City of Bossier City

Red River WWTP Expansion & Rehabilitation Project

NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

SECTION 11235
COARSE BAR SCREENS
(Influent Pump Station Red River WWTP)
PART 1 GENERAL
1.01

SCOPE OF WORK

A.

The CONTRACTOR shall furnish all labor, materials, equipment and incidentals required and
install, place in operation and field test Two (2) Coarse Bar Screens, motors and control system
at the Influent Pump Station and as specified herein. The coarse bar screen control panel shall
be combined with its associated screw washer and compactor specified in Section 11250.
Coordinate control panel requirements.

B.

Each Multi-Rake Bar Screen shall be designed and built to remove debris from the incoming
sewage by means of a bar rack that retains the debris and travelling rakes which engage the bar
rack from the front (upstream side).

C.

These Specifications are intended to give a general description of what is required, but do not
cover all details which will vary in accordance with the requirements of the equipment
application. It is, however, intended to cover the furnishing, the shop testing, the delivery and
complete installation and field testing, of all materials, equipment and all appurtenances for the
complete screening units as herein specified, whether specifically mentioned in these
Specifications or not.

1.02

RELATED WORK

A.

Yard piping, valves and appurtenances are included in Division 2.

B.

Concrete work including bases for Coarse Bar Screen Mechanisms and installation of anchor
bolts is included in Division 3, but anchor bolts shall be furnished under this Section by the
installing contractor.

C.

Painting, except as specified here, is included in Division 9.

D.

Process Instrumentation, except as specified herein, is included in Division 16.

E.

Mechanical piping, valves, pipe hangers and supports are included in the respective Sections of
Division 15.

F.

Electrical work and motor specifications, except as specified herein, are included in Division 16.

1.03

DESCRIPTION OF SYSTEMS

A.

The screening unit shall consist essentially of a bar rack, rake mechanism and chain drive,
structural frame and shall be factory assembled and tested prior to its delivery. The screening
unit shall be delivered ready for installation in its channel; it shall not require field assembly of
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

any components such as chain drive, reducer, or gears, except where partial disassembly is
required by transportation regulations or for protection of components. Also, the proposed unit
must meet the following requirements:

B.

1.

Designs using sprockets, submerged bearings, shafting below the water surface and
incorporating the use of shear pins, when the mechanism becomes overloaded, shall be
explicitly excluded under this specification.

2.

Designs employing the use of wire rope cables, hydraulic cylinder, and submersible drive
assembly shall not be allowed.

3.

All designs shall ensure that maintenance to the mechanism can be accomplished at the
operating floor level. Screens of other dimensions may require structural, mechanical,
and/or instrumentation electrical design changes which costs shall be borne by the
Contractor

Operating Conditions
1.

The below stated operating conditions are based on per unit flow rates during peak
flows.

Maximum flow
Maximum water level
Channel width
Screening width
Channel depth
Operating floor to bottom of channel

24
132
60
54.5
264
264

USMGD
inches
inches
inches
inches
inches

1.04

REFERENCE STANDARDS

A.

The equipment included in this specification shall comply with the latest edition of the
applicable codes and regulations including the following:
1.

American Society of Mechanical Engineers

(ASME)

2.

American Gear Manufacturers Association

(AGMA)

3.

National Electrical Manufacturers Association

(NEMA)

4.

American Society for Testing and Materials

(ASTM)

5.

American National Standard Institute

(ANSI)

1.05

QUALITY ASSURANCE

A.

Qualifications
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

B.

1.

The bar screen shall be the product of a single, experienced, reputable and qualified
manufacturer. The equipment shall be designed, constructed and installed in
accordance with the best practice methods, and shall operate satisfactorily when
installed.

3.

It is the responsibility of the screen Manufacturer to guarantee that the new bar screen
be compatible with the designed channel size and shall be completely operational as a
system.

4.

Bar Screens shall be CONT-FLO Type ER multi-rake bar screens as manufactured by

John Meunier, Inc., 3136 Gracedale Court, Post Falls, ID 83854, Headworks, Mahr Bar
Screen MS1 or prior approved equal.

Services of the Manufacturer Representative

1.

The system supplier shall furnish the services of competent and experienced factory
representatives who have complete knowledge of proper installation, operation and
maintenance of the equipment for a period of not less than ten (10) 8-hour days
(exclusive of travel time) in three separate visits to supervise unloading and installation
of the equipment, inspect the installed equipment, perform an initial test run, conduct
final performance testing, and provide operating and maintenance instructions to the
plant personnel.
a.

The first visit shall be for supervising the delivery, unloading, and installation of
the first bar screening unit by the Contractor and instructing the Contractor on
subsequent installation of the remaining screens and dewatering units.

b.

The second visit shall be for checking and inspecting all equipment after it is
installed.

c.

The third visit shall be to perform the initial test run, conduct final performance
testing, and provide operator training.

2.

At least two of the ten days shall be allocated solely to the instruction of plant personnel
in operation and maintenance of the equipment. This instruction period shall be
scheduled at least ten days in advance with the Owner and shall take place prior to plant
start-up and acceptance by the Owner. The final approved copies of operation and
maintenance manuals must have been delivered to the Engineer prior to scheduling the
instruction period with the Owner.

3.

If there are difficulties in operation of the equipment due to the manufacturer's

fabrication or Contractor's installation, additional service shall be provided at no change
in Contract Price or Time.

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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

1.06

SUBMITTALS

A.

Copies of all materials required to establish compliance with the specifications shall be
submitted in accordance with the provisions of the General Conditions and Section 01300.
Submittals shall include at least the following:

B.

1.

Certified shop and erection drawings showing all-important details of construction,

dimensions and anchor bolt locations.

2.

Descriptive literature, bulletins, and/or catalogs of the equipment.

3.

Complete master wiring diagrams, elementary or control schematics, including

coordination with other electrical control devices and suitable outline drawings shall be
furnished for approval before proceeding with manufacturer. Provide suitable outline
drawings showing such details as are necessary to locate conduit stub-ups and field
wiring.

4.

The total weight of the equipment including the weight of the single largest item.

5.

Complete motor and drive data.

Test Reports
1.

C.

Description of test procedures and equipment.

Operation and Maintenance Data

1.

Complete operating and maintenance instructions shall be furnished for all equipment
included under these specifications. The maintenance instructions shall include
troubleshooting data and full preventative maintenance schedules, and complete spare
parts lists with ordering information.

D.

Submit the Manufacturers Certificate of Installation, Testing and Instructions as specified in

Section 01640.

E.

In the event that it is impossible to conform to certain details of the specifications due to
different manufacturing techniques, describe completely all non-conforming aspects.

1.07

OPERATING INSTRUCTIONS

A.

Operating and maintenance manuals shall be furnished. The manuals shall be prepared
specifically for this installation and shall include all required cuts, drawings, equipment lists,
descriptions, etc. that are required to instruct operation and maintenance personnel unfamiliar
with such equipment. The number and special requirements shall be as specified in Section
01730.

B.

A factory representative of all major component manufacturers, who has complete knowledge
of proper operation and maintenance, shall be provided for two (2) days to instruct
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

representatives of the Owner and the Engineer on proper operation and maintenance. If there
are difficulties in operation of the equipment due to the manufacturer's design or fabrication,
additional service shall be provided at no cost to the Owner.
1.08

TOOLS AND SPARE PARTS

A.

One (1) set of all special tools for normal operation and maintenance shall be provided. All such
tools shall be furnished in a suitable steel tool chest complete with lock and duplicate keys.

B.

Spare Parts shall be properly bound and labeled for easy identification without opening the
packaging and suitably protected for long term storage.

C.

The screen manufacturer shall furnish their recommended spare parts. A spare parts list shall be
included with the shop drawings.

1.09

PRODUCT HANDLING

A.

All parts shall be properly protected so that no damage or deterioration will occur during a
prolonged delay from the time of shipment until installation is completed and the units and
equipment are ready for operation.

B.

All equipment and parts must be properly protected against any damage during a prolonged
storage period at the site.

C.

Factory assembled parts and components shall not be dismantled for shipment unless
permission is received in writing from the Engineer.

D.

Finished iron or steel surfaces not painted shall be properly protected to prevent rust and
corrosion.

E.

Each box or package shall be properly marked to show its net weight in addition to its contents.

1.10

WARRANTY

A.

All equipment supplied under this section shall be warranted for a period of one (1) year by the
the screen manufacturer. Warranty period shall commence on the date of Substantial
Completion of the project.

B.

The equipment shall be warranted to be free from defects in workmanship, design and
materials. If any part of the equipment should fail during the warranty period, it shall be
replaced and the units restored to service at no expense to the Owner.

PART 2 PRODUCTS
2.01

GENERAL

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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

A.

All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness
and to be especially adapted for the service to be performed. Ample room for inspection,
repairs and adjustment shall be provided.

B.

All necessary anchor bolts, nuts and washers shall be furnished by the contractor for installation
by the Contractor. Anchor bolts, nuts and washers shall be 316 stainless steel.

C.

Stainless steel nameplates giving the name of the manufacturer, the rated capacity, head, speed
and all other pertinent data shall be attached to each pump, motor and control panel.
1.

2.

3.

4.

5.

Structural frame
Side frame thickness
Dead plate thickness
Front housing thickness

0.3125 in
0.1875 in
0.08 in

Bar rack
Bar spacing
Screen rack width
Bar cross section shape
Bar thickness
Bar depth
Bar height

0.5 in
54.5 in
Rectangular
0.5 in
2.0 in
145 in

Multi-rake mechanism
Quantity of rakes
Rake tines thickness
Rake travel speed
Raking frequency

10
0.5 in
Low speed
Low speed

Chains driving system

Chain pitch
Minimum breaking load
Sprockets diameter
Number of teeth

6 in
24,000 lbf
15.7 in
8 teeth

Drive unit
Main Power Supply
Drive Motor
Standard efficiency
Enclosure
Class B design, Class F insulation

5.6 ft/minute
19 sec.

460 V, 3 Ph, 60 Hz
1.0 HP
Explosion-proof

11235-6

City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

Classification
Motor Service Factor
Reducer Service Factor
2.02

STRUCTURE

A.

Structural Frame

Class I, Division I, Group D

1.15 minimum
1.4 minimum

The structural frame shall be of self-standing design and consist of two (2) side assemblies to
support the main drive shaft, bearings and gearmotor. All its components shall be of rugged
design and be of sufficient strength to withstand all normal application loads without any
adverse deflection.
1.
The structural frame shall be made from two side frames made from thick plates. The
side frames shall include inside structural cross beam (over the maximum water level
only).
2.

A dead plate shall close the back side of the frame. The base plate, on which the bar
rack is bolted, shall be 0.39 in thick.

3.

Sealing flaps attached to the frame sides shall ensure efficient sealing arrangement to
prevent screenings from bypassing the screen zone.

4.

The frame shall be anchored to the operating floor by means of 0.32 in thick angle
supports.

5.

The front housing (above the operating floor) shall consist of removable metal sheeting.
Housing sheets shall be bolted to the structural frame.

2.03

BAR RACK, RAKE AND CLEANING MECHANISM

A.

Bar Rack

B.

1.

The bar rack shall be composed of equally spaced parallel bars.

2.

Bars shall be welded at both ends to support members which are bolted to structural frame.

3.

Bars shall be curved at the bottom of channel to maximize the amount of screenings
reclaimed by the rakes.

4.

Bars shall extend up to minimum 8 in above maximum water level. From the top end of
bars, screenings are lifted on a dead plate terminating in a knife-edge at a height
suitable for discharge.

5.

The bar rack shall be easily removable and capable of withstanding 3 ft of water level
differential.

Multi-Rake Mechanism
The multi-rake mechanism shall remove the screenings from the bar rack and lift them out of water
up to the discharge chute.
11235-7

City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

C.

1.

Robust raking tines shall be of thickness and width sufficient to enter the bar rack
without jamming.

2.

Tines plate shall be mounted on a U-channel assembled with holders connected to

chains on each side. Holders shall be made of 0.24 in thick plates.

3.

Quantity and speed of rakes shall be sufficient to satisfy with the solids loading capacity
required by the application.

Chains Driving System

Raking action shall be performed by the rotation of two lateral continuous chains travelling inside
chain guides on the inside face of structural frame.

D.

1.

Chains shall be of roller type with hollow pins, sleeves and flanged rollers.

2.

The main drive shaft shall have a diameter sufficient to carry any operating load of the
unit without distortion.

3.

Two driving sprockets shall be bolted onto the drive shaft with the pitch adapted to the
chain.

4.

The drive shaft shall be carried by two take-up upper bearings mounted on top of
structural sides in tensioning slots to adjust chains drive system and provide optimal
chains system adjustments. Tensioning slots are bolted to the frame.

Chain Guides
Chains guides shall be integrated to the structural side frame and allow chains to slide inside.

E.

1.

Chains guides shall be designed to push rakes against the bar rack and to avoid chain to
protrude into the flow.

2.

The bottom chain guiding shall be done by a revolving adjustable round guide. No
moving parts (sprockets, lower bearings, shaft) shall be located below water surface.

3.

They shall be composed of bolted U-shaped bent plates as straight parts and semicircular welded plates as round parts. These plates are 0.25 in thick.

Drive System
The main drive shafts shall be driven by means of speed-reducing gearboxes and motors. The motors
shall not be overloaded under normal operating conditions and shall be designed for heavy duty 24
hours per day service duty.
1.

The motor shall have an external protection to meet the local environmental conditions
(corro-protected). The motor shall also be of the normal starting torque and low starting
current type.

2.

The gear reducer shall be of the parallel-helical type. It shall include anti-friction
bearings with high overhang load properties, and double lip temperature oil seals riding
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

on a precision ground shafts. Gears shall be made of hardened, heat treated forged
steel as per AGMA II standards. The gearing shall be oil lubricated. The gear reducer
shall have an internal and external protection to meet the local environmental
conditions (corro-protected).
F.

Scraper Mechanism and Discharge Chute

Just above the screenings discharge point, a pivoting scraper shall clear the trash from each rake
down to the discharge chute.
1.

The scraper rotates on dedicated bearings. The scraper blade shall be removable and
made of polyethylene plate.

2.

The scraper shall get back in position by gravity. Side arms shall sit on rubber bumpers.

2.04

MATERIALS OF CONSTRUCTION

2.05

Structural frame
Housing sheets
Discharge chute
Side sealing flaps
Bar rack
Rakes
Drive shaft
Chain links and sleeves
Chain rollers
Chain pins
Drive sprockets
Chain guides
Screws, bolts and anchors
CONTROLS

A.

Main Control Panel

AISI 304 stainless steel

AISI 304 stainless steel
AISI 304 stainless steel
AISI 304 stainless steel
AISI 304 stainless steel
AISI 304 stainless steel
AISI 304 stainless steel
Extra strong carbon steel
Extra strong carbon steel
Carbon steel
High strength Cast iron
AISI 304 stainless steel
AISI 304 stainless steel

1.

The main control panel for the coarse bar screen and the associated screw washer and
compactor shall be combined in to a single main control panel for both pieces of
equipment. Refer to Section 11250 for screw washer and compactor requirements and
description of operation. The control panel shall meet the applicable requirements of
Section 16901.

2.

The control system supplied by the manufacturer shall provide total automatic machine
operation with protection against overload conditions which might damage the
equipment.

3.

The following basic components shall be assembled in a NEMA-12 enclosure, pre-wired

to identified terminal blocks. Panel hook up and installation shall be made on site by the
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

contractor. The power supply shall be 480 Volts, 3-Phase, 60 Hz. The panel shall be
located in a conditioned space outside of the Explosion Proof rated area.
a.

Main circuit breaker type disconnect switch sized for the application with front
mounted operating handle and door interlock. Provide required control
transformer with secondary side fuse protection.

b.

Reversing magnetic starters with thermal and magnetic overload protection.

c.

Circuits and relays to start and stop the cleaning and conveying mechanism.

d.

Current transformers and monitor relays to monitor motor current and protect
the system from overload conditions.

e.

Door mounted OFF - AUTOMATIC - MANUAL TEST selector switch for the screen
and washer compactor which when turned to the "MANUAL TEST" position shall
produce a start signal, energizing the mechanism for one cleaning cycle only.
This position of the selector shall be spring loaded, so that the selector can
return to AUTO position after release.

f.

Door mounted alarm reset pushbutton.

g.

Indicating lights for the following status points:

1.

Power On.

2.

Bar Screen Run Status

3.

Washer Compactor Run Status

4.

Bar Screen Overload/Over-Travel Alarm

5.
6.

Washer Compactor Overload Alarm

Channel High Level Alarm

h.

Level display indicating differential level between upstream and downstream of

the screen.

i.

Dry contact outputs rated a minimum of 3 Amps at 120Vac shall be provided to

connect to the plant control system for the following status points. Contacts
shall close when status points are true.
1.

Power On

2.

Bar Screen in Auto

3.

Washer Compactor in Auto

4.

Washwater Valve in Auto

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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

j.

5.

Bar Screen Run Status

6.

Washer Compactor Run Status

7.

Bar Screen Overload Alarm

8.

Washer Compactor Overload Alarm

9.

Channel High Level Alarm

Provide isolated, self-powered, 4-20mA output signals to connect to the plant

control system for the following status points.
1.

k.

B.

Differential water level across the screen.

Dry contact output to signal screens operating in parallel to initiate a cleaning

cycle.

Operation
1.

Refer to SECTION 16904 CONTROL DESCRIPTIONS AND SYSTEM PROGRAMMING for a

description of the interfaces with the plant control system.

2.

The screen shall be initiated to start based upon the following conditions:
a.

Differential water level: Rakes start shall be initiated when the water level
difference between the front and the back of the screen reaches the previously
mentioned set point. This system shall only be in service when the mode
selector is set to "AUTO" and shall initiate a start signal when a high flow and/or
a large screenings volume condition occur.

b.

The system shall accept a dry contact input from screens operating in parallel to
initiate a start signal when differential level is detected by other screens.

c.

Timer: The start of the timed sequenced is initiated by a sequence adjustable

timer.

d.

High water level: This circuit shall override all other start signals. This H.W.L.
signal shall make the screen run continuously. The H.W.L. start control shall
only be in service when the mode selector is on AUTO. As the water level
drops below the high level set point, the screen shall initiate a complete
cleaning cycle.

3.

Screen Blockage: In the event of screen blockage, the control system shall stop the
motor and sound an alarm. The reverse mode to try and clear the blockage is possible
with manual mode only.

4.

Thermal Protection: When the selector switch is on AUTO or MANUAL mode, the
protection circuit shall cut the power off to the motor and to the control circuit of the
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City of Bossier City

Red River WWTP Expansion & Rehabilitation Project
NE WWTP Upgrade & Rehabilitation Project
Conformed - July 2012

motor starter, should and overheating or short circuiting of the motor occur. An
overload/blockage indicating light shall be provided. The overload protection shall be
sized according to the motor nameplate full load rating. This component shall be
equipped with a manual reset and pad-lockable stop button.
5.

C.

E.

Auxiliary Control Station: Each screen shall be supplied with a local control station located near
the unit. The following components shall be assembled and pre-wired to identified terminal
blocks.
1.
AUTO / OFF / MANUAL Operation selector switch c/w spring loaded return from
"MANUAL" to OFF
2.

Manual "FORWARD - REVERSE" selector switch with spring loaded return to "OFF"
position

3.

EMERGENCY STOP Push button, pad-lockable

Differential Level Transmitters

1.

F.

Jamming Protection: A current metering system shall protect the spiral screw against
jamming. A continuous current reading (CMT) shall be monitored by an adjustable relay
(CMR). The motor starting current being higher than the setting of the CMR, the
jamming protection shall be put out of service by a time delay (TCM), for a
predetermined adjustable motor start period, long enough to allow the current to fall
below the CMR setting when it reaches its normal full load level. This component shall
be equipped with an alarm indicator light and a manual reset push button. Should this
system be energized, the overload/blockage light shall be activated.

Provide an ultrasonic type differential level transmitter for each screen to measure the
differential water level across the screen. Provide required mounting brackets to mount
level sensors in the channel. Mounting brackets and hardware shall be stainless steel.

2.
Refer to Section 16902 for instrument requirements.
High Level Float Switches:
1.

Provide optical type high level float switch to detect high water levels upstream of each
screen.

2.

Refer to Section 16902 for float switch requirements.

PART 3 EXCUTION
3.01

INSTALLATION

A.

Installation and operation shall be in accordance with instructions provided by the

Manufacturer.
END OF SECTION
11235-12