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DaimlerChrysler Construction StandardsAME-PT Plants

Date: 12/06/06

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-Conveyors2.2 Flow-through Pre-Conveyors2.3 Wedge Wire Drum Filters2.4 Pressure Filters2.5 Vacuum Filters (Primary, Polish and Washer Filtration)2.6 Washer Final Filters2.7 Secondary Bag Filters2.8 Automatic Back Flushing Filters2.9 Pumps 400 g.p.m. and greater (Filter/System, System Supply and Polish Filter)2.10 Pumps 399 g.p.m. and less (Filter/System, System Supply and Polish Filter)2.11 Self-priming Pumps – Portable Filter Pumpout Pumps2.12 Vortex Pumpback Pumps2.13 Vertical Wet Well Chip Shredding Pumps2.14 In-Floor Pumpback Systems2.15 Above Floor Pumpback Systems2.16 Lubrication System.2.17 Liquid Level Control System (Water-soluble systems)2.18 Liquid Level Control System (Straight oil systems)2.19 Tramp Oil Removal (quote as an option)2.20 Fine Particulate Removal Systems (quote as an option)2.21 Mist Collection Connections2.22 Electrical Controls2.23 Coolant Heat Exchanger2.24 Coolant Refrigeration System2.25 Pit Sump Systems2.26 Work Platforms2.27 Tank Top Access, Cover Plates and Handrail2.28 Eyewash/Shower Stations2.29 Chip Hoppers2.30 Painting2.31 Heating (for washer filters)2.32 Piping2.33 Supervision/Service

2.34 Training2.35 Sound Level/Noise Abatement2.36 Assembly and Run-off2.37 Coolant Testing Procedure for PPM

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Date: 12/06/06

PART 3 – DOCUMENTATION

3.1 COORDINATION3.2 TOTAL MAINTENANCE SPARE PARTS LIST3.3 PAYMENT TERMS AND CONDITIONS3.4 INSTALLATION3.5 LESSONS 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

1.2.1 Accessory: Device that adds effectiveness, convenience, or improved appearance to a piece of equipment that is sometimes shipped loose.

1.2.2 Gage: Device or machine designed and intended to check part features or a device to measure temperature or pressure of fluids or gases.

1.2.3 Fitting: Fitting installed on or attached to utilities connecting to equipment which allows for equipment removal or modification.

1.2.4 Roughing-In: Installation of piping and supports for the equipment prior to the final alignment of the equipment.

1.2.5 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

1.3.1 Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for DaimlerChrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.



Date: 12/06/06

1.3.2 DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.

1.3.3 All floor plan drawings must show 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. Clearance for service, 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. 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.

1.3.4 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.

1.3.5 All engineering drawings shall be developed using the Auto CAD software and version agreed upon in the CAA. All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.

1.3.6 Operation and 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.

1.3.7 The OEM shall provide a recommended spare parts list for all of the supplied machines. 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).

1.3.8 Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.

1.3.9 Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire

1.3.10 FMEA’s shall be submitted to DaimlerChrysler within four (4) weeks after the filtration supplier receives DaimlerChrysler’s purchase order.

1.3.11 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.

1.3.12 All installation submittals must show code clearances such as 42 inches from front of a panel to any obstruction and 48 inches from the fronts of two opposed facing panels.

1.3.13 All means of egress between equipment must have a minimum of 28 inches.

1.3.14 Upon delivery of all equipment and prior to final payment, the successful supplier will supply DaimlerChrysler engineering with complete as built drawings of the entire system as supplied and as installed.



Date: 12/06/06

1.3.15 Filtration supplier shall designate all utility hook-ups 4 weeks after receipt of purchase order and up date as required (i.e.: water, air, gas, etc.) (Refer to Appendix 6 of Machine & Tool Specifications)

1.4 QUALITY ASSURANCE

1.4.1 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.

1.4.2 Any and all sub-contractors to be used on this project must be approved by DaimlerChrysler.

1.4.3 Installations shall comply with all national and local codes.

1.4.4 Installations shall comply with DaimlerChrysler standards.

1.4.5 Provide survey results from datum’s and benchmarks to equipment.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 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.

1.5.2 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.

1.5.3 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.

1.5.4 Delivery of all component parts and for this system will be coordinated through the DaimlerChrysler engineering designed field representative. No deliveries will be made until all is cleared through this representative and under his /her direction.

1.5.5 Delivery will mean that the component has been unloaded at the DaimlerChrysler facility. The successful supplier will as quickly as possible, after receipt of a purchase order, supply DaimlerChrysler engineering with a timetable for delivery of component parts for the system.

1.5.6 The delivery of any and all component parts for this system will be clearly marked as to what

system it is for.

1.5.7 Each item will have the following information visible on its exterior upon delivery: Supplier's job number DaimlerChrysler's purchase order number DaimlerChrysler brass tag number Attention: (to be determined)

1.5.8 The supplier, at his earliest possible time, will supply DaimlerChrysler engineering with a timetable of events for this entire job based on the required delivery dates.



Date: 12/06/06

SELF CONTAINED COOLANT SYSTEMS

1.6.1 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.

1.6.2 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.

1.6.3 Suggested suppliers include MAYFRAN or KNOLL. A machine tool supplier’s standard will be considered for evaluation.

1.7 APPROVED SUPPLIERS

MANN + HUMMEL 7070 International Drive Louisville, KY 40258

FILTRA SYSTEMS23900 Haggerty RoadFarmington Hills, MI 48335

Durr Ecoclean – Henry Filters1350 Van Camp RoadP.O. Box 859Bowling Green, OH 43402

Knoll 313 W. Girard Madison Heights, MI 48071

PART 2 - DESIGN AND PRODUCT

2.1 DRAG CONVEYORS/SETTLING TANKS/OVERFLOW PRE-CONVEYORS

2.1.1 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

2.1.2 All drag tanks 10’0” and wider, shall include dual conveyors. Each conveyor shall have a separate drive.

2.1.3 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.

2.1.4 Discharge Ramp Angles shall not exceed 45 degrees on pre-conveyors and shall not exceed 55 degrees on other ramps.

2.1.5 Drag tank ramps shall be covered with 14 gauge mechanically fastened metal.



Date: 12/06/06

2.1.6 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.

2.1.7 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 to avoid contact with the bottom of the tank.

2.1.8 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)

2.1.9 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)

2.1.10 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. maximum limit). All chain sizes and lengths must be labeled exterior of the drive guard but on the equipment.

2.1.11 Conveyor drive guards shall be provided with solid steel housing (painted with DC spec. yellow) with expanded metal observation area (painted black).

2.1.12 All drives shall include a flight scraper. Flight scrapers shall be designed to facilitate conveyor reverse operation and be an adjustable design.

2.1.13 All bearings shall include lube lines ran to 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.

2.1.14 All oil filled reducers to have site glasses for monitoring the oil levels in the reservoir. Normal acceptable range shall have a green transparent tape over normal operating range.

2.1.15 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.

2.1.16 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.

2.1.17 A drain shall be included at the low point of the tank with a minimum 3” lockable full port ball valve with Viton seats and seals and cam lock connection with cap. All drain lines are to be flush with the bottom of the tank.

2.1.18 Each drag conveyor shall discharge chips at a minimum of 6’-6” above the filter room floor.

2.1.19 The drag conveyor shall discharge chips into a chip gondola. All chip discharge chutes are to have a flexible plastic curtain that extends 6” into the chip hopper. Filter supplier must provide a



Date: 12/06/06

false bottom tilting gondola with wheels, and fork receiver slots. Size must match existing plant standard and be verified with the plant engineer requesting the quote.

2.1.20 Sealed and bolted in place doors for flight access shall be provided on all conveyor ramps.

2.1.21 The sidewalls of the drag tank are to be designed with a maximum deflection of 1/4” when completely full of liquid.

2.1.22 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).

2.1.23 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.

2.1.24 The drag tanks shall be designed to hold 100% of the coolant with a 12” foam allowance. All drag tanks shall be sized to contain 100% of the coolant volume of the filter system, distribution piping and pumpback tanks.

2.1.25 All multiple drag tank systems shall include a minimum of two dirty tank equalizer pipes with isolation valves. Each of the equalizer pipes shall be sized to flow 50% of the system flow rate. All interconnecting piping supports are to be pre-mounted to the filter system for easy installation. No supports to the floor.

2.1.26 The coolant overflow from the clean tank shall enter the dirty tank on the pump side of the separating wire panel if pumps are located in the drag tank (example: pressure filter or dirty flume flush systems). Additionally, the coolant shall flow over a dispersion plate/baffle prior to entering the drag tank in order to prevent pump cavitation.

2.1.27 All filtration systems that handle chips (6” or longer) that have the potential to bundle shall have a hinge belt conveyor.

2.1.28 A compression plate shall be designed for a hinged belt conveyor to prevent tumbling of chips down the ramp.

2.1.29 Provisions must be included to prevent coolant from dripping on the floor or any other piece of equipment.

2.1.30 Direction flow arrows are required for all belts and chains

2.2 FLOW-THROUGH PRE-CONVEYORS (Required for aluminum chips) OVERFLOW PAN TYPE PRE-CONVEYORS (required for steel chips)

2.2.1 The Pre-conveyors shall be designed for heavy-duty industrial type use and shall conform to the following minimum conditions:

2.2.2 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.

2.2.3 Permanent belt pre-conveyors are to have belt wash cleaning facilities. The belt wash coolant supply piping is to include a wye strainer with minimum 30 mesh and a pressure gauge with ball valve and be easily accessible and removable for cleaning.



Date: 12/06/06

2.2.4 All permanent media pre-conveyor belts shall incorporate an auto-tracking device to ensure that the media is properly aligned within the tank.

2.2.5 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.

2.2.6 Each pre-conveyor shall be designed to remove 150% of the stated chip volume with a maximum speed of 36” per minute.

2.2.7 Each conveyor shall discharge chips at a minimum of 6’-6” above the filter room floor.

2.2.8 The chips from the 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 a chip gondola. All chip discharge chutes are to have a flexible plastic curtain that extends 6” into the chip hopper. Filter supplier must provide a false bottom tilting gondola with wheels, and fork receiver slots. Size must match existing plant standard and be verified with the plant engineer requesting the quote.

2.2.9 The sidewalls shall be designed with a maximum deflection of 1/4” when completely full of liquid.

2.2.10 Discharge Ramp Angles shall not exceed 45 degrees.

2.2.11 Pre-conveyors shall have a safety overflow with high level sensing in case of plugged screens or media

2.2.12 A permanent belt flow-through type primary conveyor with bolted down (recessed bolt heads) wedge wire support panel structure for non stringy iron and aluminum chips and a hinge pan conveyor for steel stringy chips.

2.2.13 Permanent belt flow-through type primary conveyors MUST be able to operate with the belt removed in the case of a torn or damaged belt. The HMI is to have a selector switch for either operating in a ‘Belt’ or ‘No Belt’ condition.

2.2.14 Wedge wire with permanent belt conveyors shall receive the coolant/chips and remove the chips from the coolant and drain the coolant, along with a minimal amount of chips, into the tank.

2.2.15 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.

2.2.16 All components of the pre-conveyor shall be readily available for repairs.


2.2.18 Provisions must be included to prevent coolant dripping on the floor or any other piece of equipment from the permanent media, discharge chute, ramp or any other component of the system.


2.2.20 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



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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. Permanent media conveyor for aluminum and/or non stringy iron chips

2.3 WEDGE WIRE DRUM FILTERS (Iron Filters)

2.3.1 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.

2.3.2 Tank construction is to follow same specifications called out for Section 2.1 - Drag Conveyors.

2.3.3 The wedge wire drums shall be designed to withstand a vacuum of 15” mercury with a set point up to 10” mercury.

2.3.4 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.

2.3.5 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.

2.3.6 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.

2.3.7 The OEM shall verify each isolation valve position for the drum filters at DaimlerChrysler site prior to the initial fill of the system.

2.3.8 Provide pumps as specified elsewhere in this specification.



2.3.11 The chips from the conveyor discharge directly into a chip gondola. All chip discharge chutes are to have a flexible plastic curtain that extends 6” into the chip hopper. Filter supplier must provide a false bottom tilting gondola with wheels, and fork receiver slots. Size must match existing plant standard and be verified with the plant engineer requesting the quote.

2.3.12 A drain shall be included at the low point of the tank with a minimum 3” lockable full port ball valve with Viton seats and seals and cam lock connection with cap. All drain lines are to be flush with the bottom of the tank.



Date: 12/06/06


2.4 PRESSURE FILTERS (Use only where scope of work identifies for specific applications)

2.4.1 Provide pressure filters for filtering coolant to a “super clean” grade for applications as designated or where this method provides the best available technology.

2.4.2 The coolant tanks shall include separate clean and dirty compartments designed to receive clean coolant from a central system or dirty coolant from honing or grinding operations. The dirty compartment shall be designed to hold a minimum of 7 minutes of total system flow and the clean compartment shall hold two consecutive index cycles of total system flow. Ref. Appendix A for flux rate.

2.4.3 The filter shall be a flat bed style with a liquid seal, o-ring or air seal. The filtration system shall be sized for a flux rate per scheduled “Appendix A” of this specification.

2.4.4 Provide an isolation valve with metered bypass to bypass this filter during the media index cycle.

2.4.5 (Note: bypass will dump directly back to settling dirty tank to keep pumps from deadhead condition)

2.4.6 The inlet of each pressure filter shall include an automatic and a lockable manual valve.

2.4.7 Provide a drain valve and air purge to empty the pressurized section to allow for quick indexing of media. Valve seats and seals must be Viton or Teflon suitable for coolant planned for use on the system.

2.4.8 During index cycle, the pressure vessel must be adequately blown down with air in order to minimize coolant carry-off by the disposable media and chips.

2.4.9 During index, the permanent belt media shall be cleaned by using clean coolant with a minimum pressure of 50 psi and/or brush.

2.4.10 Provide pumps as specified elsewhere in this specification.

2.4.11 All filters utilizing roll media shall include media installation diagrams for both the disposable and permanent media. The diagram shall be located near the rewinder of the filter.

2.4.12 All pressure filters must include dirty media rewinders with a re-useable core.

2.4.13 All pressure filters shall index based on pressure with a timed over-ride.

2.4.14 Each filter shall include a clean media holder with reusable cores with alignment collars.

2.4.15 In the case of seal failure of the pressure filter, the filter must divert any coolant and by-pass back to the dirty tank. Upon any failure, the pressure filter must include an alarm for an over pressure fault above and beyond those alarms called out elsewhere in these specifications.

2.4.16 Pressure filter shall be built with an easily removable upper dome providing access to the belt seal and internal structure / media support, unless determined by the DCX Eng. that it is not required.

2.4.17 Belt seal shall be of a solid elastomer mounted in an upper dome or lower structure support. The Belt seal must be mechanically fastened. (No adhesive accepted)



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2.4.18 Carrier belt to include a molded-in seal material to provide a “new” seal at each index.

2.4.19 If a proprietary “upper dome structure” of the pressure filter is used, it shall be pivoted or guided for accurate alignment of belt seal after each index.

2.4.20 Each pressure filter inlet shall have a flow balancing valve, or orifice plate with a direct reading flow meter to accurately set the flow rate through the filter.

2.4.21 The bypass line must have a balancing valve or orifice plate to provide an accurate flow rate around the filter during a media index. (This is required so as not to starve the clean coolant system serving other equipment.)

2.4.22 The pressure filter shall have a tank constructed of a minimum of ¼ inch thick mild steel and a minimum 3/8 inch thick bottom, pressure vessel i.e. upper dome shall be rated for a minimum 125 psig and constructed of material as required to meet this criteria. Note: no code pressure stamp is required for areas that experience a 15 psig or less differential.

2.4.23 The inlet on all pressure filters shall have a dispersion plate. The dispersion plate shall be designed to minimize localized chip build-up.

2.4.24 Permanent belt media will be quoted in the base bid with capabilities inherent within to superimpose disposable media with minimal disruption.

2.4.25 Two upper dome pressure switches shall indicate initial index as well emergency high-pressure failure.



2.4.28 All chip discharge chutes are to have a flexible plastic curtain that extends 6” into the chip hopper.


2.5 VACUUM FILTERS (Primary, Polish and Washer Filtration)

2.5.1 Vacuum filters shall be quoted in permanent and/or disposable media configurations per the Project Scope of Supply.

2.5.2 Design must be such that the swarf and chips shall be automatically discharged in the DaimlerChrysler standard hopper at a discharge height of 6’-6” above the plant floor. All chip discharge chutes are to have a flexible plastic curtain that extends 6” into the chip hopper. Filter supplier must provide a false bottom tilting gondola with wheels, and fork receiver slots. Size must match existing plant standard and be verified with the plant engineer requesting the quote.

2.5.3 Discharge Ramp angles shall not exceed 45 degrees where conveyors are used to transport chips.

2.5.4 All multiple vacuum filter tank systems shall include a minimum of two dirty tank equalizer pipes with isolation valves. Each of the equalizer pipes shall be sized to flow 50% of the system flow rate. All interconnecting piping supports are to be pre-mounted to the filter system for easy installation. No supports to the floor.



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2.5.5 Filter discharge swarf and chips shall be as dry as possible to minimize coolant carry-off.

2.5.6 Minimum coolant operating levels in Vacuum Filters shall be 2’-6” above any floor type media bed filter septum and 2’-0” above any elevated media bed vacuum chambers with a minimum of 12” above the top of pipe inlet to horizontal pump or 12” above the bottom of the lowest pump impeller on the highest installed pump, whichever is greater. Refer to retention times in flux rate tables for additional requirements.

2.5.7 Vacuum Filters shall have a minimum of 1’-0” freeboard, without overflow, after shutdown and drain back and at this level, shall include sufficient capacity to contain the Clean Tank volume.

2.5.8 Clean Tanks shall be sized for one (1) minute or two consecutive indexes, whichever is longer, minimum useable volume and shall include the following features:

10% re-fill line with an automatic valve, manual isolation valve and orifice. Clean tank overflow box with overflow piping towards rear of vacuum filter tank

between a baffle plane and near any new media entry so as not to cause erosion of the filter cake from the media.

Clean tanks shall be designed to prevent vortexing during index. Clean tanks above 250 gallon useable capacity shall have a sloped bottom (1/8”

per foot minimum) sloped towards the vacuum break piping and drain connection side to allow flushing and cleaning. Low point drains connection to the filter tank. Drain connection shall include as a minimum 3 inches port ball with lockable lever handle and cam lock connection with cap. All drain lines are to be flush with the bottom of the tank.

Tank top hinged inspection door (18” x 18” minimum, larger per OSHA if used for access.)

Ladder for access to the inspection door for clean tanks over 4’-6” high above the filter tank top. Access ladders shall have handrails extending 3’-0” above the clean tank top. Access ladders shall have safety cages where required by OSHA.

The clean tank refill line shall include an auto-valve that is controlled by an adjustable tuning fork level switch to prevent continuous filling during operation. The ejector flow needs to be discharged into the bottom of the clean tank to allow for aeration. The auto-valve is to open during a filter index and remain open until the coolant level reaches the high level tuning fork.

Filter system pumps are to be sized as if there was a continuous 10% clean tank make-up.

The clean tank make-up flow rates are not to be included when calculating the required filtration area.

2.5.9 Clean Tanks shall include low level and OK to Index level switches.

2.5.10 All Vacuum Filters shall provide continuous, uninterrupted filtered coolant supply.

2.5.11 Under no circumstances, including system shutdown and drain back, shall the liquid in the dirty tank/filter tank be allowed to flow into the clean tank or overflow out of the tank. The overflow of the clean tank shall be designed to be a minimum 6” above the dirty tank.

2.5.12 All vacuum media filters shall have wedge wire plate as the filter septum. Wedge wire plates shall have a minimum of 40% open area. Flux rate shall be designed per “Appendix A” of this specification. Flux rates are to be calculated based on open area of the wedge wire plates in conjunction with the open area of the filter belt/media. Septum area calculations for flux rates cannot include screen angle frames or side angle supports for conveyor chain or seal area.



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2.5.13 Wedge wire plates are to be removable for inspection or replacement. Except for 3 ft. and 4 ft. wide filters or except for Central Coolant Filters 38 square feet of plate or less.

2.5.14 All floor type vacuum boxes shall have maximum allowable openings on the ends for clean out. Clean-outs shall be bolted and gasketed type (2 minimum per filter) Except for 3 ft and 4 ft. wide filters or except for Central Coolant Filters 38 square feet of plate or less.

2.5.15 The clean outs shall be designed so there is no lip protruding up from the bottom of the vacuum chamber. This is to facilitate cleaning of the box.

2.5.16 A drain shall be included below the filter septum complete with a minimum 3” lockable full port ball valve with Viton or Teflon seals and seat and a Cam Lock connection with cap. All drain lines are to be flush with the bottom of the tank.

2.5.17 Vacuum Filter Tanks shall be fabricated with a minimum 3/8” mild steel ramp and bottom with a minimum 1/4” thick mild steel side and back plates. The bottom plate of the filter unit shall be designed so that it is rigid enough for rigging with a rigger special located at each end of the tank.

2.5.18 Filter Tank shall include an inlet velocity diffuser to prevent incoming dirty flow from disturbing the filter bed.

2.5.19 Filters “4 ft.” wide shall use X-348 or S-348 Conveyor chain and Filters “6 ft.” and “8 ft.” wide shall use X-458 or S458 Conveyor Chain. If X-type chain is used it is not recommended that any reverse jog option is used since this could cause the chain to separate.

2.5.20 If X-Chain is used, a flight must be inserted in every link so the chain cannot separate.

2.5.21 Alternate conveyor chain ( C-55 or D662) may be proposed on filters 4 ft. and less in width on washers, grinders and/ or honing operations on roll media applications with reasoning substantiated in bidders proposal. In which case , 3/8 ‘ X 1 ½” minimum cold roll steel flights must be used and spaced at every 2nd chain pitch (approx. 3”)

2.5.22 All flights for vacuum media filter must utilize T-Bar flights constructed of cold roll steel. Angle iron flights are not acceptable.

2.5.23 Two flights are required on lead-in and lead-out of filter septum to promote positive sealing.

2.5.24 Vacuum Filters drive units shall incorporate a shear pin/shear hub design safety mechanism on the drive shaft with electronic detection of shear pin failure. 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. maximum limit).

2.5.25 Gear reducers shall not be mounted directly on the head shaft on 6 and 8 ft. wide filters.

2.5.26 All vertical turbine pump bearings shall be tubed to lube blocks and have an automated lube system to provide proper lubrication. Provide lube for Life bearings or Zerk fittings with proper lube on other slow speed shafts. Refer to Controls Specification –Lubrication.

2.5.27 Vacuum set point shall not exceed 10-inches mercury but the filter system shall be designed for 20-inches mercury and to be tested at wet runoff.

2.5.28 All Vacuum Filters and associated piping shall be constructed for freestanding installation on the plant floor.



Date: 12/06/06

2.5.29 The filter units shall include any and all gages, pressure switches, and any other component required to make the filters fully automatic with the ability to troubleshoot the filters during their operating time.

2.5.30 Ejector Suction Lines shall include sight flow indication as well as unions and isolation valves and 20-40 Mesh screen wye strainer with blow down to facilitate ejector removal for maintenance. A Vacuum gauge shall be provided on the suction leg. All ejectors shall be Penberthy.

2.5.31 The ejector shall be placed at the highest point possible of the vacuum box to remove any entrained or entrapped air and additionally on the pump suction header. The ejector discharge lines shall be piped to the bottom of the clean tank.



2.5.34 If the filter system is designed to operate with 100% permanent media, the dirty belt wash discharge needs to be diverted to a small disposable media filter that has side seals.

2.5.35 The filters shall include one (1) conveyor forward jog and E-stop station in each of the following locations:

One (1) on Ramp Drive One (1) on Rewinder One (1) on Media Wing.

2.5.36 All components of the Filter shall be readily available for repairs.

2.5.37 All filter belts and disposable media shall incorporate an auto-tracking device to ensure that the media is properly aligned in the filter system.

2.5.38 The make, model and size of media belts must be labeled on the equipment.


2.5.40 Aqueous washing machine filters shall be provided either by way of a remote are system servicing multiple machines or a stand-alone unit at each individual washing machine. At a minimum, vacuum type filter shall be provided with permanent belt media as the primary filter with a Russell Filter automatic backflushing filter as the secondary filter. Additionally, an oil skimmer is to be quoted as an option for removing tramp oil from the system. Washer filters shall include:

Mild steel Filter Tank Body and Clean Tank construction Mild steel chain consistent with the filter supplier’s standard design. Mild steel conveyor flights. Drive components (shafts, sprockets, and bearings) type 304 stainless. Filter system piping can be plastic “Green” pipe. Filter/System Pump(s) are specified elsewhere in this specification. Also refer to the Bid Request Breakdown for any heating and insulation

requirements. Secondary filtration shall be quoted per Bid Request Breakdown. Automated backflush filters are required



Date: 12/06/06

A valved automated blow down line with a minimum 1 inch full port ball valve. The blow down is to be set on a timer so that approximately one (1) gallon of wash solution is purged from the filter system daily.

2.5.41 Filters described as “Permanent Media (Endless Belt) Vacuum Filters with Disposable Media” shall be initially provided with the following design features PLUS the Disposable Media features described afterwards:

The Permanent Filter (Endless Belt) Media used on these units shall be provided for micron clarities as stated on the data sheets.

Belt wash and or brush-off/cleaning facilities. Belt wash coolant supply piping is to include a wye strainer with minimum 30

mesh, a differential pressure switch and a pressure gauge with ball valve and be easily accessible and removable for cleaning without draining or shutting down the filter system.

Filter suppliers shall describe in their proposal, the complete features of their permanent media (Endless Belt) system including but not limited to, belt path, cleaning method, belt attachment/drive, high-pressure cleaning, multi-section or single section belt replacement features, etc.

If applicable, Belt-wash pumps may be consistent with filter supplier’s standard design. A Stand-by Belt-wash Pump is not required in the quotation. Filter supplier shall state in the quotation, type, model and manufacturer and performance of the pump.

All “bottom return” belt filters or filters with belt external to the filter tank shall include appropriately designed drip pans or false bottom and guarding.

Belt drainage/dripping on the plant floor shall not be accepted. Belt Guarding shall be provided to minimize the possibility of damage to the belt

and to eliminate safety hazards/exposed pinch points. Belt Guarding shall be designed with ease of maintenance in mind including

bolted and removable features and visual inspection features while guards are in place.

Bottom belt return systems must be designed as to prevent the growing of fungus or bacteria on the belt or in the containment area that could cross contaminate the system

One (1) complete Media Belt shall be provided for each filter. One (1) complete (not section) Replacement belt shall be quoted as an Option in

each filter system quote. (In the event of multiple filters in a single system, one (1) replacement belt shall be quoted)

Permanent Media filters must include a mechanical edge seal for the filter belt and disposable media. This seal must be engaged during the normal operation and during the filter index cycle to insure no by-pass of chips. During the bid process, an alternate price for eliminating the mechanical edge seal is to be provided.

Provisions must be included to prevent coolant dripping on the floor from the permanent media, filter discharge chute and the filter ramp.

2.5.42 Filters described as being “Vacuum Filters with Disposable Media” shall also include the following features. Filters designated as Roll Type Disposable Media shall be initially provided with the following:

Air or electric driven media rewinders, utilizing a reusable media core. Rewinders shall include full roll detection.

End of media switch that shall light a light and sound an alarm when the filter is nearly out of media. The supplier shall be responsible for total control of the media, clear into the spent media rewinder (as applicable).



Date: 12/06/06

The disposal roll type filter media used on these units shall be for micron clarities as stated on the data sheets.

Filters shall utilize “industry standard” media widths of 38”, 51”, 72” and 92” as applicable to the quoted filter size.

Media rolls shall not exceed 500 yards in length. Media rolls with width that exceeds 72-inches shall not exceed 250 yards in length.

Media wing with space for spare roll storage. Media Wing shall be mounted at floor level whenever possible. A hoist/lift assist shall be permanently attached to each filter if the media (new

roll, spent roll or spare roll) cannot be located within 5’-3” of finished floor and accessed with a fork truck. The hoist/lift assist shall move the media (without coolant dripping on the floor/equipment) to an area that can be accessed with a fork truck. Unless noted otherwise in the Scope of Supply

Two (2) rolls of filter media provided with each Vacuum Filter. Media shall be 4.0 oz. Powerloft as manufactured by Crystal Filtration.

All secondary polish filters and zoned pump backs are to be hardwire interlocked to the main filter control panel.

If multiple vacuum filters are used on a single system, equalization/isolation pipes and valves are required between the filters.

If multiple vacuum filters are used on a single system, dedicated vacuum switches must be used on each filter.

During index, all flights must be washed prior to making contact with clean media. Vacuum box must be designed to maintain a constant coolant velocity in ALL

areas of vacuum box. Vacuum filters with a filtration rate of 250 gpm and greater shall include a means

of backflow prevention during the vacuum break cycle to prevent media lift / billowing.

Provisions must be included to prevent coolant dripping on the floor from the spent media, spent media roll, filter discharge chute and the filter ramp.

Belt drainage/dripping on the plant floor shall not be accepted.

2.5.43 All components of the Filter shall be readily available for repairs.

2.6 SECONDARY BAG FILTERS

Where clarity requires bag filters they shall be as follows:

2.6.1 The sentinel bag filter units shall be sized for 10 gpm per square foot of filter area on a standard #2 bag (4.4 sq.ft./bag) with options for sizing for 25 and 50 sq. ft. pleated elements as indicated in the Scope of Supply. For Duplex arrangements, normal mode shall be with both vessels operating, but designed to be capable of operating at full design flow with one (1) on stand-by, vessel operating mode achieved with a single manual operator. With three (3) or more vessels operating it is permissible to have individual, manually operated inlet and outlet isolation valves on each filter vessel. Each vessel shall include inlet/outlet pressure gauges, differential pressure switch, valved drains, air vents, and two (2) complete sets (per vessel) of filter bags. All bag filter vessels shall be ASME coded and stamped. Cover lifters shall be provided for all vessels with six (6) bags or more. Filter vessels and piping shall be fabricated from carbon steel unless otherwise indicated on the Project Specification Checksheet. Any such proposal must be provided with a life cycle cost analysis of any disposable media versus a non-disposable media option. Bag filter vessels for washers shall be type 304 Stainless Steel construction. Outlet connections are not allowed in the lower one-half of the housings.

Approved manufacturers for bag filters or approved equals:



Date: 12/06/06

Russell FiltrationP.O. Box 6403 Plymouth, MI 48170

Rosedale Filtration Products/Zealtek LLC29445 Beck RoadWixom, MI 48393

2.8 AUTOMATIC BACK FLUSHING FILTERS

2.6.2 Where indicated in the Scope of Supply, provide a bank of automatic back flushing filters mounted on top of a dirty tank. The filtered, clean coolant shall be delivered directly to the manufacturing floor or to the super clean tank via system pressure through the automatic back flushing filter(s). The dirty back flushed discharge shall return to the primary system dirty reservoir or nearby flume as applicable. The dirty discharge from the automatic back flushing filter and the filter system belt wash must be diverted to a small disposable media filter (quote an alternate price to add side seals). The dirty discharge must not disrupt the filter cake upon entering the filter. This filtered coolant must then be discharged into the back of the primary filter dirty tank so as to not disrupt the filter cake.

2.6.3 If coolant is to be used for back flushing the filter elements, the clean coolant pumps need to be sized to handle the additional flow requirements due to the back flushing filters without affecting the designed flow rates and pressures to the machines.

2.6.4 An adjustable flow balancing and measurement orifice, circuit setter valve or a combination of flow venturi and lockable index valve shall be provided to adjust or balance the flow through each back flushing system. (Refer to valve specifications)

2.6.5 The automatic back flush filters shall use 60 micron but not less than 30 micron permanent two dimensional micro screens depending on the application and per Appendix A unless specified differently in the scope of supply. This screen shall be stainless steel or other non corrosive material and properly supported and sealed to handle a minimum pressure differential of 100 psig in either direction without failure or implosion of the elements.

2.6.6 All automatic back flush filters shall use compressed air or clean filtered coolant as a back-flushing medium. If using compressed air, an air switch shall alarm the control panel if the air pressure is lost. An air purge valve must be provided to allow automatic purging during the refill cycle.

2.6.7 All automatic back flush filters shall be furnished with all controls and all motors, automatic valves and alarm devices to provide a complete and operational system. The system shall be connected to the primary PLC for monitoring and alarms. (Refer to Controls Specifications for details).

2.6.8 Multiple back flush filters shall be piped and wired with lockable valves and lockable switches to allow service of one unit while others remain on line. Inspection and Maintenance of the elements or dump valves shall be required only annually. Provide check valve between compressed air accumulator and automatic isolation valve to protect air assemblies from coolant.

2.6.9 Provide differential pressure gauges and switches, which shall signal the back flush sequence and shall alarm if the differential pressure is greater than the maximum (10 Psig) which indicates the elements are plugged. A visual flow device shall be provided at each branch outlet of each back flush filter to verify flow.



Date: 12/06/06

2.6.10 If auto back flush filters are to be used for supplying coolant to the machining operations, the back flush filters shall provide continuous, uninterrupted filtered coolant supply to the machining operations at the designed flow rate and pressure via a parallel system or via a clean tank sized to allow for two rapid index sequences (dedicated clean tank only for filter high pressure debur applications only)

2.6.11 All coolant inlet valves need to be designed with flow controls.

2.6.12 Manual lockable valves shall be provided for supply and drain functions in order to perform maintenance.

Approved manufacturers for back flushing filters: Russell Filtration

P.O. Box 6403 Plymouth, MI 48170

Alternate pricing will be considered for Rosedale back flushing filter with micro screen.Supplier must identify prove installation with 1 years service and Total Cost of Ownership data.

Rosedale Filtration Products/Zealtek LLC29445 Beck RoadWixom, MI 48393

2.7 PUMPS 400 gpm. and GREATER (Filter/System, System Supply and Polish Filter)

2.7.1 All Filter/System & System Supply pumps shall be Process Systems or Gould Vertical Turbine Pumps with a high thrust base (motor thrust stand) mounted on an appropriately sized steel mounting plate and shall include motors, couplings, coupling guards and independent pump thrust bearing.

2.7.2 There shall be a sufficient number of system pumps running on a continual basis with one (1) additional pump for standby, for each set of pumps, completely mounted and piped in place unless otherwise noted in the scope of supply.

2.7.3 NOTE: For Dual Filter Systems with dedicated clean tanks, EACH filtration unit shall include provisions for the future “on-the-fly addition of one additional pump to serve as a stand-by. Provisions shall include the suction piping with isolation valve in place, the discharge riser connected to the main header completewith manual valve, pressure gauge, local disconnect switch mounted and wired in place (exceptwiring to the motor) and electrical components installed in the control panel. For Dual Filter Systems with a common clean tank, only one future pump provision is required.

2.7.4 All Vertical Turbine Pumps shall be “mounted” on the tanks in a dry saddle mount to facilitate ease of removal. Conduit and piping shall be arranged for ease of pulling motors and pumps. Provide isolation valves for maintenance and open side support for horizontal removal.

2.7.5 Vertical turbine pumps shall be fabricated with stainless steel shafts, ductile iron impellers and cast iron flanged columns and cast iron bowls.

2.7.6 Selection of pump models shall be accomplished with maximum standardization on multiple system purchases.



Date: 12/06/06

2.7.7 Pump motors shall be premium efficiency U-Frame sized to be non-overloading throughout the entire pump performance curve and shall have a maximum speed of 1800 rpm.

2.7.8 Pumps shall be sized and selected to develop maximum efficiency at design flow. Pumps shall be selected left of best efficiency point on the performance curve and left of center unless variable speed drives are utilized, select pump at best efficiency point.

2.7.9 It shall be the successful supplier's responsibility to include and incorporate any and all additional structural support required for the installation of these pumps.

2.7.10 NOTE: per the filter sizing data sheets, there are filters with sides’ heights of 4’-0” and with flows larger than 400 g.p.m. It is left to filtration supplier’s discretion as to whether the use of vertical turbine pumps is practical in these cases. If the filtration supplier elects to quote horizontal pumps due to vertical turbine pump length/support issues, it should be made clear in the filtration supplier’s proposal. All filters with 6 ft. side heights (and greater) and flows of 400 g.p.m. (and greater) shall include vertical turbine pumps in the base bid.

2.7.11 The pumps shall be complete with all suction piping back to the point of equipment connection.

2.7.12 All of the SUCTION PIPING SHALL be sized to handle the volume specified at a maximum velocity less than 5 feet per second through standard weight (Sch. #40) steel pipe (Piping and fittings should be appropriately sized per the specific applications).

2.7.13 For externally mounted pumps, each pump suction shall include an isolation valve to allow servicing of pump without draining the filter.

2.7.14 Pumps are to be piped off the bottom half of the suction piping header.

2.7.15 The suction piping header shall have an air ejector and an air collection box for removing air from the suction piping header.

2.7.16 The pumps shall each discharge into a full discharge pipe riser system that shall connect into a common pump header. The pump header shall be piped with an end-flanged joint or grooved joint where it shall then constitute the distribution system that shall supply the machining area.

2.7.17 All of the COOLANT DISTRIBUTION HEADER PIPING will be sized to handle the volume specified at a velocity of 8-12 feet per second with consideration for total pressure loss to allow a minimum pressure as indicated in the utility data sheets at the point of connection to the machines through standard weight (Sch. #40) steel pipe (Piping and fittings should be appropriately sized per the specific applications.)

2.7.18 The main header above the pumps will have a 6-inch diameter face, liquid filled pressure gage supplied from a gage cock installed for ease of vision from the floor and with a Pressure Transducer. The main header assembly is to be pre-assembled and shipped as a complete header system. The header also to include header supports (pre-mounted and bolt connection), valves, checks, expansion joints, gauges, transducers, etc. Refer to the DaimlerChrysler Construction Standard Section 15122 – Meters and Gages.

2.7.19 Each pump discharge riser will incorporate the following:

Check valve Butterfly valve Liquid filled pressure gage, 4 inch diameter face ¼” Sample port with ball valve, each sampling port is to include a drain pipe. Each gage will be supplied through a ¼ inch valve for isolation



Date: 12/06/06

Structural bracing and anchors on header riser from coolant tank Flex couplings with tie rods or equivalent of 5 victaulic style 77 is required on each

riser.

2.7.20 The Main System Pump piping design shall include an automatic pressure regulating system. The design shall incorporate a constant pressure control valve system or variable speed drive pumps (for single pump filter systems). If a control valve is used it shall be a Dezurik Vee-Port Valve that shall modulate (to maintain constant pressure in the system) as the system pressure changes due to machines being turned on or off. The control valve shall have manual valves located between the valve and the supply and suction headers so this valve can be isolated for maintenance without shutting the system down. The linear valve shall be set up to dump the gallons of one half (1/2) pump to the suction side of the pump or clean sub-floor. If the pressure increases/decreases, the system shall automatically start/stop pumps to maintain a (+) or (-) 3 PSI. ( Note: Controls shall limit starting and stopping of motors so as not to trip the thermal overloads)

2.7.21 Sound abatement material is required on all pressure regulating valves and orifice plates 4 feet upstream and 4 feet downstream of valve or orifice plate. For pressure regulating valves or orifice plates that are provided by the filter supplier but installed by others, the sound abatement material must be provided by the filter supplier to the installation contractor.

2.7.22 The start-up of the system shall be set-up with a slow header fill to reduce movement of the supply piping. The logic shall be set-up to open the linear valve full open and then start the first pump. (In this stage you are basically dumping all the gallons back into the pump suction and very little is put into the supply header.) After a period of time and system does not see 10 PSI on the main header the valve automatically closes in increments of 10% until the system reaches the operating pressure on the main header. The slow fill process will last approximately 1 to 2 minutes depending on the size of the system and size of the supply header. After the slow fill is complete the system will go into automatic pressure control.

2.7.23 Provisions shall be made for the pumps to be used to pump out the coolant system tanks to industrial waste treatment/coolant holding facilities. Each system shall require a minimum 3-inch coolant pump out line. Each pump out connection line shall have a check valve, orifice plate, pressure transducer (to shutdown system in pumpout mode), butterfly valve with lockable handle and a minimum 3” male cam-lock fitting and cap.

2.7.24 All tanks must have full pump-out capabilities.

2.7.25 Coolant shall be pumped from the filter into a common header distribution system out to the machines and flush nozzle locations.

2.7.26 The Filtration System supplier is to provide a schematic diagram for each filtration system showing distribution piping (supply and return) sizes and valving.

2.7.27 All system distribution piping, flume flush drops and machine supply lines from the main filtration system header shall be designed by an Architect Engineer and shall be provided and installed by contractors or Daimler Chrysler designated trades.

2.7.28 Supplier shall provide all NPSHR and NPSHA calculation sheets with pump curves with bid and after final design.

2.7.29 Pump seal reliefs are to be piped back to the clean tank.

2.8 OPTIONAL - PUMPS 399 gpm and LESS (Filter/System, System Supply and Polish Filter)



Date: 12/06/06

2.8.1 All Filter/System & System Supply pumps may be Gusher Pumps horizontal centrifugal, back pull-out design, steel base mounted and shall include motors, flexible couplings, and coupling guards (Close-coupled pump/motors are not acceptable) or as previously specified in paragraph 2.8 for 400 gpm and over.

2.8.2 There shall be a sufficient number of system pumps running on a continual basis with one (1) additional pump for standby, for each set of pumps, completely mounted and piped in place unless otherwise noted in the scope of supply. Note: Stand alone washer filters for an individual washer shall not have a standby pumps.

2.8.3 Horizontal Centrifugal Pumps shall be all iron construction including casing and impeller. Pumps shall include mechanical seal, tungsten carbide or better and water slinger in the event seal fails.

2.8.4 Selection of pump models shall be accomplished with maximum standardization on multiple system purchases.

2.8.5 Pump Motors shall be premium efficiency U-Frame sized to be non-overloading throughout the entire pump performance curve.

2.8.6 Pumps shall be sized and selected to develop maximum efficiency at design flow. Pumps shall utilize variable speed drives and pressure control to maintain system pressure at +/- 3 psig.

2.8.7 Pump motor and coupling alignment shall be performed with a laser alignment device.

2.8.8 Pumps shall be mounted in a fabricated steel drip tray. The drip tray shall include threaded drain coupling with plug, and level pads. All drain lines are to be flush with the bottom of the tank or drip pan.

2.8.9 Pump Suction and Discharge piping practices shall be the same as described in the previous paragraph 2.8 “Pumps 400 g.p.m. and greater (Filter/System, System Supply and Polish Filter).

2.8.10 Pump motor and coupling alignment shall be performed with a laser alignment device.

2.9 SELF-PRIMING PUMPS – PORTABLE FILTER PUMPOUT PUMPS (one per plant)

2.9.1 All Self-priming pumps will be Gorman-Rupp Pumps “T” Series (as applicable), horizontal centrifugal, steel base mounted and will include motors, flexible couples, and coupling guards (Close-coupled pump/motors are not acceptable, V-belt drive is acceptable if necessary). V-belt drive designs will include motors in-line with pumps (not piggyback or side by side) and complete with adjustable belt take-up motor base, sheaves, belts and guards. Pumps shall be designed to allow external adjustment of impeller clearance without access through any inspection covers. V-belt size shall be labeled on side of belt guard.

2.9.2 The pump shall be sized for 175 gpm at 25 psi. The motor shall operate at 480V.

2.9.3 Self-Priming, horizontal centrifugal pumps will be all iron construction including casing and impeller, Pumps will include mechanical seal, tungsten carbide or better.

2.9.4 Selection of pump models will be accomplished with maximum standardization on multiple system purchases.

2.9.5 Pump Motors shall be premium efficiency U-Frame sized to be non-overloading throughout the entire pump performance curve.



Date: 12/06/06

2.9.6 Pump shall be sized and selected to develop maximum efficiency at design flow. Pumps will be selected left of best efficiency point on the performance curve.

2.9.7 The pump, motor, motor starter, etc shall be mounted in a fabricated steel tray with fork slots. Each pump shall include a pre-mounted starter, prewired with a welder outlet plug with 50 feet of cable, an electrical cable reel, 25 feet of reinforced 3” suction hose with female cam lock connection and 30 feet of reinforced discharge hose with a female cam lock connection. There are to be hose reels for both the suction and discharge hoses. This unit shall be completely portable and skid mounted with fork slots. All cam lock fittings are to include caps.


Check valve Butterfly valve Liquid filled pressure gage, 6 inch diameter face Each gage will be supplied through a ¼ inch valve for isolation

2.10 VORTEX PUMPBACK PUMPS

2.10.1 All Vertical vortex pump back pumps with a maximum shaft length of 33 inches shall be a top pull out design with iron mounting plate, NEMA motor, couplings and coupling guards. Mounting plate shall house thrust and radial bearing independent of motor bearings.

2.10.2 The Vortex Pump shall be mounted on a round flange ½ “thick mild steel plate, which mounts directly to the pump back sump.

2.10.3 All conduit and piping shall be mounted for ease of pump removal. Provide flexible electric whip long enough to be able to pull out pump rotating parts for inspection.

2.10.4 Pump motors shall be premium efficiency U-Frame sized to be non-overloading throughout the entire pump performance curve.

2.10.5 The pumps shall be complete with schedule #80 discharge piping to a point above the sump cover with a flanged end or cut grooved end.

2.10.6 The pump shaft shall be top drilled and threaded for eyebolt attachment.

2.10.7 The Throttle bushing if required by design shall be carbon steel

2.10.8 Impeller shall be Vortex hardened ductile iron or CD4MCu. Casing shall be cast iron or hardened ductile iron.

2.10.9 Pump shall handle solids up to the same diameter as the discharge pipe up to a maximum of 2 inches.

2.10.10 Provide full cantilever design to maintain bearings out of coolant.

2.10.11 Lubrication of vortex pumps shall be via the DaimlerChrysler controls specification “Lubrication Secton”.

2.10.12 Approved manufacturers: Egger, Process Systems-Magnum, or Great Lakes - Gusher




Date: 12/06/06

HDL Swing Check valve Full port shutoff/isolation valve 150 PSI liquid filled pressure gage, 6 inch diameter face Each gage will be supplied through a ¼ inch valve for isolation Structural bracing and anchors on header riser from coolant tank Flex couplings with tie rods or equivalent of 5 victaulic style 77 is required on each

riser.

2.10.14 Filtration supplier is responsible for controlling and interlocking all pumpback system pumps. Provide high level alarm to shut off coolant supply valve and “high-high” level alarm and interlock to shut filter system off if a “high-high” level is reached. Pumpbacks to have control and pneumatic panels pre-mounted and pre-wired to control panel. The 480 volt cords wired to the panel with the phase rotation tags. All pump motors to be provided with cord grips. Operation of the pumpback to include weekend mode, interlocks to the machines, shutoff valves on the clean and super clean supply and proximity switches on the actuators for position. Interlocks are also required to the associated oil mist collection system.

2.11 VERTICAL WET WELL CHIP SCHREDDING PUMPS ( Do not use schredding pumps for stringy steel chips )

2.11.1 The vertical wet well chopper pump shall be specifically designed to pump waste solids at heavy consistencies without plugging or dewatering of the solids. Materials shall be macerated and conditioned by the pump as an integral part of the pumping action. The pump must have demonstrated the ability to chop through and pump high concentrations of solids such as plastics, aluminum, heavy rags, grease and hair balls, wood, paper products and stringy materials without plugging, both in tests and field applications. Pump shall be manufactured by Vaughn Co., Inc. or equal. All equals shall have at least three years prior experience with the same style pump in the same application. Pumps with fabricated impeller, cutter bar or casing shall not be acceptable.

2.11.2 The pump casing shall be of semi-concentric design, with the first half of the circumference being cylindrical beginning after the pump outlet, and the remaining circumference spiraling outward to the pump outlet. Casing shall be ASTM A536 ductile cast iron with all water passages to be smooth, and free of imperfections that inhibit good flow characteristics.

2.11.3 The impeller shall be semi-open type with pump out vanes to reduce seal area pressure, and to draw lubricant down from the reservoir should seal leakage occur. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar at the intake openings, with a set clearance between the impeller and cutter bar of .010” to .015”. Impeller shall be cast from ASTM A148 Gr. 90–60 alloy and heat treated to minimum 60 Rockwell C Hardness and dynamically balanced. The impeller shall be keyed to the shaft and have no axial adjustments and no set screws.

2.11.4 The cutter bar shall be recessed into the pump bowl, with a funnel shaped inlet opening, and shall extend diametrically across entire pump suction opening. Cutter bar shall be cast from ASTM A148 Gr. 90-60 cast alloy steel and heat treated to minimum 60 Rockwell C Hardness.

2.11.5 The upper cutter shall be threaded into the casing above the impeller, designed to cut against the pump-out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal area. Upper cutter shall be cast from ASTM A48 Gr. 90-60 cast alloy steel and heat treated to minimum 60 Rockwell C Hardness.



Date: 12/06/06

2.11.6 The impeller shall be secured to the shaft using a special cutter nut, designed to cut stringy materials and prevent binding. The cutter nut shall be cast from ASTM A48 Gr. 90-60 cast alloy steel and heat treated to minimum 60 Rockwell C Hardness.

2.11.7 The lower stub shaft shall be AISI 4140 heat treated. Upper shaft extension shall be AISI 1045 turned, ground and polished. The shaft column shall be 4 inch OD precision steel tubing welded to steel flanges and machined with piloted bearing fits for concentricity of all components. All support column tubes shall be leak tested. Distance between shaft bearings shall not exceed critical speed dimensions.

2.11.8 The pump shaft ball bearings shall all be oil bath lubricated by DaimlerChrysler approved I.S.O. Grade 46 turbine oil, with the exception of the top bearings, which shall be greased packed. The bearings shall have a minimum B-10 life rated 100,000 hours. Shaft thrust shall be taken up by either a double row angular contact ball bearing or two back-to-back mounted single row angular contact ball bearings, which bear against a machined shoulder on one side and the seal sleeve on the other side. Overhang from the centerline of the lower thrust bearing to the seal faces shall be a maximum of 1.2”, with a mechanical seal to isolate the bearings from the pumped media at up to 250 F.

2.11.9 The mechanical seal shall be fitted with silicon carbide seal faces to provide long life expectancy in the presence of grit and abrasive solids. The seal shall ride on a 316 stainless steel shaft sleeve, with the seal tension held by set screws. Seals shall be tested for flatness within 2 Helium light bands under a Helium light source and optical flat.

2.11.10 Automatic oil level monitor shall be located above the mounting plate and be fitted with an internal oil level switch to detect oil level and shut off the motor in event of low oil level. A sensitive relay shall be included for mounting in the motor control panel.

2.11.11 The pump assembly shall be mounted vertically on a common steel base plate with 150 pound discharge flange. A ¼” NPT pressure tap shall be located above the deck plate.

2.11.12 The shaft coupling shall be T.B. Woods Sureflex elastomeric type with a minimum 1.5 service factor based on the drive rated horsepower, and shall be protected with a guard meeting OSHA requirements.

2.11.13 The motor stool shall be a fabricated carbon steel weldment machined with piloted fits to positively align the C-flanged premium efficiency motor and pump shaft, with no adjustments.

2.11.14 The pump base plate shall be fabricated from carbon steel, ½” minimum thickness, and shall include lifting lugs.

2.11.15 Stainless steel nameplates shall be attached to the pump and drive motor giving the manufacturer’s pertinent data.

2.11.16 All pump motors shall be premium efficiency sized for non-overloading conditions throughout the entire pump performance curve.

2.11.17 All conduit and piping shall be mounted for ease of pump removal. Provide flexible electric whip long enough to be able to pull out pump rotating parts for inspection.

2.11.18 The pumps shall be complete with schedule #80 discharge piping to a point above the sump cover with a flanged end or cut grooved end.




Date: 12/06/06

HDL Swing Check valve Full port shutoff/isolation valve 150 PSI liquid filled pressure gage, 6 inch diameter face Each gage will be supplied through a ¼ inch valve for isolation Structural bracing and anchors on header riser from coolant tank Flex couplings with tie rods or equivalent of 5 victaulic style 77 is required on each

riser.

2.11.20 Filtration supplier is responsible for controlling and interlocking all pumpback system pumps. Provide high level alarm to shut off coolant supply valve and “high-high” level alarm and interlock to shut filter system off if a “high-high” level is reached.

2.12 IN-FLOOR PUMPBACKS SYSTEMS

2.12.1 Pumpback must take into account and address foreseeable issues with foam, coolant aeration, parts and tooling, machine tool integration, shut-down, start-up, stringy chips and ease of repair.

2.12.2 Pumpback must incorporate a flow through parts catcher that is made of 1” x 4” bar grating. The parts catcher needs to be easy to remove and clean. In the event that the parts catcher becomes plugged, there shall be an overflow slot capable of overflowing 125% of the pumpback flow into the pumpback tank.

2.12.3 The pump discharge piping is to be designed so that there are no overhead interferences in the event that a pump needs to be removed. Pump discharge piping needs to be offset with pipe flanges or victualic fittings so that discharge riser is not located directly above the pump.

2.12.4 The pumpback tank system must be designed to accept a flow through chip shredder. The electrical control panel must have spare space available for any future starters, fuses, etc., the main disconnect must be sized for the addition of a shredder and the PLC must have enough spare I/O if a shedder is required. The tank also requires enough room for a future shredder.

2.12.5 The pumpback will be designed to operate as a stand alone system and will be complete with an electrical panel with a variable frequency drive. The pumpback system also requires automatic clean, super clean, and flume flush shutoff valves with proximity switches. A flow regulating valve is also required for each flume flush drop. Each pumpback system shall be hard wired interlocked to each machining center, mist collector, high pressure coolant skid and the central filtration system that applies to each specific pumpback system. If the flume flush drop does not occur at the end of the clean coolant supply header, an additional End of Line automatic valve needs to be provided on the clean coolant header with a flush drop to the flume. Additionally, the ends of the super clean coolant headers require an End of Line flush drop with an automatic valve. The flume flush and End of Line automatic valves are to be located 4’ to 6’ above finished floor. All automatic valves require flow controls and valve position switches.

2.12.6 The pumpback system requires a 4 point bubbler system and duplicate emergency high level switch (tuning fork or equal) to monitor liquid level and control the pump. A High-High level switch (tuning fork or equal) shall be hard wired to the central filtration system. In the event that the coolant level reaches the High-High level switch, the central filtration system is to be shutdown. The pumpback controls must also monitor for leakage in the containment sump. If moisture is detected in the containment sump, a fault with an alarm must be generated.

2.12.7 The pumpback system requires a visual liquid level device on the HMI. All levels need to be able to be modified/adjusted with the HMI The levels that need to be displayed are the following:

Pump Off DepthPump On Depth



Date: 12/06/06

Operating LevelHigh Level Setting

2.12.8 The pumpback tanks shall be cylindrical with conical bottoms. The tank shall be designed to hold 1.5 minutes worth of rated flow after the high level is reached with 1’ of freeboard. The flume can be used as a coolant reservoir during emergency shutdown only.

2.12.9 The top of the pumpback tanks shall be a minimum of 6” above the floor, the sump liners shall also be above the finish floor to prevent fluids on the floor from entering the liners. All pump motors must be above finished floor.

2.12.10 Each pumpback tank and liner unit must incorporate a minimum 1 ¼” pump suction line that is piped into the dry sump in order to pump out the secondary containment.

2.12.11 Each pumpback liner is to be designed to be embedded in concrete. The conical tank is to be designed to fit inside of the sump liner. The conical tank is to be attached to the sump liner to prevent the tank from floating in the event of flooding.

2.12.12 The following interlocks are to be provided: Pumpback to machining centers

o Pumpback operationalo Coolant high levelo Coolant emergency high level

Machining center to pumpbacko Coolant request

Pumpback to mist collectoro Pumpback operational

Pumpback to high pressure coolant skido Pumpback operational

Central filtration system to pumpbacko Central filtration system start-up

2.12.13 Each pumpback will include ¼” thick steel Slip-Not, Grade #2 tank top cover plates reinforced for a 250#/sq. ft pedestrian loading. Inspection hatches (12” x 12”) are required on each pumpback tank. The hatches shall be ¼” thick hinged plastic covers with steel grating protection underneath the cover.

2.12.14 Each pumpback tank is to have a mist collection connection point. All mist collection connection pipes provided by filtration supplier to have a funnel type flange welded or epoxy sealed to the mist collection pipe with 1/16” holes drilled into the pipe to allow for drain back if the field connection leaks.

2.12.15 Refer to Section 2.12 for pumpback pump specifications.

2.13 ABOVE FLOOR PUMPBACK SYSTEMS

2.13.1 Pumpback must take into account and address foreseeable issues with foam, coolant aeration, parts and tooling, machine tool integration, shut-down, start-up, stringy chips and ease of repair.

2.13.2 The pump discharge piping is to be designed so that there are no overhead interferences in the event that a pump needs to be removed. Pump discharge piping needs to be offset with pipe flanges so that discharge riser is not located directly above the pump.



Date: 12/06/06

2.13.3 The pumpback will be designed to operate as a stand alone system and will be complete with an electrical panel. The pumpback system also requires automatic shutoff valves on the pump discharge. Each pumpback system shall be hard wired interlocked to each machining center and mist collection system.

2.13.4 The pumpback system requires low and high coolant level sensors and duplicate emergency high level switch (tuning fork or equal) to monitor liquid level and control the pump. The emergency high level switch signal shall be interlocked to the machining center so that the machine will cycle stop and the coolant inlet valve will be closed.

2.13.5 The pumpback tanks shall be cylindrical with conical bottoms. The tank shall be designed to hold 1 minute worth of rated flow after the high level is reached.

2.13.6 The following interlocks are to be provided: Pumpback to machining centers

o Pumpback operationalo Coolant high levelo Coolant emergency high level

Pumpback mist collectoro Pumpback operational

2.13.7 Each pumpback will be 100% enclosed. Inspection hatches are required on each pumpback tank. The hatches (12” x 12”) shall be made of plastic and hinged with steel grating protection underneath the cover.

2.13.8 Refer to Section 2.12 for individual pumpback pump specifications.

2.14 LUBRICATION SYSTEM

2.14.1 All systems utilizing Vertical Turbine Pumps shall include an automatic lubrication system to the line shaft bearing and top and bottom bearings.

2.14.2 The lubrication system shall be in accordance with DaimlerChrysler’s latest Controls Specifications –Lubrication

2.14.3 The lubrication system shall be controlled by the Main System PLC.

2.14.4 The supplier shall supply the entire lubrication system, completely wired and mounted on the filter prior to shipment. The system shall be supplied with all distribution blocks. OEM must supervise installation, purging and start of lube system at project site.

2.14.5 Final connections of lubrication lines from the pump lube system to the pumps shall be installed in the field for pit mounted systems. (Filter supplier shall provide as much field mounted lube tubing as practical). If the filtration system is to be run-off on the supplier’s floor as a complete unit, then the installation of the lube lines is to be completed prior to the run-off. All lube lines are to remain on the filter system tanks during shipping. Unions are to be installed in the lube lines at the break points. (Note: Supplier is to verify lube lines are purged prior to system start up.)

2.15 LIQUID LEVEL CONTROL SYSTEM (Water-soluble systems)

2.15.1 Each system shall include an automatic liquid level sensing and coolant mixing system as outlined below, to control the city/process water initial fill line, RO water make-up and control the amount of soluble oil or wash solution that shall be introduced during make-up.



Date: 12/06/06

2.15.2 Each system shall utilize transducer level detection with levels displayed on the Main Filter System Human/Machine Interface (HMI) screen (or approved equal system).

2.15.3 A mechanical coolant level detection system needs to be designed into each filter tank. It is to be designed in a quiet area of the filter tank. It is to be calibrated to the inch so that the coolant depth on the HMI can be validated.

2.15.4 The liquid level control system shall include the following:

Low liquid level signal High liquid level signal Auto make-up on Auto make-up off Also, a mechanical emergency high liquid level switch, which shall signal and

alarm and shut a spring fail closed ball valve on the main water line of the make-up panel. The automatic valve shall be located at the water connection to the panel.

Air Fault Light to signal Low or No Air

2.15.5 The Initial Fill System shall be operated via manual valve and sized for a two (2) hour system fill utilizing city water.

2.15.6 The Make-up Soluble Oil/Synthetic Water System shall be automatic and designed for use with RO Water. The Water Make-up System shall include an automatic, venturi actuated make-up valve (Dosatron) as well as an in-line Meter (ABB magnetic flow meter) with flow rate and totalizer indications and 4-20 mA output. In addition to a liquid level control system, the filtration supplier shall supply for each Filtration System one (1) automatic Soluble Oil/Synthetic make-up station. This feed system shall be capable of dispensing Neat oils from drum or totes. The station shall utilize a stand capable of supporting and securing four (4) 55 gal. Neat oil drums or one (1) 250-350 gal. Neat oil tote. A containment pan shall extend below the stand to capture and contain all possible leaks from the Neat oil drums or totes. This system shall utilize an air operated diaphragm pump or electric metering pump with a shock-dampening unit, to pump Neat oil from the stand to the filtration system only if the venture style will not function properly.

2.15.7 For WASHER FILTERS and in addition to a liquid level control system as specified elsewhere in this specification, the filtration supplier shall supply for each primary WASHER FILTER SYSTEM one (1) automatic chemical feed system. This feed system shall be capable of dispensing chemical concentrate from drum or totes. The station shall utilize a stand capable of supporting and securing four (4) 55 gallon chemical drums or (1) 250-350 gallon chemical tote. A stainless steel or plastic containment pan shall extend below the stand to capture and contain all possible leaks from the chemical drums or totes. This system shall utilize an air operated diaphragm pump, with a shock-dampening unit, or an electric metering pump to pump concentrate from the stand to the filter system only if the venture style will not function properly.

2.15.8 The Make-up system shall also be capable of making up City/Process water, RO Water and Neat Oil independently but automatically.

2.15.9 City Water Make-up loops where designated Process Water is not provided shall include back-flow prevention (Watts 909): provided by the filtration supplier and shipped loose. RO Water Make-up shall include an approved air gap fitting at the filter for back flow prevention.

2.15.10 The Level Control/Make-up System shall be mounted pre-piped and pre-wired on the respective equipment (This includes pneumatic tubing as well).



Date: 12/06/06

2.15.11 R.O. Water : Each system shall require a Reverse Osmosis (RO) fill connection. DaimlerChrysler’s supply shall drop into the Make-up panel, for normal level control of the system. For washers, the piping shall be CPVC Schedule 80 with stainless steel modulating valve from a float mounted in a perforated plastic tube.

2.15.12 Process Water : Each system shall require a process water fill line connection. DaimlerChrysler’s supply shall drop into the make-up panel, for fast fill of the system. This fast fill shall have a manual valve and flow transducer with fast fill total and rate indicated on the system HMI.

2.15.13 Compressed Air : System shall require a compressed air line that shall be a minimum 1-inch pipe (provided and installed by DaimlerChrysler or designated contractor) from the header, down to the Make-up or Air panel at which point it may be reduced to the size requirements at the system. The air system shall be provided by the filtration system supplier and shall include a lockout valve, filter, regulator, low-pressure switch and coalescer with manual drain.

2.15.14 This 1-inch pipe drop shall incorporate a valve and union at 6’-6”, above the finished floor prior to any distribution.

2.16 LIQUID LEVEL CONTROL SYSTEM (Straight oil systems)

2.16.1 Each system shall include an automatic liquid level sensing and Oil Make-up system as outlined below; to control the plant pressurized initial fill line, and control the amount of oil that shall be introduced during make-up.

2.16.2 Each system shall utilize transducer level detection with levels displayed on the Main Filter System Human/Machine Interface (HMI) screen (or approved equal system).

2.16.3 The liquid level control system shall include the following:

Low liquid level signal High liquid level signal Auto make-up on Auto make-up off Also, a mechanical emergency high liquid level switch, which shall signal and

alarm and shut a spring fail closed ball valve on the main oil line of the make-up panel. The automatic valve shall be located at the oil connection to the panel.

2.16.4 The Initial Fill System shall be operated via manual valve and sized for a two (2) hour system fill utilizing tanker truck oil supply.

2.16.5 The Level Control/Make-up System shall be mounted pre-piped and pre-wired on the respective equipment. (This includes pneumatic tubing as well)

2.16.6 Plant Oil : Oil shall be manually fed into the filtration system either by tote or tanker truck.

2.16.7 A fast fill with camlock fitting and cap shall have a manual valve and flow transducer with fast fill total and rate indicated on the system HMI.

2.16.8 Compressed Air : System shall require a compressed air line that shall be 1-inch pipe (provided and installed by DaimlerChrysler) or designated Contractor from the header, down to the Make-up or Air panel at which point it may be reduced to the size requirements at the system. The air system shall be provided by the filtration system supplier and shall include a lockout valve, filter, regulator, low-pressure switch and coalescer with manual drain. This 1-inch pipe drop shall incorporate a valve and union at 6’-6”, above the finished floor prior to any distribution.



Date: 12/06/06

2.17 TRAMP OIL REMOVAL (Quote as an option)

2.17.1 Each water soluble filtration system shall require a tramp oil removal system.

For Individual Filtration Units:

2.17.2 These systems shall be capable of removing the tramp oil from the surface of the dirty tank, filter tank or clean tank as recommended by the filtration system supplier and skimming device manufacturer. Units shall turn over the complete system volume once every 8 hours.

2.17.3 All filtration suppliers shall quote Tramp Oil Removal Systems as provided by:

Russell Filtration Inc.Super Separator System

P.O. Box 6403Plymouth, Mich. 48170 Ph. (734) 451-1175

2.17.4 Recovered Tramp Oils shall be discharged into a separate tote container.

2.17.5 Unit shall be able to be cleaned of settled solids, suspended solids, and floating solids without use of strainers. The skimmer shall be designed to compensate for level fluctuations in the tank.

2.18 FINE PARTICULATE REMOVAL SYSTEM (quote as an option for Honing Filters )

2.18.1 Provide centrifugal separators for each central filter system which shall be fed from the pressurized coolant header and which will return coolant back to the system.

2.18.2 Where the separator cannot be located to drain back by gravity to the central filter or flume, the system shall be provided with a receiving surge tank and a pump with check valve and controls.

2.18.3 Provide a rolling hopper with a dumping feature to collect chips for disposal. The system shall Operate at a minimum of 2000 G’s and shall remove fine particulate to maximize coolant life.

2.18.4 The system shall utilize an ABB 601 series variable speed drive with a single motor and positive locking clutch for scrapper blades and bowl synchronization.

2.18.5 The entire rotating assembly shall be designed with a “quick-change” rotor assembly. Provide a quote for annual service agreement to trade out the entire rotating assembly with the latest continuous improvements.

2.18.6 The coolant inlet tubing shall be stainless steel and shall be designed to avoid excessive abrasion yet maintain the minimum velocity for proper operation. An automatic (NC) coolant inlet valve full port ball valve with Viton or UHMPE seals and seats shall be provided to shut off coolant during the scrapping mode.

2.18.7 The unit shall include all starters, and controls with full diagnostics including vibration monitoring to enhance trouble shooting and maintainability.

2.18.8 The unit shall be designed for 480 volt, 3 phase, and 60-hertz power connections unless designated otherwise. Compressed air if required shall be designed with appropriate filter,



Date: 12/06/06

pressure regulators, T-handle lockouts and designed for an incoming pressure of no greater than 60 psig.

2.18.9 Approved manufacturer: CentraSep Other approved equal

2.19 MIST COLLECTION CONNECTIONS

2.19.1 Each primary containment including filter tanks, drag/settling tanks, pre-conveyors, pumpback tanks and clean tanks shall have a strategically located mist collection connection. Consideration shall also be given for mist collection connections on inlet boxes. All mist collection connection pipes provided by the filtration supplier to have a funnel type flange welded or epoxy sealed to the mist connection pipe with 1/16” holes drilled into the pipe to allow drain back if the field connection leaks.

2.19.2 The connections must provided a maximum velocity of 1500 feet per minute and based on an air flow of 10 C.F.M./ SQ. FT. of wet surface area.

2.19.3 Supply and Installation of mist collection equipment and ductwork is to be designed by a DaimlerChrysler designated Architect or Engineering Company.

2.20 ELECTRICAL CONTROLS

2.20.1 All electrical systems shall conform to the latest DaimlerChrysler Control Specification that is included or referenced in the Bid Package becoming a part of this entire specification.

2.20.2 The Suppliers shall be responsible for supplying any and all electrical components required to make this a complete and operable system.

2.20.3 On individual filter systems, components shall be pre-wired to the respective filter unit mounted electrical control panel. This includes high and low voltage.

2.20.4 On multiple tank filter systems, each filter/pre-conveyor shall include a filter mounted local control panel with common freestanding Main Control Panel. Motor Starters for each filter and respectively mounted pumps shall be mounted in the Local Panel. Motor Starters for items shared commonly by multiple filters, such as pre-conveyors and drag conveyors shall be mounted in the Main Control Panel. The Local Panels on each tank are to be daisy chained together for communication purposes. Additionally, connections to each panel for data and power (24V and 480V) are to be via Harting connectors.

2.20.5 The individual conveyors drives shall have start/stop buttons located at the discharge end of the unit for service maintenance/hopper change out. The conveyor start/stop function is to be designed with a timer so that the conveyor will automatically re-start after a pre-determined amount of time. This timer needs to be adjustable from the HMI. A display on the main panel HMI shall indicate the position of these pushbutton stations.

2.20.6 Each individual motor in the system shall have its own fused safety disconnect that shall be mounted and wired in close proximity to the motor it serves but not in the way of service.

2.20.7 All motors used in this program shall be T.E.F.C.B.B. Premium Efficiency “U” Frame only .



Date: 12/06/06

2.20.8 All motors shall be 1,750 RPM, unless specifically designated and/or otherwise approved in writing.

2.20.9 All motors 3 HP and larger shall have non-PCB power factor correction capacitors for brown field sites where local power factor correction is used. These capacitors shall be attached to the electrical panel they service and all wiring shall be complete prior to installation of the electrical panel. All others shall use central power factor correction located at substations by others.

2.20.10 Control of multi Pump Motors on a single system shall allow individual selection of pumps and have an option for an automatic mode to rotate pump motor duty ensuring that motors with the lowest run hours are running while the motor with the highest run time is on stand-by.

2.20.11 The successful supplier shall be responsible for including any and all other components (not specifically mentioned herein) that are required to make this a completely, fully automatic, totally safe, engineering approved system.

2.20.12 All separation points in the system shall terminate in a junction box with terminal strips for ease of connection.

2.20.13 All pump back systems associated with a filter system shall be hard wire interlocked with the machine tool equipment, mist collectors, high pressure coolant skids, machine coolant valve and main filter system. Refer to Sections 2.14 and 2.15 for interlock requirements.

2.20.14 All wiring shall be ran in rigid (steel) conduit except at points of connections to motors, switches, etc. as defined in DaimlerChrysler's electrical standards.

2.20.15 On above floor pre-piped and pre-wired filter systems, the conduit must remain on the filter tanks for shipping. Break points need to be designed into the system to facilitate teardown and re-assembly.

2.20.16 Each Filter shall have the following analog signals:

Vacuum Main Header Pressure Tank Liquid Levels Temperature

2.20.17 Each Filter shall have the following discrete signals:

Index failure Vacuum/Pressure filter belt motion detection Media Rewinder Full Media Roll Low Media Roll Empty Conveyor Failure Clean Tank Low Level Filter Tank Emergency High Level Low Pump Pressure Low Air Pressure High vacuum for vacuum type filters High pressure for pressure type filters Pre-Conveyor/Drag Tank failure Pre-conveyor belt motion detection Motor overload



Date: 12/06/06

Lube low level Clean tank level OK Pumpback failure (for system with Pumpback units) Belt wash failure

2.20.18 Each Filter System shall include “weekend mode” with adjustable “on duration” and over ride and customization for holidays” for aeration and recirculation out to the entire system utilizing a minimum number of system pumps as required to maintain a minimum flow velocity of 4 feet per second in the distribution piping when activated for one hour circulation event.

2.20.19 Each filter system is to be hard wired interlocked to the associated mist collector system. Upon system shutdown or entering weekend mode, the filter system should drop the signal to the mist collector.

2.21 COOLANT HEAT EXCHANGER (refer to Specification 15710 Heat Exchangers)

2.21.1 Provide price for heat exchangers to cool and maintain the coolant temperature at a constant supply temperature of 75° F ± 2° F to the cutting machines, or as specified in OEM coolant data sheets.

2.21.2 Provide plates of type 316 stainless steel with Viton gaskets. Frame size shall be large enough to accomplish a 25% improvement in cooling capacity by the addition of plates. Pipe connectors shall be grooved.

2.21.3 Provide pneumatic activated 2-way modulating valve assembly for temperature control, where supply and return system are connected by end of line relief valves. Provide pneumatic activated 3 way modulating valve, where supply and return systems are not connected by end of line relief valves. This modulating valve shall be placed on the “chilled water out” line. Provide temperature and pressure gauges on all pipe inlets and outlets that are easily visible from finished floor or top of filter tank. Differential pressure sensors are required across the chilled water and process coolant plates for detecting a blocked condition.

2.21.4 Provide drain valves at the lowest points and isolation valves at all connections. On tank top mounted heat exchanger skids, the process coolant drains are to be piped into the dirty tank. Label all pipe connection as “Chilled Water In “, “Chilled Water Out”, “Process Coolant In “ “Process Coolant Out”.

2.21.5 The heat exchanges shall be mounted on a skid that can be lifted via a fork truck with a solid cover deck over all structural members. The skid shall include a NEMA – 12 electric enclosure with all controls mounted, prepped and wired. Panel shall include a circuit breaker. The control RTD shall be mounted in the “Process Coolant In” connection and wired to the controls. The heat exchanges shall be integrated into the filter controls so that the heat exchange shuts off if the filter pumps shut off. The filter HMI is to control the temperature settings for the heat exchanger.

2.21.6 Provide all extensions for pressure gauges and thermometer and RTD’S to allow for 2 inches thick insulation. The heat exchanger skid is to be pre-insulated.

2.21.7 Wye strainers are required on the “Chilled Water In” and “Process Coolant In” lines. The strainers are to be 60 mesh.

2.21.8 The “Process Coolant Out” discharge is to be piped directly into the pump suction piping or the vacuum chamber.



Date: 12/06/06

2.21.9 The coolant filter supplier shall include the coolant flows through the heat exchanger when selecting the pump sizes. The heat exchanger is to be sized to handle both the loads from the cutting operations and from the coolant pumps.

2.22 COOLANT REFRIGERATION SYSTEM (Alternate Price)

2.22.1 Provide alternate pricing to provide each system with a mechanical chiller refrigeration system. The Chiller system shall utilize, water-cooled primary refrigeration unit and an in-direct heat exchanger with water-glycol loop that shall be capable of cooling the entire volume of coolant in the system and maintain a constant supply of 75F 2F coolant temperature to the machines, or as specified in OEM coolant data sheets.

2.22.2 In-direct heat exchangers shall be provided on a by-pass loop from the main filter system supply header. The “Process Coolant Out” discharge is to be piped directly into the pump suction piping or the vacuum chamber.

2.22.3 The temperature for the entire coolant system shall be controlled by a sensor located in the pump supply header that shall send a signal to the chiller unit indicating what the temperature of the coolant is in the system. At this time, the chilled water circuit shall open and/or close to handle the signal and maintain the proper temperature of the coolant. A description of the systems to be quoted is as follows:

Reservoir tank with pump circulating glycol through an evaporator. Discharge from evaporator to reservoir tank and/or to heat exchanger. Plate and frame heat exchanger with chilled glycol and machine coolant as the (2)

fluids. Compressor/Condenser/Evaporator to maintain chilled glycol temperature.

2.22.4 Supplied with this refrigeration system shall be a complete chilled water system that shall incorporate its own chilled water holding tank, circulating pump, all controls, gages, etc; to make this a totally self-contained fully automatic system. The system shall be mounted on a structural steel base with solid decking over top of any structural members

2.22.5 The coolant filter supplier shall include the coolant flows through the heat exchangers when selecting pumps. The heat exchanger and chiller must handle both the load from the cutting operation and from the pumps.

2.22.6 The Filtration supplier’s quotation shall state cooling water flow requirements.

2.22.7 Wye strainers are required on the “Chilled Water In” and “Process Coolant In” lines. The strainers are to be 60 mesh.

2.22.8 Misc. Design Comments: Ambient Design Conditions: Temperature: 0 o -110o F. Design coolant temperature set point: 75o +- 2o F, or as specified in OEM coolant

data sheets. Chillers shall be located indoors. The machine shall be delivered, preset for start up at 75F. Coolant temperature adjustable range from 70F to 90F. Glycol water adjustable range of 40F to 60F. Provide a dx condenser on the roof with oil load and hot gas by pass. The cooling system shall be designed to dissipate the full heat load and maintain

a constant temperature to the system as designated. Temperature to have set point and ambient tracking control.



Date: 12/06/06

Unit to come completely pre-assembled and "Skid" mounted with all interconnecting supply and discharge piping.

Drawings to be made per DCX CAD standards. Approval drawings to be sent in a timely fashion to meet target ship dates,

assuming one week approval process. Comply with DCX noise standards. Electrical panel fabrication and wiring to be done per the controls specifications.

2.22.9 Electrical Requirements: (Refer to Controls Specifications for details) All control wiring to be 24 VDC. Local control panels that are to be mounted on

the equipment; all wiring between skid components and local control panel are to be completed by supplier.

Supplier to provide the following interlocks to the system control panel: 1. Chiller Enabled 2. Chiller Fault 3. Over Temperature Fault

Various alarms should be displayed on local control panel with push to test lights All faults to a common interlock. Fault contact opens on fault. Disconnects to be provided (mounted and wired) for every motor that can be

serviced with the chiller partially running. If the motor not running results in the entire system being shutdown; then a local disconnect is not required; as the main disconnect shall suffice.

Control of the units to be by PLC. Supply power to be 460V/ 3P /60 Hz Nema 12 panel Flange mounted disconnect to be provided on local control panel (fuse protected) Across the line starter for compressor motor No motors larger than 75 Hp All motors 3 HP and larger shall have non-PCB power factor correction capacitors

for brown field sites where local power factor correction is used. These capacitors shall be attached to the electrical panel they service and all wiring shall be complete prior to installation of the electrical panel. All others shall use central power factor correction located at substations by others.

Power On/Off switch Local/Off/Remote switch Wiring to use liquid tight conduit for condensers. Air temperature probe mounted to unit for ambient tracking Temperature controllers to be Honeywell or approved equal

2.22.10 Condensers: Locally mounted Must include fan control via variable speed drive or step control to maintain the

required suction gas temperature at the compressor.

2.22.11 Recirculation pump: End suction, centrifugal. (1) pump preferred (NO STAND-BY) for circulation of glycol to the in-direct heat

exchanger near the filtration system. Motors to be 1750 rpm, U-frame, premium efficiency Isolation valves on suction and discharge Pressure gauge (with ¼” isolation valves) on pump discharge

2.22.12 Evaporators: Direct expansion with refrigerant expanded in the tubes and water in the shell. Water side to be baffled to control flow across the tube surface. Constructed in accordance with ASME code section VII, and so stamped



Date: 12/06/06

2.22.13 Refrigeration/ Compressors: Refrigerant Type: R-134A Dual circuit, direct expansion (where required) Thermostatic expansion valve Back pressure regulator Liquid receiver Service valves Removable high side filter dryer Liquid line sight glass Oil level sight glass Oil pressure pump Oil strainer Oil differential pressure switch Liquid line solenoid valve High and low refrigeration gauges and switches Full refrigerant charge Full level of oil Semi-hermetic reciprocating, or open drive, or screw (for large units) Crankcase heater Multi-step capacity control: Cylinder unloading & hot gas bypass. Reversing switch to alternate the lead compressor Vibration dampeners on compressor bases

2.22.14 In-Direct Heat exchanger (refer to specification 15710 – Heat Exchangers): Plate & Frame Inlet and outlet pressure gauges to detect blockage; and differential pressure

switch Stainless steel plates (.5 mm minimum) Alternating fluid passages and counter-flow pattern Cleanable, removable plates 3-way proportional valve on chilling side inlet for diverting flow to reservoir tank. Viton gaskets/o-rings on “hot side”

2.22.15 Reservoir Tank: Capacity equal to (2) times the recirculating pump flow plus piping volume. Stainless steel construction Armaflex Insulation Low Level Switch Temperature transmitter Temperature gauge Fluid level sight glass Tank drain with 2” ball valve

2.22.16 Mechanical Components: Refer to component specifications for details

2.22.17 Start-up & Training: EACH Refrigeration System price shall include five (5) days of Service for Start-

up and Installation Supervision, including all living and travel expenses. Service should be quoted based upon ten (10) hours per day, Monday through

Friday only. As a part of the quotation, Refrigeration System supplier shall also state per diem

and hourly rates, including travel and living for straight time, overtime and holidays.



Date: 12/06/06

The Supervision shall be on call and available to the plant within twelve (12) hours of the call at any time deemed necessary by DaimlerChrysler.

One (1) day of On-Site Training Services Refrigeration system must be included in the quotation.

Training should be quoted based upon one (1) day, 8 hours per day Classroom and Field Training at DaimlerChrysler facility for ten (10) personnel.

Training shall include both electrical and mechanical aspects of the Refrigeration system.

Pricing shall include a total of ten (10) training manuals, per filter system. Training shall include travel and living, and shall be submitted for straight time

only.

2.22.18 Sound Levels: Equipment shall be designed to meet the latest DaimlerChrysler Standard Sound

Requirements as set forth in the Manufacturing Standards Sound Level Specification for Industrial Machinery and Equipment.

The Refrigeration Systems shall be sized and designed using only one of the following named companies.

o Koolant Koolers, Inc.o Alpha Engineered Refrigeration Companyo Thermal Care

2.22.19 Provide protective covering for stored equipment

2.22.20 Do not allow use of equipment for temporary facilities, except when approved in writing by DaimlerChrysler

2.23 PIT SUMP SYSTEMS

2.23.1 Any pits containing filter equipment shall have a sump with pump and the filtration system supplier shall provide design.

2.23.2 Pits will be designed with a 2'-0" x 2'-0" x 2'-0" concrete sump with a double contained steel sump with a containment inspection port. The filtration system supplier will provide one (1) operating, air operated flap valve pump (due to the capabilities of handling line size solids) which will be located on the plant floor when possible and will pump from the pit sump to plant industrial waste. The Sump Pump will require a 3” suction and 3” discharge with tranquilizer on the discharge of the pump to prevent pipe shock at 30 psi on 60 psi. Additionally, there shall be a valved pneumatic bypass around the level controller of the pump. The filter supplier is responsible to provide any air pressure regulating devices if required. This Sump Pump will be controlled by pneumatic level control, level sensing tube (APCo #1014 or approved equal) that will be installed in the sump. In addition, the filtration system supplier will provide one (1) mechanical type float switch for sensing and signaling emergency high levels in the sump. The level switch and level sensing tubes will be supplied pre-mounted on mounting plates/brackets which will facilitate field mounting of these devices to the pit floor. The filtration system supplier will provide serrated bar grating, 1" x 4" pattern with 1-1/2” high x 3/16" thick bearing bars reinforced for a 250#/sq.ft. pedestrian loading coverage of the pit sump.

2.24 WORK PLATFORMS

2.24.1 Work platforms required under these specifications and/or as part of this system will be constructed to conform to OSHA standards as minimum design criteria. The supplier, when instructed through these specifications, will incorporate structural materials as designated, as long as they meet or exceed the OSHA requirements.



Date: 12/06/06

2.24.2 Generally, all platform access area will include serrated steel bar grating, 1" x 4" pattern with 1-1/2" high x 3/16" thick bearing bars reinforced for a 250#/sq.ft. pedestrian loading.

2.24.3 A minimum of 6'-8" headroom will be provided under all platforms, including piping or other items mounted below the platform.

2.24.4 All platform section/pieces are to be clearly marked and an installation drawing is to be provided that shows how the pieces are to be re-assembled.

2.24.5 All platforms for above floor filter systems are to be pre-installed on the suppliers floor prior to shipping.

2.24.6 The successful supplier will supply work platforms at all points in the systems (locate 6-feet or more above the walk area of the finished floor of the pit, top of tank, and/or factory floor) that require periodic maintenance, but not limited to, the following:

All drive units and take - ups All pumps All conveyors All motors All controls, limit switches, etc. All valves Open side of tankage where maintenance will be required. Access to bag filters as required.

2.25 TANK TOP ACCESS, COVER, PLATES and HANDRAILS

2.25.1 Filter Tanks, Drag Tanks and Pre-Conveyors will include 1/4" thick steel Slip-Not, Grade #2 tank top cover plates reinforced for a 250#/sq.ft. pedestrian loading. Consideration will be given for "normal" inspection/access areas on all tank tops. In these areas, 1/4" thick hinged plastic covers (12” x 12”) will be provided with a steel grating protection area underneath the cover when removed. All coverplates must include 1 inch holes in the covers with pipe caps welded to the bottom to prevent mist. There also must be a mist angle installed under each coverplate seam.

2.25.2 Ramps will include sheet steel (10 gal.) bolted, removable covers.

2.25.3 All tanks with the tank top over 3’-6” above the floor and where maintenance access may be required will include perimeter handrail and OSHA approved toe kick plate. This handrail will be fabricated from 1-1/4" steel pipe welded and utilizing pipe elbows/tees at intersections and turns. (No mitered and welded pipe joints on handrails)

2.25.4 Where access is required, all tanks above grade or in pits will include at a minimum, one (1) access ladder or one (1) ships ladders to OSHA l standards.

2.25.5 All inspection hatches are to be hinged.

2.25.6 All ladders and stairs are to have auto-closing swing gates. Confined space placards must be provided for each access point.

2.25.7 All cover plates are to be framed in with ¼” x ¼” bar stock in order to prevent cover plate movement.



Date: 12/06/06

2.25.8 All above floor filter systems require a stairway to the tank top for maintenance access.

2.26 EYEWASH/SHOWER STATIONS

2.26.1 Supplier shall provide one (1) Haws model #8317 Eyewash/Shower station for each remote filtration system. The Eyewash Stations may be shipped loose in the original packing for field assembly by DaimlerChrysler or designated union trades.

2.27 CHIP HOPPERS

2.27.1 Chip hoppers to be designed and fabricated to contain chips and associated debris for no less than 10 hours of production given a 150,000 annual volume. Galbreath Model No. H250, Part No. 3632, size 2.5 cubic yards with capacity for 6000 pounds. Exceptions may be identified in scope of work descriptions.

2.27.2 A chip hopper is to be provided under every discharge chute.

2.28 PAINTING

2.28.1 All painting will conform to DaimlerChrysler Corporation color code and paint standards.

2.28.2 The successful supplier will be responsible for ensuring that any and all parts of this system will be painted to conform to Chrysler Standards. This will include all electrical components, piping, tankage, guarding, and all conveyors that are not immersed in liquid. (DO NOT PAINT INTERNAL TANK)

2.29 HEATING (For Specific Washer Filters – only where absolutely required)

2.29.1 A heating package will be required for washer filters that are identified as needing this option, and will be for 180° F continuous operation and a two (2) hour temperature rise time (ambient to 180° F).

2.29.2 All heating requirements for Washer Filters will utilize natural gas. Alternate pricing for electric or steam shall be provided if feasible for plant specific locations.

2.29.3 The filtration supplier is responsible for gas exhaust requirements on the filter units. Natural Gas heating systems will be ventilated to the outdoors (through the plant roof). DaimlerChrysler or designated union trades will provide and install ducting from the filter system exhaust connection to and out of the roof.

2.29.4 The Filter Tank and Clean Tank shall be insulated with 2" thick with a 16 gal. Stainless steel jacket using formed trim strips to prevent water contamination. Piping shall be insulated with a minimum 1" thick fiberglass and jacketed insulation or as designated by a registered Architect Engineer.

2.30 PIPING

2.30.1 The successful supplier will be responsible for supplying a schematic piping drawing of all piping required for the complete and operational installation of these systems. A registered Architect Engineer (provided by others) shall design the actual routing, anchoring and support of the coolant distribution piping from the header at the filter.

2.30.2 All piping (unless otherwise specified) will conform to DaimlerChrysler latest piping standards as outlined in the master specifications – Section 15231.



Date: 12/06/06

2.30.3 All points of connection to or from the equipment and/or existing piping will be made through the use of a valve and union and/or flange or grooved end pipe connection as required.

2.30.4 All orifice plates and pressure/flow regulating valves require sound abatement material 4 feet upstream and downstream from the orifice plate or regulating valve.

2.30.5 All flume flush drops require a manual valve downstream of the pressure/flow regulating device or orifice plate. The valve is to have a minimum 6 position lockable style handle.

2.30.6 Rolled groove pipe ends are the preferred method where practical.

2.30.7 Manual Valves 6" diameter and less will be equiped with locking position lever handles. Manual valves 8" and larger will use hand wheel/gear actuators. The successful supplier will supply and install gear operated butterfly valves and check valves for all pump discharge piping.

2.30.8 All Systems will have valves with Viton or Teflon seats and seals compatible with the water-soluble or straight oil coolant in the system.

2.30.9 All pump discharge headers will be shipped fully assembled and ready for installation. The filtration system supplier will provide orifice plates that are required for the filtration system suppliers’ provided pumps.

2.30.10 All headers provided by the successful filter supplier shall provide a structural design and all anchoring material for the headers at the filters. Anchors shall attach to the tanks and or its framing. All anchors are to be installed on the filter suppliers floor prior to shipping.

2.30.11 All piping is to include identification and flow direction labels.

2.30.12 All valves are to have labels indicating normal operating position.

2.30.13 All pressure gauges need to have normal operating ranges indicated as identified in the DaimlerChrysler Construction Standard Section 15122 – Meters and Gages.

2.30.14 For coolant distribution piping systems that do not have Flume Flush drops or ‘End of Line’ flush drops located at the end of the distribution piping, a 1” by-pass line with a manual ball and check valve needs to be provided in order to flush the fines from the piping system. On gravity return systems, the by-pass line can be piped directly to the flume. For above floor pumpback systems, the by-pass line can be piped into the dirty coolant return header.

2.31 SUPERVISION/SERVICE

2.31.1 Supplier shall provide in the quotation adequate service time to support the installation, debug and system integration based on the project complexity. No addition funding will be provided for living and travel expenses once the P.O. is awarded. A minimum of ten (10) days of service for start-up and installation supervision per filter system must be included in the quotation.

2.31.2 Service should be quoted based upon ten (10) hours per day, Monday through Friday only.

2.31.3 As a part of the quotation, supplier will also state per diem and hourly rates, including travel and living for straight time, overtime and holidays.

2.31.4 The Supervision will be on call and available to the plant within twelve (12) hours of the call at any time deemed necessary by DaimlerChrysler.



Date: 12/06/06

2.31.5 For Chiller Supervision, See Coolant Refrigeration Systems.

2.32 TRAINING

2.32.1 Three (3) days of On-Site Training Services for each type of filter system must be included in the quotation.

2.32.2 Training should be quoted based upon three (3) days, 8 hours per day Classroom and Field Training at DaimlerChrysler facility for ten (10) personnel.

2.32.3 Training will include both electrical and mechanical aspects of the filter systems, flume systems and pump-back systems as well as other system components.

2.32.4 Pricing will include a total of ten (10) training manuals per filter system.

2.32.5 Training will include travel and lodging and shall be submitted for straight time only.

2.32.6 For Chiller Training see Refrigeration Systems.

2.33 SOUND LEVEL/NOISE ABATEMENT

2.33.1 Equipment will be designed to meet the latest DaimlerChrysler Standard Sound Requirements as set forth in the Manufacturing Standards Sound Level Specification for Industrial Machinery and Equipment and become a part of this total specification.

2.33.2 Any enclosures required to ensure that these requirements will be met will be provided in the proposal. DaimlerChrysler will not accept statements to the contrary.

2.34 ASSEMBLY and RUNOFF

2.34.1 Where possible, equipment will be assembled on supplier's floor and prepared for inspection by DaimlerChrysler and run off per the “authorization to ship process”. Exceptions for full assemblies during runoff must be identified in proposals for field assembled units only. All above floor filter systems are to be pre-piped and pre-wired for equipment runoff.

Ramps mounted Chain and flight conveyors installed. Conveyor drives fully assembled. Drive guards installed. Clean Tanks mounted and piped. Pre-conveyors and Drag Tanks mounted on/along side of Filters. All chutes,

interconnects, overflows, etc. will be installed on the filter suppliers floor prior to runoff.

All tank welds must be dye penetrate tested. All tanks must be filled with water and leak tested. If the size of the tanks

prevents this from occurring, the filter supplier will be responsible for ALL costs to fix the leaks using DaimlerChrysler or designated union trades.

All conveyors (including Vacuum Filters) shall be run for a minimum of Twenty (20) continuous hours with an intermittent index every 10 minutes.

Media Rewinders and Media Wings installed. Roll Media ran and cycled through all Vacuum Filters. Tank top perimeter handrails and access ladders mounted. Tank top and Ramp Covers in place. Lubrication Panel will be mounted and wired on the filter. Interconnecting lube

lines from the panel to the Vertical Turbine Pumps shall be furnished and installed



Date: 12/06/06

by the filter supplier. If installation of the interconnecting lube lines is not physically possible, installation will be completed by DaimlerChrysler or designated union trades with DCX engineering approval.

Level Control/Make-up/Pneumatic Panels mounted, plumbed and wired on the filter.

Vertical Turbine Pumps mounted on filters complete with Suction and Discharge Piping in place and including all interconnecting piping from the Main Header to the Filter and Clean Tank. Vertical Turbine Pump Motors may ship loose for field installation. In which case, the filtration system supplier will state this in the proposal. The filtration system supplier shall paint per the specifications all vertical turbine pump motors.

Horizontal Pumps and motors shall be mounted in drip trays and complete with Suction and Discharge Piping in place and including all interconnecting piping from the Main Header to the Filter and Clean Tank.

Local Filter Control Panels fully mounted and wired on the filters. For multiple filter systems, where a Main Control Panel is required, the

interconnecting conduit is to be installed on each tank with break points so that the conduit/cable tray will remain on the tanks for shipping.

All PLC programs will be loaded on supplier's floor. Control Panels will be fully functional tested for proper control, monitoring and operation prior to shipment.

Motor Disconnect switches shall be fully wired to motors and control Filter systems with multiple tanks require alignment plates between each tank

(front and back) to assist with locating each tank in relation to each other. All piping is to be installed on the filter system for runoff. On systems with

multiple tanks, the piping is to be designed with break points (union, flanges, etc.) so that the piping can remain on the tanks for shipping. All piping is to remain on the filter tanks unless shipping height and width restrictions prevent this from occurring.

Each complete filtration system will be subject to a minimum two (2) weeks of continuous run with reasonable chip loading on DaimlerChrysler's floor prior to full acceptance by DaimlerChrysler.

2.35 COOLANT/WASHER CLARITY TESTING PROCEDURE for PPM

2.35.1 Purpose: Gravimetric analysis allows particulate contamination to be isolated from water diluted and oil based metalworking fluids. Once isolated, the contamination can be quantified on a weight per unit volume basis. It can also be examined under a microscope. Viewing particles under the microscope provides information with respect to type, size and geometry of particulate.

2.35.2 Laboratory Equipment: (minimum) Graduated Cylinder calibrated to contain (TC)(appropriately sized for sample)Vacuum Pump or Aspirator and HoseSidearm Erlenmeyer Flask (appropriately sized)Microfiltration Apparatus (Filter funnel, support screen, etc. sized to fit Erlenmeyer)Polycarbonate Membranes (porosity as desired: 8, 5, 3, 1 micron)Forceps (for handling membranes)Analytical Balance (accurate to 0.1 mg)Microscope (for viewing particulate under magnification)Solvents in squirt bottles as appropriate (Distilled water, Petroleum Ether, Methanol)



Date: 12/06/06

2.35.3 Procedure: 1.Set up microfiltration apparatus by connecting vacuum pump suction to sidearm Erlenmeyer

flask. Membrane support hardware should be set up in the top of the Erlenmeyer flask. Set vacuum pump to maintain 10” Hg vacuum.

2.Weigh polycarbonate membrane on analytical balance. This membrane should be appropriately selected for the desired particulate analysis. Generally, eight micron membranes are used for this test.

3.Record weight of membrane and place membrane onto membrane support hardware, covering support screen. The more reflective side of the membrane should face up.

4.Place microfiltration reservoir on top of membrane and membrane support hardware and clamp in place with microfiltration apparatus clamp.

5.Thoroughly mix sample and measure in graduated cylinder. (usually 100 mL)6.Start vacuum pump and pour measured sample into microfiltration reservoir. 7.Rinse graduate using distilled water, methanol and petroleum ether.8.Rinse excess fluid from membrane using distilled water and methanol. This should remove any

excess water-soluble materials. Make the final rinse with petroleum ether to remove any residual oil.

9.Once dry, reweigh the membrane. The weight gain of the membrane, when compensated for the sample size, will result in mg/L, or ppm.

10. Place membrane (with background, if desired) into a membrane analyslide case. The slide case can be labeled with any pertinent information desired and particles viewed under a microscope.

11. Microscopic evaluation can be accomplished and interpreted as required.

2.35.4 Notes: Volumetric glassware is listed as calibrated to contain (TC) or to deliver (TD). Typically when a fluid is transferred from a piece of measuring glassware to the mixing glassware no other fluid is desired in the mix. Therefore what ever droplets remain in the graduate are not important and are therefore not rinsed into the solution. The glassware used is calibrated to deliver and the volume assumes a standard film will remain coating the glassware sides. In this procedure the larger metal chips have a tendency to settle which have to be rinsed from the bottom. Rinsing the glassware ensures these particles are include in the count and since the solids are the only material of interest the solvents do not interfere with the results. Using cylinders calibrated TC ensures that the proper amount of fluid is used.

2.35.5 Calculations: Milligrams per liter, or parts per million can be calculated by dividing weight gain of membrane by the volume of the sample. Below is an example:Membrane weight with dirt 0.02005 gMembrane tare wt. 0.01885 gDifference 0.00120 g This is the weight of dirt in the sample

The sample volume was 100 mL, which is 0.1 L

The weight per volume can be written as 0.0012 g / 0.1 L or 12 mg / 1 L12 mg/L is equal to 12 ppm.

In general, when a 100 mL sample is used for analysis, the weight difference is multiplied by 10,000 to find ppm. For example: If the weight difference is 0.01059 then the decimal place should be moved four places to the right, resulting in 105.9 ppm. When dirt loads are very heavy, the membrane will “blind” and flow through the membrane will slow and may stop completely. In this case, a smaller sample size is warranted. If necessary, a sample size as small as 10 mL can be used. In this case, the decimal place must be moved five



Date: 12/06/06

places to the right. For example: Using a sample size of 10 mL, the weight difference on the membrane is 0.02472 resulting in 2,472 ppm.

Microscopic examination of the membrane is subjective. The microscope should have a scale within one of the oculars. This scale can be used to estimate size of chips observed. The geometry and appearance of the chips may also be of some interest. Again, these observations are very subjective.

PART 3 - DOCUMENTATON

3.1 COORDINATION

3.1.1 The successful supplier of the filters shall attend coordination meeting with the Architect / Engineering Company and chip conveying suppliers as required coordinating the size of pits, trenches and chip chutes.

3.1.2 These meetings will be held weekly from the date that some substantial drawings are available from the filter supplier. Meeting will optimize the use of personnel until a coordinated design is accomplished.

3.2 TOTAL MAINTENANCE SPARE PART LIST

3.2.1 The successful supplier shall prior to shipment to the plant, provide an electronic version of the recommended spare parts list per the latest DaimlerChrylser TMS electronic format reference Section 15980(contact DCX Plant Engineer). If during the launch the supplier modifies the parts, they shall update the electronic version of the spare parts list.

3.3 PAYMENT TERMS and CONDITIONS

3.3.1 Final payment for this job will not be made until all component parts have been delivered, installed, started-up and run to the satisfaction of the DaimlerChrysler engineer.

3.3.2 Final payment will not be made until all as-built drawings, electrical drawings, operation and instruction manuals, control log, spare parts list, and any other component concerning this system and covered in this specification and other specifications, attached herewith and/or mentioned in this specification, has been conformed to in all respects and approved by DaimlerChrysler engineering.

3.3.3 Refer to Purchase order for clarification.

3.4 INSTALLATION

3.4.1 The successful supplier shall provide site supervision during the installation, start up and debug of the filter systems.

3.4.2 DaimlerChrysler Corporation or designated Union trades shall install equipment per the supplier’s recommendations.

3.5 LESSONS LEARNED

3.5.1 A plant installed auto-valved coolant flush lines on the ends of all coolant supply lines. These valves are controlled by the filter system when it is auto-started or when it comes out of week-end mode. This allows for the air to be purged from the piping whenever the filter system begins pumping coolant. This has two benefits: (1) It greatly reduces pipe movement at start-up, (2) It allows the coolant to flush any fines that might build up on the bottom/end of the coolant piping.



Date: 12/06/06

The problem occurred at the plant because these valves were located up in the truss space, so the flush piping is at a minimum 25 feet long before it discharges into the flume at atmosphere. What happens is that at start up, the valves stay open until coolant is flowing out of the flush line and into the flume ( approx. 10 minutes). When the valve closes, a vacuum is created that does not allow the coolant to flow freely out of the drain pipe and into the flume. After about 15 seconds, an air pocket makes its way to the top of the drain line and the coolant is rapidly released into the flume which causes the pipe to jump violently. The plant installed vacuum breakers to the flush lines to solve this problem. However if the valves would have been installed near floor level, in order to reduce the length of pipe that could create a vacuum, this situation would never have occurred.

3.5.2 Provide manual isolation valves above floor immediately ahead of flume flush nozzles. This is required to provide back pressure on throttling or balancing valves to minimize noise.

3.6 FILTER SIZING TABLES

3.6.1 ALUMINUM OPERATIONS-CENTRALIZED & STAND ALONE COOLANT FILTRATION SYSTEMS

The Following Specification Items and Guidelines shall be incorporated in to this Bid per Coolant-Aluminum Applications

Aluminum Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping

Clean CoolantClarity/Retention 25 µm (avg.) @ Type 1 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)

Flux Rate GPM/Sq.Ft.

Min. Retention Time in Minutes/Filter Flow (Operating)

Flux Rate GPM/Sq.Ft

.

Min. Retention Time in

Minutes/Filter Flow (Operating)

Primary Conveyor 250 um 75-100 Not applic.Endless Belt (Vacuum) 14-18 3 7-9 4-5Auto Backflush Filter - 30 um - two dimensional

25-35 Not applic. 3-5 Not applic.

Aluminum Operations Honing, Lapping, Polishing, Valves Seats, Backflush from Self-cleaning Filters

Super-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)


Min. Retention Time in Minutes/Filter Flow

(Operating)


Min. Retention Time in Minutes/Filter Flow (Operating)

Roll Media (Vacuum) 8-10 3 4-5 4-5Roll Media (Pressure) 15 1-2 7-9 4-5

Aluminum Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping SERVING High Pressure and Super-Clean/Side Stream Requirements




Date: 12/06/06


Retention Time in Minutes/Filter

Flow (Operating)Flux Rate

GPM/Sq.Ft.

Retention Time in

Minutes/Filter Flow

(Operating)Roll Media (Vacuum) 8-10 3 4.5 4.5Endless Belt (Vacuum) 14-18 3 7-9 4-5Auto Backflush Filter Filter - 30 um - two dimensional


Aluminum Operations GrindingSuper-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)


Retention Time in Minutes/Filter Flow

(Operating)



(Operating)Roll Media (Vacuum) 8-10 3 4-5 4-5Roll Media (Pressure) 15 1-2 7-9 4-5

Type 1 PPM RequirementParticle Size PPM1. Larger than 8µm 15 to 302. Between 8µm and 1µm 100 to 3003. Average particle size less than 25µm



Applicable Specifications:

The scope of supply will be quoted as indicated below. “N/A” denotes “Not applicable to Aluminum Operations

Base Bid Option Not

Req’rdSpec Item Specification

X 1.3 SubmittalsX 1.4 Quality AssuranceX 1.5 Delivery, Storage and Handling

X 1.6 Self Contained Coolant SystemsN/A 2.1 Drag Conveyors /Settling Tanks/Overflow Pre-Conveyors

X 2.2 Flow-Through Pre-Conveyors (Required for aluminum chips) Overflow Pan Type Pre-Conveyors (required for steel chips)

N/A. 2.3 Wedge Wire Drum Filters (Iron Filters)X 2.4 Pressure Filters (Only where specified in scope of work)



Date: 12/06/06

X 2.5 Vacuum Filters (Primary, Polish and Washer Filtration)X 2.5 Primary Filtration – Permanent Media Belt Only

X 2.5 Primary Filtration – Roll Media OnlyX 2.5 Primary Filtration – Permanent Media Belt w/ Roll Media Capability

X 2.5 Super clean/Side Stream Filtration – Roll Media OnlyX 2.5 Super clean/Side Stream Filtration – Permanent Media Belt w/ Roll

Media CapabilityN/A 2.6 Washer Primary Filtration – Permanent Media Belt OnlyN/A 2.6 Washer Primary Filtration – Roll Media OnlyN/A 2.6 Washer Primary Filtration – Permanent Media Belt w/ Roll Media

CapabilityN/A 2.6 All Stainless Construction-(If 2.6 is to be quoted, it will also apply

to 2.7)X 2.7 Secondary Filtration – Bag Filter Filtration

X 2.8 Automatic Back Flushing FilterX 2.9 Pumps 400 g.p.m. and Greater-(Vertical Turbine)

X 2.10 Pumps 399 g.p.m. and Less-(Horizontal Centrifugal)X 2.11 Self-Priming Pumps – Portable Filter Pumpout PumpsX 2.12 Vortex Pumpback PumpsX 2.13 Vertical Wet Well Chip Shredding Pumps

X 2.14 In-Floor Pumpback SystemsX 2.15 Above Floor Pumpback Systems

X 2.16 Lubrication SystemsX 2.17 Liquid Level Control System (Water-soluble systems)X 2.17 Compatible with RO Water Make-up (Stainless Make-up

Piping/Meter/Valving)X 2.17 Coolant Tote Stand (For Neat Oil Supply)

N/A 2.17 Coolant Tote Stand (For Washer Filters w/ SS Containment)2.18 Liquid Level Control System (Straight oil systems)

X 2.19 Tramp Oil RemovalX 2.20 Fine Particulate Removal System (quote as an option for Honing

Filters)X 2.20 Centra-SepX 2.20 Other (DCX Identify):

X 2.21 Mist Collection ConnectionsX 2.22 Electrical ControlsX 2.22 Plant Specifics w/ Approved Components List AttachedX 2.22 Electric Motors Plant Specifics w/ Approved Components List

AttachedX 2.22 Pneumatics- Plant Specifics w/ Approved Components List

AttachedX 2.23 Coolant Heat ExchangerX 2.23 Water-Cooled Plate & Frame Heat Exchanger only

X 2.22 Coolant Refrigeration SystemX 2.25 Pit Sump Systems

X 2.26 Work PlatformsX 2.27 Tank Top Access, Cover Plates and HandrailsX 2.28 Eyewash/Shower StationsX 2.29 Chip HoppersX 2.30 Painting

N/A 2.31 Heating (For Washer Filters)N/A Natural Gas Fired



Date: 12/06/06

N/A ElectricN/A Steam

X 2.32 PipingX 2.33 Supervision/ServiceX 2.34 TrainingX 2.35 Sound Level/Noise AbatementX 2.36 Assembly and RunoffX 2.37 Coolant Testing Procedure for PPMX 3.1-3.5 Drawings, Spare Parts List, Payment Terms and Conditions,

Installation

3.6.2 PART WASH OPERATIONS-CENTRALIZED & STANDALONE COOLANT FILTRATION SYSTEMS

The Following Specification Items and Guidelines shall be incorporated in to this Bid per Central Coolant-Part Wash Applications

Washer Operations Part WashingClean CoolantClarity/Retention 30 µm (avg.) @ Type 1 PPM Requirements (see below)Coolant Type Water Based



Flow (Operating)Roll Media (Vacuum) 8-10 3Endless Belt (Vacuum) 14-18 3Auto Backflush Filter Filter - 30 um - two dimensional

25-35 Not applic.



The scope of supply will be quoted as indicated below. “N/A” denotes “Not applicable to filtration on Washer Operations

Base Bid Option Not



X 1.6 Self Contained Coolant SystemsN/A 2.1 Drag Conveyors /Settling Tanks/Overflow Pre-Conveyors


N/A. 2.3 Wedge Wire Drum Filters (Iron Filters)



Date: 12/06/06

N/A 2.4 Pressure Filters (Only where specified in scope of work)X 2.5 Vacuum Filters (Primary, Polish and Washer Filtration)

N/A 2.5 Primary Filtration – Permanent Media Belt OnlyN/A 2.5 Primary Filtration – Roll Media OnlyN/A 2.5 Primary Filtration – Permanent Media Belt w/ Roll Media CapabilityN/A 2.5 Super clean/Side Stream Filtration – Roll Media OnlyN/A 2.5 Super clean/Side Stream Filtration – Permanent Media Belt w/ Roll

Media CapabilityX 2.6 Washer Primary Filtration – Permanent Media Belt OnlyX 2.6 Washer Primary Filtration – Roll Media Only

X 2.6 Washer Primary Filtration – Permanent Media Belt w/ Roll Media Capability

X 2.6 All Stainless Construction-(If 2.6 is to be quoted, it will also apply to 2.7)

X 2.7 Secondary Filtration – Bag Filter FiltrationX 2.8 Automatic Back Flushing FilterX 2.9 Pumps 400 g.p.m. and Greater-(Vertical Turbine)X 2.10 Pumps 399 g.p.m. and Less-(Horizontal Centrifugal)

X 2.11 Self-Priming Pumps – Portable Filter Pumpout PumpsX 2.12 Vortex Pumpback PumpsX 2.13 Vertical Wet Well Chip Shredding PumpsX 2.14 In-Floor Pumpback SystemsX 2.15 Above Floor Pumpback Systems

X 2.16 Lubrication SystemsX 2.17 Liquid Level Control System (Water-soluble systems)

X 2.17 Compatible with RO Water Make-up (Stainless Make-up Piping/Meter/Valving)

X 2.17 Coolant Tote Stand (For Neat Oil Supply)X 2.17 Coolant Tote Stand (For Washer Filters w/ SS Containment)

X 2.18 Liquid Level Control System (Straight oil systems)X 2.19 Tramp Oil Removal

X 2.20 Fine Particulate Removal System (quote as an option for Honing Filters)

X 2.21 Mist Collection ConnectionsX 2.22 Electrical ControlsX 2.22 Plant Specifics w/ Approved Components List AttachedX 2.22 Electric Motors Plant Specifics w/ Approved Components List


AttachedX 2.23 Coolant Heat ExchangerX 2.23 Water-Cooled Plate & Frame Heat Exchanger onlyX 2.22 Coolant Refrigeration System

X 2.25 Pit Sump SystemsX 2.26 Work PlatformsX 2.27 Tank Top Access, Cover Plates and HandrailsX 2.28 Eyewash/Shower StationsX 2.29 Chip HoppersX 2.30 PaintingX 2.31 Heating (For Washer Filters)

X Natural Gas FiredX Electric



Date: 12/06/06

X SteamX 2.32 PipingX 2.33 Supervision/ServiceX 2.34 TrainingX 2.35 Sound Level/Noise AbatementX 2.36 Assembly and RunoffX 2.37 Coolant Testing Procedure for PPMX 3.1-3.5 Drawings, Spare Parts List, Payment Terms and Conditions,

Installation

3.6.3 STEEL OPERATIONS-CENTRALIZED & STANDALONE COOLANT FILTRATION SYSTEMS

The Following Specification Items and Guidelines shall be incorporated in to this Bid per Coolant-Steel Applications

Steel Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping





GPM/Sq.Ft.

Retention Time in

Minutes/Filter Flow

(Operating)Wedge Wire Drum 20 6Primary Conveyor-Settling Not applic. 1-2 Not applic. 2Endless Belt (Vacuum) 14-18 2-3 7-9 3-5Auto Backflush Filter Filter - 30 um - two dimensional


Steel Operations Honing, Lapping, Polishing, Valves SeatsSuper-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)



(Operating)



(Operating)Roll Media (Vacuum) 2-4 2-3 0.5-1 3-5Roll Media (Pressure) 4-6 1-2 2-3 1-2

Steel Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping SERVING High Pressure Skids and Super-Clean Requirements





GPM/Sq.Ft.

Retention Time in

Minutes/Filter Flow

(Operating)Roll Media (Vacuum) 8-11 2-3 4-5 3-5Endless Belt (Vacuum) 8-10 2-3 7-9 3-5



Date: 12/06/06

Roll Media (Pressure) 15 1-2 2-3 1-2Auto Backflush Filter Filter - 30 um - two dimensional


Steel Operations GrindingSuper-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)



(Operating)




Flux rates for Straight Oil applications require verification of Oil viscosity and operating temperature.





The scope of supply will be quoted as indicated below. “N/A” denotes “Not applicable to Steel Operations

Base Bid Option Not



X 1.6 Self Contained Coolant SystemsX 2.1 Drag Conveyors /Settling Tanks/Overflow Pre-Conveyors

N/A. 2.2 Flow-Through Pre-Conveyors (Required for aluminum chips) Overflow Pan Type Pre-Conveyors (required for steel chips)

X 2.3 Wedge Wire Drum Filters (Iron Filters)X 2.4 Pressure Filters (Only where specified in scope of work)X 2.5 Vacuum Filters (Primary, Polish and Washer Filtration)X 2.5 Primary Filtration – Permanent Media Belt OnlyX 2.5 Primary Filtration – Roll Media Only

X 2.5 Primary Filtration – Permanent Media Belt w/ Roll Media Capability



Date: 12/06/06

X 2.5 Super clean/Side Stream Filtration – Roll Media OnlyX 2.5 Super clean/Side Stream Filtration – Permanent Media Belt w/

Roll Media CapabilityN/A 2.6 Washer Primary Filtration – Permanent Media Belt OnlyN/A 2.6 Washer Primary Filtration – Roll Media OnlyN/A 2.6 Washer Primary Filtration – Permanent Media Belt w/ Roll Media


to 2.7)X 2.7 Secondary Filtration – Bag Filter Filtration

X 2.8 Automatic Back Flushing FilterX 2.9 Pumps 400 g.p.m. and Greater-(Vertical Turbine)X 2.10 Pumps 399 g.p.m. and Less-(Horizontal Centrifugal)




X 2.17 Coolant Tote Stand (For Neat Oil Supply)N/A 2.17 Coolant Tote Stand (For Washer Filters w/ SS Containment)

X 2.18 Liquid Level Control System (Straight oil systems)X 2.19 Tramp Oil RemovalX 2.20 Fine Particulate Removal System (quote as an option for Honing

Filters)X 2.21 Mist Collection ConnectionsX 2.22 Electrical ControlsX 2.22 Plant Specifics w/ Approved Components List AttachedX 2.22 Electric Motors Plant Specifics w/ Approved Components List





N/A 2.31 Heating (For Washer Filters)N/A Natural Gas FiredN/A ElectricN/A Steam

X 2.32 PipingX 2.33 Supervision/ServiceX 2.34 TrainingX 2.35 Sound Level/Noise Abatement



Date: 12/06/06

X 2.36 Assembly and RunoffX 2.37 Coolant Testing Procedure for PPMX 3.1-3.5 Drawings, Spare Parts List, Payment Terms and Conditions,

Installation

3.6.4 CAST & NODULAR IRON OPERATIONS-CENTRALIZED & STANDALONE COOLANT FILTRATION SYSTEMS

The Following Specification Items and Guidelines shall be incorporated in to this Bid per Coolant-Cast & Nodular Iron Applications

CI & NI Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping





GPM/Sq.Ft.

Retention Time in

Minutes/Filter Flow

(Operating)Wedge Wire Drum 14-16 6 Not applic. Not applic.Primary Conveyor-Settling Not applic. 1-2 Not applic. 2Endless Belt (Vacuum) 14-18 2-3 5-8 3-5Auto Backflush Filter Filter - 30 um - two dimensional


CI & NI Operations General Machining, Turning, Milling, Boring, Hobbing, Drilling, Tapping SERVING High Pressure Skids and Super-Clean Requirements


Flux Rate GPM/Sq.Ft.Retention Time in Minutes/Filter Flow (Operating)


Retention Time in

Minutes/Filter Flow

(Operating)Roll Media (Vacuum) 4-6 2-3 2-3 2-3Endless Belt (Vacuum) 6-8 2-3 3-4 3-5Roll Media (Pressure) 15 1-2 4-5 1-2Auto Backflush Filter - 30 um - two dimensional


CI & NI Operations GrindingSuper-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)



(Operating)



(Operating)Roll Media (Vacuum) 2-3 2-3 1-2 2-3Roll Media (Pressure) 6-8 1-2 4-5 1-2



Date: 12/06/06

CI & NI Operations HoningSuper-Clean CoolantClarity/Retention 10 µm (avg.) @ Type 2 PPM Requirements (see below)Coolant Type Water Based Oil (60 SSU @ 100 ºF)



(Operating)




Flux rates for Straight Oil applications require verification of Oil viscosity and operating temperature.



Type 3 PPM RequirementParticle Size PPM1. Larger than 8µm 10 to 152. Between 8µm and 1µm 50 to 1003. Average particle size less than 15µmApplicable Specifications:

The scope of supply will be quoted as indicated below. “N/A” denotes “Not applicable to Cast Iron & Nodular Iron Operations

Base Bid

Option Not Req’rd

Spec Item

Specification


X 1.6 Self Contained Coolant SystemsX 2.1 Drag Conveyors /Settling Tanks/Overflow Pre-Conveyors


X 2.3 Wedge Wire Drum Filters (Iron Filters)X 2.4 Pressure Filters (Only where specified in scope of work)

X 2.5 Vacuum Filters (Primary, Polish and Washer Filtration)X 2.5 Primary Filtration – Permanent Media Belt OnlyX 2.5 Primary Filtration – Roll Media Only

X 2.5 Primary Filtration – Permanent Media Belt w/ Roll Media CapabilityX 2.5 Super clean/Side Stream Filtration – Roll Media OnlyX 2.5 Super clean/Side Stream Filtration – Permanent Media Belt w/

Roll Media Capability



Date: 12/06/06

N/A 2.6 Washer Primary Filtration – Permanent Media Belt OnlyN/A 2.6 Washer Primary Filtration – Roll Media OnlyN/A 2.6 Washer Primary Filtration – Permanent Media Belt w/ Roll Media


to 2.7)X 2.7 Secondary Filtration – Bag Filter FiltrationX 2.8 Automatic Back Flushing Filter

X 2.9 Pumps 400 g.p.m. and Greater-(Vertical Turbine)X 2.10 Pumps 399 g.p.m. and Less-(Horizontal Centrifugal)




X 2.17 Coolant Tote Stand (For Neat Oil Supply)N/A 2.17 Coolant Tote Stand (For Washer Filters w/ SS Containment)X 2.18 Liquid Level Control System (Straight oil systems)

X 2.19 Tramp Oil RemovalX 2.20 Fine Particulate Removal System (quote as an option for Honing

Filters)X 2.21 Mist Collection ConnectionsX 2.22 Electrical ControlsX 2.22 Plant Specifics w/ Approved Components List AttachedX 2.22 Electric Motors Plant Specifics w/ Approved Components List





N/A 2.31 Heating (For Washer Filters)N/A Natural Gas FiredN/A ElectricN/A Steam

X 2.32 PipingX 2.33 Supervision/ServiceX 2.34 TrainingX 2.35 Sound Level/Noise AbatementX 2.36 Assembly and RunoffX 2.37 Coolant Testing Procedure for PPMX 3.1-3.5 Drawings, Spare Parts List, Payment Terms and Conditions,



Date: 12/06/06

Installation


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