Chrysler Construction Standards
AME-PT Plants
Date: 12/03/08
SECTION 15196 – COOLANT FILTRATION
PART 1 - GENERAL
1.1 SUMMARY
1.2 DEFINITIONS 1.3 SUBMITTALS 1.4 QUALITY ASSURANCE 1.5 DELIVERY, STORAGE AND HANDLING 1.6 SELF CONTAINED COOLANT SYSTEMS 1.7 APPROVED SUPPLIERS
PART 2 – DESIGN AND PRODUCT
This Section includes the following:
2.1 Drag Conveyors/Settling Tanks/Overflow Pre-Conveyors
2.2 Flow-through Pre-Conveyors
2.3 Wedge Wire Drum Filters
2.4 Pressure Filters
2.5 Vacuum Filters (Primary, Polish and Washer Filtration)
2.6 Secondary Bag Filters
2.7 Automatic Back Flushing Filters
2.8 Pumps 400 g.p.m. and greater (Filter/System, System Supply and Polish Filter)
2.9 Pumps 399 g.p.m. and less (Filter/System, System Supply and Polish Filter)
2.10 Self-priming Pumps – Portable Filter Pumpout Pumps
2.11 Vortex Pumpback Pumps
2.12 Vertical Wet Well Chip Shredding Pumps
2.13 In-Floor Pumpback Systems
2.14 Above Floor Pumpback Systems
2.15 Lubrication System.
2.16 Liquid Level Control System (Water-soluble systems)
2.17 Liquid Level Control System (Straight oil systems)
2.18 Tramp Oil Removal (quote as an option)
2.19 Fine Particulate Removal Systems (quote as an option)
2.20 Mist Collection Connections
2.21 Electrical Controls
2.22 Coolant Heat Exchanger
2.23 Coolant Refrigeration System
2.24 Pit Sump Systems
2.25 Work Platforms
2.26 Tank Top Access, Stairs, Cover Plates and Handrail
2.27 Eyewash/Shower Stations
2.28 Chip Hoppers
2.29 Painting
2.30 Heating (for washer filters)
2.31 Piping
2.32 Supervision/Service
2.33 Training
2.34 Sound Level/Noise Abatement
2.35 Assembly and Run-off
2.36 Coolant Testing Procedure for PPM
PART 3 – DOCUMENTATION
3.1 COORDINATION
3.2 TOTAL MAINTENANCE SPARE PARTS LIST
3.3 PAYMENT TERMS AND CONDITIONS
3.4 INSTALLATION
3.5 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
14. Visit https://gsp.extra.chrysler.com/mfg/amedd/powertrain.htm for access to all 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 Chrysler‘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.
1.3.2 Chrysler 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 Chrysler 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 (CAD Administration Agreement). All engineering drawings, upon successful completion of this project become the property of Chrysler 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. The Operation and Maintenance Manuals are due no later than 90 after receipt of purchase order for special machines and 30 days for standard machines.
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 Chrysler TMS electronic format (contact Chrysler plant engineer). The spare parts lists are due no later than 90 after receipt of purchase order for special machines and 30 days for standard machines.
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 Chrysler within four (4) weeks after the filtration supplier receives Chrysler’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 Chrysler engineering with complete as built drawings of the entire system as supplied and as installed.
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 Chrysler.
1.4.3 Installations shall comply with all national and local codes.
1.4.4 Installations shall comply with Chrysler 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 Chrysler 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 Chrysler 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 Chrysler facility. The successful supplier will as quickly as possible, after receipt of a purchase order, supply Chrysler 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 Chrysler's purchase order number Chrysler brass tag number Attention: (to be determined)
1.5.8 The supplier, at his earliest possible time, will supply Chrysler engineering with a timetable of events for this entire job based on the required delivery dates.
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. This price is to include chip hoppers with drop down tugger hitches.
1.6.2 Machine tool supplier shall provide drawings and details with proposal of such devices for review by Chrysler. Details shall include utility use, filtration clarity, chip discharge height, chip crushers, chip hoppers with drop down tugger hitches and all alternate costs 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
FILTRA SYSTEMS
23900 Haggerty Road
Farmington Hills, MI 48335
Durr Ecoclean – Henry Filters
1350 Van Camp Road
P.O. Box 859
Bowling Green, OH 43402
Knoll
313 W. Girard
Madison Heights, MI 48071
NO FABRICATION OF TANKS OR CONVEYORS ARE ALLOWED OUTSIDE OF THE UNITED STATES OF AMERICA. NOTE FABRICATION QUALITY AND EXTREMELY LATE DELIVERIES HAVE RESULTED FROM FABRICATIONS MADE IN MEXICO.
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.
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 Chrysler 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.