DaimlerChryslerConstruction Standards
AME-PT Plants
Date: 06/12/06
SECTION 15196 – COOLANT FILTRATION
PART 1 - GENERAL
1,1 SUMMARY
1.2 DEFINITIONS 1.3 SUBMITTALS 1.4 QUALITY ASSURANCE 1.5 DELIVERY, STORAGE AND HANDLING 1.6 SELF CONTAINED COOLANT SYSTEMS 1.7 APPROVED SUPPLIERS
PART 2 – DESIGN AND PRODUCT
This Section includes the following:
2.1 Drag Conveyors/Settling Tanks/Overflow Pre-Conveyors
2.2 Flow-through Pre-Conveyors
2.3 Wedge Wire Drum Filters
2.4 Pressure Filters
2.5 Vacuum Filters (Primary, Polish and Washer Filtration)
2.6 Washer Final Filters
2.7 Secondary Bag Filters
2.8 Back Flushing Polish Filters
2.9 Pumps 400 g.p.m. and greater (Filter/System, System Supply and Polish Filter)
2.10Pumps 399 g.p.m. and less (Filter/System, System Supply and Polish Filter)
2.11Self-priming Pumps (Filter and Flush Supply)
2.12Vortex Pumpback Pumps
2.13Vertical Wet Well Chopper Pumps
2.14Lubrication System.
2.15Liquid Level Control System (Water-soluble systems)
2.16Liquid Level Control System (Straight oil systems)
2.17Tramp Oil Removal (quote as an option)
2.18Fine Particulate Removal Systems (quote as an option)
2.19Mist Collection Connections
2.20Electrical Controls
2.21Coolant Heat Exchanger
2.22Coolant Refrigeration System
2.23Pit Sump Systems
2.24Work Platforms
2.25Tank Top Access, Cover Plates and Handrail
2.26Eyewash/Shower Stations
2.27Chip Hoppers
2.28Painting
2.29Heating
2.30Tank and Pipe Installation
2.31Piping
2.32 Supervision/Service
2.33 Training
2.34 Sound Level/Noise Abatement
2.35 Assembly and Run-off
PART 3 – DOCUMENTATION
3.1DRAWINGS
3.2COORDINATION
3.3OPERATION AND MAINTENANCE MANUALS
3.4TOTAL MAINTENANCE SPARE PARTS LIST
3.5DELIVERY
3.6PAYMENT TERMS AND CONDITIONS
3.7INSTALLATION
3.8LESSONS LEARNED
Related Sections include the following:
1. Division 15 Section 15050 "Basic Mechanical Materials and Methods"
2 .Division 15 Section 15185 "Cutting Machine Coolant Piping"
3 .Division 15 Section 15122 "Meters and Gages"
4. Division 15 Section 15110 "Valves"
5 .Division 15 Section 15060 “Hangers and Supports”
6 .Division 15 Section 15815 “Metal Ducts.”
7. Division 15 Section 15889 “Oil Mist / Dust Collection Systems”
8. Division 15 Section 15970 “Machine Tool and Process Equipment Installation”
9. Division 05 Section 05500 “Metal Fabrication”
10. SMI-148 “Maintenance of Water Based Coolant”
11 Division Section 15980 “Total Maintenance Spare Parts”
12. Division Section 15710 “Heat Exchangers”
13. AMEPT Controls Specifications
1.2 DEFINITIONS
Accessory: Device that adds effectiveness, convenience, or improved appearance to a piece of equipment that is sometimes shipped loose.
Gage: Device or machine designed and intended to check part features or a device to measure temperature or pressure of fluids or gases.
Fitting: Fitting installed on or attached to utilities connecting to equipment which allows for equipment removal or modification.
Roughing-In: Installation of piping and supports for the equipment prior to the final alignment of the equipment.
Support: Device normally anchored or resting on foundations or building construction, for supporting and securing equipment to foundations or floors or other structural members.
1.3 SUBMITTALS
Drawings & Manuals: The OEM shall submit one (1) hard copy and (1) electronic set of prints for DaimlerChrysler‘s approval within four (4) weeks of receiving a purchase order. Upon job completion, the OEM shall ship one (1) set of as built drawings with the machine, and supply one CD to the responsible AMEPT Engineer. Three (3) sets and one (1) CDof operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. shall be shipped directly to the plant, per AMEPT instructions.
DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.
All floor plan drawings mustcomply with machine tool drawing requirements andshow the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine.Provide “ML” style drawings per DaimlerChrysler Machine & Tool Specifications. Clearance for service & maintenance, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. Show required clearances for control panel door swings and filteraccess. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.
The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to DaimlerChrysler prior to altering the machine, ancillary equipment or orientation.
All engineering drawings shall be developed using theAuto CAD software and version agreed upon in the CAA. All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.
Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.
The OEM shall provide a recommended spare parts list of this machine. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS electronic format (contact DCX plant engineer). Note- spare parts shall be available from sources within the country where the equipment is intended for use.
The OEM shall provide Control electrical and fluid power drawings for all field wiring diagrams for field-installed wiring or lube or pneumatic tubing(refer to Controls Specifications for Details).
FMEA’s shall be submitted to DaimlerChrysler within four (4) weeks after the filtration supplier receives DaimlerChrysler’s purchase order.
The filtration supplier shall be responsible for complete review and verification of all flows, machine tool data, layouts, heat loads and any other information that may be mentioned in this specification.
All installation submittals of control panels must show code clearances such as 42 inches from the front of a panel to any obstruction and 48 inches between the fronts of two opposed facing panels.
All exit ways must have a minimum clearance of 28 inches.
1.4 QUALITY ASSURANCE
Fabricator Qualifications: A firm experienced in producing metal fabrications similar to those indicated for this Project and with a record of successful in-service performance, as well as sufficient production capacity to produce required units.
Any and all sub-contractors to be used on this project must be approved by DaimlerChrysler.
Installations shall comply with all national and local codes.
Installations shall comply with DaimlerChrysler standards.
Provide survey results from datums and benchmarks.
1.5 DELIVERY, STORAGE, AND HANDLING
A designated contractor prior to unloading must inspect all equipment and all damage must be reported on the shipper and to the appropriate DaimlerChrysler project engineer.
All equipment delivered to the project site must be unloaded promptly and placed in its intended
rough in location or at a minimum inside a facility which provides protection from the elements.
All equipment must be inspected to assure that the equipment drawings are included with the
shipment, which identifies the required information to allow a quick and accurate installation.
1.6SELF CONTAINED COOLANT SYSTEMS
Where CNC style machine tool equipment is being purchased, they have the option of providing pricing for self contained coolant filters and / or dry chip discharges for gondola pick up and / or central chip evacuation.
Machine tool supplier shall provide drawings and details with proposal of such devices for review by DaimlerChrysler. Details shall include utility use filtration clarity, chip discharge height, chip crushers and all alternate cost for this option.
Suggested suppliers include MAYFRAN or KNOLL. A machine tool suppliers standard will be considered for evaluation.
1.7APPROVED SUPPLIERS
MANN + HUMMEL 7070 International Drive Louisville, KY 40258
FILTRA SYSTEMS 23900 Haggerty Road Farmington Hills, MI 48335
Knoll 313 W. Girard Madison Heights, MI 48071
PART 2 - DESIGN AND PRODUCT
2.1DRAG CONVEYORS/SETTLING TANKS/OVERFLOW PRE-CONVEYORS
Each tank (where practical) shall have its own single drag conveyor, which shall include its own drive motor, gear reducer, shear pin hub assembly and cantinary type take-up
All drag tanks 10’0” and wider, shall include dual conveyors. Each conveyor shall have a separate drive.
Tanks shall be fabricated with ¼” thick, mild steel side and back plates and 3/8” thick abrasion resistant (AR) or ½” mild steel bottom and ramp plates.
Discharge Ramp Angles shall not exceed 45 degrees on pre-conveyors and shall not exceed 55 degrees on other ramps.
Drag tank ramps shall be covered with 14 gauge mechanically fastened metal.
The conveyors shall use S-458 chain with cotter pins. It shall be the supplier's responsibility to size the flights for this conveyor, using 3-inch by 3-inch x ¼ inch angle flights as a minimum size, which shall be attached in a manner for ease of removal without having to part the chain and/or shut the rest of the system down.
The return flight or the chain inside the tankage shall be supported and/or carried the entire length of the tankage back to the radius that returns the flight toavoid contact with the bottom of the tank.
These drag conveyors shall be driven by an Ohio (or approved equal) heavy-duty industrial type gear reducer drive unit. The Drive shall be sized for a minimum of two (2) times the worse case of the following:
- Chip Volume
- Weight (conveyor assembly and chip load)
The drive unit shall incorporate a shear pin/shear hub design safety mechanism on the drive shaft with an electronic means of detecting shear pin failure (no-rotate prox. switch)
Conveyors must use reducers, drive sprockets and RC chain with bolt-on/removable guarding. (No direct mounting of reducers to head shaft,except for 3 ft. and 4 ft. wide filters or except for Central Coolant Filters ( 38 sq. ft. limit ).
Conveyor drive guards shall be provided with solid steel housing (painted with DC spec. yellow) with expanded metal observation area (painted black).
All drives shall include a flight scraper. Flight scrapers shall be designed to facilitate conveyor reverse operation and be an adjustable design.
All bearings shall includelube lines ran to a lube blocks which are easily accessible from the plant floor or from filtration supplier provided platforms. Automatic lubrication system to provide proper lubrication to all vertical turbine pumps. Provide lube for life bearings or zerk fittings with proper lube on other slow speed shafts. Refer to Controls Specification- Lubrication.
These drag conveyors shall not move any faster than 36-inches per minute and shall have their own on/off automatic selector switch, forward and reverse jog.
These tanks shall include an inlet box with welded piping to protect the drag from large foreign objects suggested spacing 4 inches between sides of pipes and low liquid level limit switch/sensing device. Each inlet box must have deflection plates to distribute chips evenly across the pre conveyor or drags and away from tail shafts and sprockets. Provide pumps as specified elsewhere in this specification.
A drain shall be included at the low point of the tank with a 3” lockable full port ball valve with Viton seats and seals and cam lock connection.
Each drag conveyor shall discharge chips at a minimum of 6’-0” above the filter room floor.
Under normal operating conditions, the drag conveyor shall discharge chips into a chip-processing conveyor (supplied by others). The filter supplier is required to supply a removable chip discharge chute with hinged cover and a manual diverter gate so that if the chip-processing conveyor becomes inoperable, the chips can be discharged into a chip gondola. Filter supplier must provide a tilting gondola with wheels, and fork receiver slots. Size must match existing plant standard and be verified with the plant engineer requesting the quote.
Sealed and bolted in place doors for flight access shall be provided on all conveyor ramps.
The sidewalls of the drag tank are to be designed with a maximum deflection of 1/4” when completely full of liquid.
If the drag tank ramps must be shipped loose, the ramps shall incorporate locating holes, insuring proper alignment between the ramp and the tank. The field weld between the ramp and tank shall include a continuous lap weld (by others).
If a primary conveyor is incorporated into the filtration system, the drag tank design shall support the weight of the primary conveyor with brim full of liquid.
The drag tanks shall be designed with adequate volume in order to eliminate overflow of coolant. All drag tanks shall be sized to contain 100% of the coolant volume of the filter system including a 6” foam allowance.
All multiple drag tank systems shall include a minimum of two dirty tank equalizer pipes and valves. Each of the equalizer pipes shall be sized to flow 50% of the system flow rate.
The coolant overflow from the clean tank shall enter the dirty tank on the pump side of the separating wire panel. Additionally, the coolant shall flow over a dispersion plate/baffle prior to entering the drag tank in order to prevent pump cavitation.
All filtration systems that handle chips (6” or longer) that have the potential to bundle shall have a hinge belt conveyor.
A compression plate shall be designed for a hinged belt conveyor to prevent tumbling of chips down the ramp.
2.2FLOW-THROUGH PRE-CONVEYORS (Required for aluminum chips) OVERFLOW PAN TYPE PRE-CONVEYORS (required for steel chips)
The Pre-conveyors shall be designed for heavy-duty industrial type use and shall conform to the following minimum conditions:
These conveyors shall be designed, built, for “piggy-back” installation over the respective Vacuum Filter or wedge wire filter. The only exception being on aluminum chips an endless permanent belt conveyor is acceptable as the pre conveyor ahead of any Primary filter.
Tanks shall be fabricated with ¼” thick, mild steel side and back plates and 3/8” thick abrasion resistant (AR) or ½” mild steel bottom and ramp plates.
Each pre-conveyor shall be designed to remove 150% of the stated chip volume with a maximum speed of 36” per minute.
The chips from the pre-conveyor shall not discharge on the ramp of the main chip drag conveyor. All chips shall bypass the main drag conveyors and discharge directly into the chip processing equipment or gondola.
The sidewalls shall be designed with a maximum deflection of 1/4” when completely full of liquid.
Discharge Ramp Angles shall not exceed 45 degrees.
Pre-Conveyors shall have a safety overflow with high level sensing in case of plugged screens or media
This should be a flow-through type primary with 1/8” perforated screens for non stringy iron chips, pan conveyorfor steel stringy chips or permanent belt pre-conveyor for aluminum chips.
Perforated screen conveyors shall receive the coolant and chips and remove the chips from the coolant and drain the coolant, along with a minimal amount of chips, into the tank.
The Pre-conveyor shall be designed and fabricated to eliminate splashing and/or misting at the point of contact to the liquid in the tank.
All components of the Pre-conveyor shall be readily available for repairs.
This unit shall incorporate a heavy-duty drive mechanism and other characteristics as described in the drag conveyors including (but not limited to):
- Pan conveyors for curly or stringy chips
- Cantinary for non curly or non stringy chips
- Shear hub protection
- Wear strips as required on return carriers (shear alloy minimum 3/8” thick)
- No direct mounting of drive to head-shaft
- Flight scraper
- Guarding
- 2 x drive sizing
- Forward/reverse jog
- Automated lube system for bearings
- Mist collection connections
- Ramps being covered with 14 gauge solid metal
- Same cover plate material and design as drag tanks.
2.3WEDGE WIRE DRUM FILTERS (Iron Filters)
Wedge wire drum filters are acceptable for filtering of iron coolant systems. These filters shall be complete with settling tank and drag out chain and flight conveyors. The tanks shall be fabricated with minimum ¼” thick mild steel and with 3/8” thick abrasion resistant (AR) or ½” mild steel bottom and ramp plates. Discharge ramp shall not exceed an angle of 55 degrees.
Tank construction is to follow same specifications called out for Section 2.1 - Drag Conveyors.
The wedge wire drums shall be designed to withstand a vacuum of 15” mercury with a set point of 10” mercury.
The wedge wire drums shall be designed to catch material with cake greater than 50 microns with nominal wedge wire opening sizes of 200-250 micron. Flux rate shall be as scheduled in “Appendix A” of this specification.
The wedge wire drums shall be removable without draining the coolant from the tank. Each drum shall have an isolation valve to allow removal during production.
Each drum shall index via a pneumatic cylinder with ratchet mechanism based on the vacuum reaching 7"of mercury or by default every 12 hours whichever occurs first.
The OEM shall verify each isolation valve position for the drum filters at DaimlerChrysler site prior to the initial fill of the system.
Provide pumps as specified elsewhere in this specification.
2.4PRESSURE FILTERS