and structural members
designed for submerged service shall have a minimum thickness of 1/4 inch.

8.

Two (2) rake arms with steel blades and adjustable stainless steel squeegees are
required. A skimmer counterweight shall be provided on each of the rake arms to
support the scum skimmer assembly.

DRIVE MECHANISM
1.

The drive mechanism shall be completely factory assembled and tested in the
clarifier manufacturer's shop to assure that the drive is operating properly and to
calibrate the drive control. A complete test report shall be sent to the Engineer
verifying that the drive meets the quality assurance of the manufacturer and
Engineer per this section.

2.

The drive mechanism, shall include a variable frequency drive motor, primary
worm gear reducer, pinion gear, turntable type main spur gear, drive base,
breaking pin hub coupling, drive and driven sprockets, and drive chain with guard.
The gear motor for each drive shall be suitable for operation under all weather
conditions and shall be provided with a sealed conduit box. The motor shall be
inverter duty rated at a maximum 0.75 horsepower, 460 volt, at 1750 rpm in
accordance with specification 11060.

3.

Drive mechanism components shall be designed in accordance with AGMA

standards for 24-hour continuous duty, moderate shock load, and 20-year design
gear life. The torque used in the AGMA sizing calculations shall be the minimum
continuous running torque indicated in the performance and design requirements
section. The torque rating of the drive shall be the lower of values determined
based on strength and durability calculated using the current AGMA standard.
Main and worm gear shaft bearings shall be designed for a minimum L-10 life of
100,000 hours.

4.

The variable frequency drive gearmotor shall drive a special, single reduction
intermediate worm gear reducer through a roller chain drive. The special worm
gear reducer shall be constructed of cast 40,000 psi high-duty iron and shall have
a hardened and ground alloy steel worm, which operates in a cast 40,000 psi highduty iron gear case with oil fill and drain plugs and external grease fittings. The
variable frequency drive motor shall be designed for continuous duty NEC Class I
Division II applications in accordance with the references listed in this
specification. Gears shall be AGMA Quality 8 or better. The driving and driven
gears shall be designed in accordance with ANSI/AGMA for a service factor of
1.50. The drive shall operate the steel driver and driven sprockets. After
completion of the specified field test, the converter driven shall be furnished with

11192 - 8

a sprocket set which shall provide the sludge collection header with a tip speed of
10 feet per minute.

F.

5.

A galvanized, stainless steel, or FRP chain guard suitable for all sprocket
combinations shall be provided. Provision shall be made for manual adjustment of
chain tension.

6.

The main spur gear shall be of the split type and materials shall comply with the
requirements of ANSI/AGMA 2001-D04. For inspection and maintenance of the
interior of the center column, each spur gear shall have an access opening of not
less than 24 inches in, diameter. A properly reinforced fabricated aluminum
cover plate with lifting holes shall be provided for the cover plate. If the spur
gear is steel, it shall be designed and rated in conformance with AGMA Quality 5
with a service factor of 1.5 or greater.

7.

The entire sludge collector mechanism shall be suspended from the turntable,
which in turn, shall be supported on a ball bearing assembly that uses large
diameter hardened steel bearing balls. The bearing balls shall run in full contour
raceways or in an oil bath on replaceable tempered carbon spring steel inserts
placed in annular raceways in the gear and turntable base. A felt or neoprene seal
and dust shield shall also be included with each spur gear housing to protect the
oil bath from contamination. The gear case shall be complete with an oil fill and
drain line with plugs, as well as an oil level indicator pipe. A cast iron or
stainless steel drive base shall be provided for mounting each drive unit.

TORQUE OVERLOAD PROTECTION SYSTEM

The drive mechanism shall be provided with a torque overload protection system consisting of
an electromechanical overload device and a backup shear pin with a visual load indicator
showing the load on the mechanism. The overload device shall be designed to measure thrust of
the worm gear shaft and be provided with an indicator showing the load on the mechanism. The
indicator shall be visible from the Access Bridge and shall cover the range of torque specified up
to the peak rating. The overload device shall include two switches, the first to activate a remote
alarm and the second to shut down the unit. The device shall be factory calibrated to activate the
alarm switch (normally closed) when the torque load on the mechanism reaches 120 percent of
the minimum continuous running torque and activate the main cut-out switch (normally closed)
at 130 percent of the minimum continuous running torque. The overload device shall be
enclosed in a watertight NEMA 4X housing. Each torque switch shall be NEMA 4X DPDT,
rated 5 amps at 120 volts AC. A back-up shear pin shall be provided in a shear pin sprocket on
the input shaft to the worm gear reducer. The shear pin shall be selected to break when the load
on the mechanism reaches 160 percent of the minimum continuous running torque. Rotation
direction shall be as indicated on the drawings.
G.

SKIMMER AND SCUM TROUGH

The mechanism shall be provided with one skimming arm to collect and move surface scum
from the annular space between the influent well and the scum baffle adjacent to a heavy,
fabricated steel scum trough. This trough shall be provided with a steel approach lip, which
11192 - 9

extends from the effluent weir. The skimmer arm shall include a scum deflector plate, a support
boom and a hinged aluminum blade with neoprene wiping edges. Provisions shall be
incorporated into the design of the skimming arm to permit adjustment of the skimming blade
position with respect to its penetration into the liquid within the tank. The equipment
manufacturer shall be responsible for setting the lip elevation of the scum trough in relation to
the effluent weir. The skimming mechanism shall be supported by structural steel members
rigidly fixed to one of the rotating truss arms. Skimming arms shall be designed to prevent
binding and undue deflection when in contact with the scum baffle or scum trough. Supports
shall be constructed of FRP.
H.

I.

WALKWAY AND OPERATING PLATFORM

1.

An access bridge shall be furnished for the sludge collector mechanism and shall
consist of structural steel sections interlaced for rigidity. The Access Bridge shall
be supported on the main spur gear housing, which in turn, shall be supported by
the center column support structure. The bridge shall span from tank wall to
center of tank, as shown on Drawings. The bridge shall include a 48-inch wide
aluminum grating floor walkway. The operating platform shall include an
aluminum grating floor walkway 36 inches wide circling the exposed portion of
the drive unit.

2.

The bridge shall be interlaced for rigidity, with supports designed to take thermal
expansion, contraction, and differential settlements. Walkways and platform
surfaces shall be aluminum grating and enclosed with aluminum handrails as
specified in Sections 05520 and 05530. No single piece of grating shall weigh
more than 80 pounds. Longitudinal and transverse bars shall be continuous.

3.

The walkway and operating platform shall be provided with aluminum pipe hand
railing as shown. Platform floor shall be aluminum grating. Hand railing shall be
as specified in Section 05520 and as shown on the drawings. Kick plates, 1/4
inch by 3-inch thick size, shall be provided surrounding the platform and access
bridges.

4.

The equipment walkways and the operating platform shall be designed to support,
in addition to dead load, a live load of 100 psf. Deflection shall be limited to
1/360 of span for live load or 1/240 of span for live load plus dead load,
whichever condition controls. The center operating platform shall be supported
from the center pier/drive gear.

5.

Permanent Pad Eyes shall be provided along both sides of the walkway and
around the perimeter of the platform at 10-feet maximum intervals. Pad Eyes and
supporting structural members shall be designed to accommodate a 5000-lb
impact load.

SCUM BAFFLE

11192 - 10

J.

1.

Scum baffles shall be FRP as shown on the drawings. Scum baffle fasteners shall
provide a flush surface on the face toward the interior of the tank for smooth
uninterrupted passage of the scum-scraper side wiper blades.

2.

Assembly Hardware
a.

Stainless steel, ISS Type 304.

b.

Provide hook anchors, -inch by 6 inches by 2 inches.

SPARE PARTS

The following spare parts shall be provided for the equipment specified in this Section. Spare
parts shall be tagged and stored as specified in Section 11000.
1 set, all bearings and bearing seal rings for drive unit
2 sets, all gaskets
2 sets, spur gear felt seal and replaceable bearing races.
2 sets, neoprene seal rings for sludge withdrawal manifold equipment.
PART 3
3.1

EXECUTION

GENERAL

Installation, start-up and testing shall be conducted in accordance with Section 01810 and
Section 11000.
3.2

FIELD TESTING

In addition to the installation and acceptance tests set forth in other portions of the contract
documents, the equipment furnished under this section shall be subject to the following field
performance tests. Provide all equipment and instrumentation necessary to complete the testing
procedures outlined below. Testing shall, be performed under the direct supervision of a factory
trained and certified representative. Testing of equipment shall be conducted in accordance with
the requirements of Sections 01810 and 11000.
A.

OPERATING TESTS

Each primary clarifier shall be filled with potable water to its operating level and the mechanism
operated continuously at its maximum speed for a period of not less than 48 hours. Following
the maximum speed test, the mechanism shall be operated at 25, 50 and 75 percent speeds for
continuous periods of not less than 6 hours. At no time during the operating tests shall the
equipment fail on torque overload or exhibit indications of binding or uneven operation. The
Contractor shall record torque valves as registered on the drive mechanism torque indicator and
motor amperage (all 3 phases) at 3-hour intervals.

11192 - 11

After successful completion of the fully submerged operating test, the mechanism shall be
operated at full speed with no more than 1.5 feet of water in the sedimentation tank for a period
of not less than 6 hours. The Contractor, as described above, shall take data records.
If the mechanism should fail on torque overload or, in the opinion of the Engineer, the
mechanism should exhibit indications of binding or improper adjustment, the Contractor shall
immediately halt the tests and remedy the problem. After completion of necessary repairs or
adjustments, the tests shall be repeated. Failure to successfully complete the test in six attempts
shall be considered sufficient cause for rejection.
B.

TORQUE TEST

Load test the entire collector mechanism by anchoring collector arms individually. In successive
tests, he shall demonstrate the sludge collection mechanism's (including drive unit, cage, gears
and structures) capability to withstand not less than 180 percent of the specified minimum
continuous running torque. Prior to initiating the test, the Contractor shall furnish the
Construction Manager with sketches and calculations illustrating the test procedure and
demonstrating how the specified torque will be applied to satisfy this requirement.
3.3

FIELD SERVICE

Provide the services of a factory-trained representative for the Clarifier Mechanism for a
minimum of one trip of 2 days duration to supervise final installation of the equipment. And, a
minimum of one trip of 3 days duration to supervise required field-testing and startup of the
Clarifier equipment.
3.4

TRAINING

Training shall be conducted in accordance with Section 01820 and Section 11000. Training
shall consist of a minimum of one 4-hour session addressing the theory of operation, testing,
troubleshooting, and maintenance of the system.
** END OF SECTION **

11192 - 12