REHABILITATION AND IMPROVEMENT OF THE ARKANSAS RIVER LIFT BRIDGE, MP 410.6
JOB SPECIAL PROVISIONS
FY2017 TIGER GRANT NO. 157600102
FRA GRANT AGREEMENT NO. 69A36520401680TIIAR
July 23, 2021
Arkansas River Lift Bridge, MP 410.6
Table of Contents
Page General Special Provisions ...... 1 Maintaining Railroad Operations ...... 1 Coordination of Marine Navigation ...... 4
Electrical Special Provisions ...... 7 Electrical Rehabilitation ...... 8
Mechanical Special Provisions ...... 59 M100 – General Mechanical Specifications ...... 60 M101 – Sheaves, Trunnions, Bearings ...... 81 M102 – Counterweight Wire Ropes ...... 84 M103 – Counterweight Balancing...... 89 M104 – Machinery Bearing Liners ...... 93 M105 – Wire Rope Socket Keepers ...... 95 M106 – Aux Drive Shifter Assembly ...... 97 M107 – Machinery Brake ...... 99 M108 – Span Guide ...... 101 M109 – Main Motor ...... 103 M110 – Motor Brake ...... 105 M111 – Bevel Gear Plate ...... 107 M112 – Gearbox Seal ...... 108 M113 – Uphaul Rope Deflector Sheave Bolt ...... 110 M114 – Acceptance Testing ...... 111 M115 – Training and Supervised Operation ...... 113 M116 – Operation and Maintenance Manual ...... 114 M117 – Span Locks ...... 120
Structural Special Provisions ...... 122 Counterweight Jacking and Support ...... 123 Bearing Replacement...... 125 Foundation Protection Riprap ...... 130 Dumped Riprap ...... 131
Bridge Interlocking and Signals Specifications ...... 133 34 42 23 Railway Signal Control Equipment ...... 134 34 42 44 Signal Engineering Requirements ...... 170 34 42 45 Signal Installation Requirements ...... 173
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Arkansas River Lift Bridge, MP 410.6
GENERAL SPECIAL PROVISIONS
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MAINTAINING RAILROAD OPERATIONS
a. General Requirements. All railroad tracks within and adjacent to the Contract Site are active, and rail traffic over these facilities shall be maintained throughout the Project. Railroad traffic and operations will occur continuously and in either direction throughout the day and night on these tracks, except during the work windows described below. The Contractor shall become familiar with the train schedules at this location and shall coordinate and schedule the work so that construction activities do not interfere with railroad operations, except as noted herein.
b. Work Windows. Work windows for this Contract shall be coordinated with the Arkansas and Missouri Railroad’s Designated Representative. Types of work windows include Absolute Work Windows and Conditional Work Windows, as defined below:
1. Absolute Work Window. An Absolute Work Window is a period that construction activities are given priority over railroad operations. During this time frame the designated railroad track will be inactive for train movements and may be fouled by the Contractor. At the end of an Absolute Work Window the railroad track and/or signals must be completely operational for train operations and comply with all Arkansas and Missouri Railroad (AMRR) and Federal Railroad Administration requirements, codes, and regulations for operational tracks.
Absolute Work Windows may be scheduled during the week, Monday through Friday, from 8:00 a.m. till 3:00 p.m., and on the weekends starting at 5:00 a.m. on Saturday morning through 7:00 a.m. Monday morning.
2. Conditional Work Window. A Conditional Work Window is a period that railroad operations have priority over construction activities. When construction activities may occur on and adjacent to the railroad tracks within 25 feet of the nearest track, an AMRR flag person will be required. The AMRR flag person will be provided, as needed during construction, to the Contractor at no cost. At the direction of the AMRR flag person, upon approach of a train, and when trains are present on the tracks, the tracks must be cleared (i.e., no construction equipment, materials, or personnel within 25 feet, or as directed by the AMRR Designated Representative, from the tracks). Conditional Work Windows are available for the Project.
The Contractor shall make written requests for both Absolute and Conditional Work Windows at least two weeks (14 days) in advance of work. The written request must include a detailed work plan, including a description of the work to be performed, the exact location of the work, a schedule of activities, and the type of window requested.
c. Bridge Closures. When work will require the bridge to be closed to train traffic for a period that exceeds the allowable duration of the Absolute Work Windows, the Contractor shall submit a detailed work plan for a requested bridge closure. The work plan for a bridge closure will include a Gantt chart showing planned activities at hourly intervals. Work plans shall be submitted to the AMRR for review and approval no less than 30 days prior to the start date of the requested closure.
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d. AMRR Contact Person. The designated representative from the AMRR for this rehabilitation project is:
Mr. Jeromy Houchin Arkansas and Missouri Railroad 306 East Emma Springdale, AR 72764 Office: (479) 751-8600 Cell: (479) 790-0647 Email: [email protected]
e. Measurement and Payment. All costs incurred by the Contractor in complying with the above requirements shall be considered as completely covered by the prices bid for the various items of work included in the contract.
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COORDINATION OF MARINE NAVIGATION
a. Description. This work consists of conforming all operations in the waterway to the requirements or directions of the U.S. Coast Guard and the U.S. Army – Corps of Engineers.
b. Construction Requirements.
1. Signing. Four channel warning signs shall be securely erected, one on each channel bank upstream and downstream of the Arkansas and Missouri Railroad Lift Bridge at 500 feet from the centerline of the bridge.
The signs shall be a minimum of 4 feet by 8 feet exterior grade, ¾-inch thick plywood and shall be painted with two coats of exterior grade white enamel paint. The lettering shall be painted with black exterior grade paint. The letters shall be a minimum of 8 inches high, using uppercase block lettering indicating “Overhead Bridge Construction 500 Feet Ahead”.
2. Observer. Whenever construction is in operation over the navigation channel, the Contractor shall provide one observer to be positioned to watch for oncoming marine vessels from either direction. An audible signal shall be sounded for all work over the channel to cease when a marine vessel is 500 feet from the bridge. An all-clear signal shall be sounded when the vessel has passed the construction area and work may resume. The observer shall have a radio that can be used to communicate with the marine vessel.
The Contractor shall notify the Contractor’s bridge operator whenever workers are in a position to be affected by marine traffic. The bridge operator will notify the Contractor’s observer that vessels are approaching and from which direction.
All work, including flame-cutting, welding, and similar spark-producing operations, shall be suspended whenever a marine vessel, regardless of size, is approaching the bridge and is within 500 feet of the bridge and shall remain suspended until the entire marine vessel has completely passed away from the bridge area.
3. Obstructions. Should the Contractor, during progress of work, lose, throw overboard, sink or misplace any material, machinery, plant or appliance, he shall immediately recover and remove the same. The Contractor shall give immediate notice, with the description, location and depth of any item not recovered immediately, to the U.S. Army Corps of Engineers; and when required by the U.S. Coast Guard shall mark or buoy such item until it is recovered and removed.
4. Lighting. The Contractor shall provide and maintain whatever navigation lights and other navigation signals or facilities as may be required by the U.S. Coast Guard on all temporary construction or vessels and on all existing permanent construction. Temporary lights, signals or facilities, when required by the U.S. Coast Guard, shall be provided and maintained by the Contractor until final acceptance of the work under this contract.
5. Scheduled River Closure. The following river closures have been agreed upon by the Arkansas and Missouri Railroad and the U.S. Coast Guard, 8th District. These closures may be scheduled to occur during the months of January through September. When possible, river navigation will be allowed to continue during the closures by transferring barges under the closed span.
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River closures shall be directly coordinated with the U.S. Coast Guard. The Contractor shall submit detailed work plans for each requested river closure which are to include a Gantt chart showing planned activities at hourly intervals. Note that activities are to be planned in a manner that will result in the shortest river closure duration required to complete the individual repair which may require the Contractor to perform work 24 hours/day until the river can be fully reopened to navigation. The work plans will also provide information on when and how barge traffic can be maintained during the activities. Work plans shall be submitted to the U.S. Coast Guard for review and approval no less than 45 days prior to the start date of the requested closure. At that time, work plans will also be provided to the U.S. Army Corps of Engineers to keep them informed of upcoming river closures and construction activities.
A. A two-week (14 days) maximum river closure will be allowed to complete the following mechanical rehabilitation activities: remove and replace sheaves, trunnions, trunnion bearings, and counterweight wire ropes at each tower. The following electrical activities may also be performed at this time: remove the existing electrical equipment inside the machinery house and install a new motor control center, control cabinets, and a variable frequency drive. The Contractor has the option to perform the mechanical repairs simultaneously at both towers; however, if the Contractor proposes to complete the repairs at one tower at a time, a break in construction is required prior to beginning repairs at the second tower to raise the span and allow queued marine traffic to pass.
B. A 24-hour (1 day) maximum river closure will be allowed to complete the following mechanical rehabilitation activities: remove the existing longitudinal span guides on each side of the south end of the lift span and replace with new longitudinal span guides. A short break in construction is required prior to beginning repairs at the second guide to raise the span and allow queued marine traffic to pass.
C. A four-day maximum river closure will be allowed to complete the following mechanical rehabilitation activities: remove and replace the motor and motor brake in the machinery house. The following electrical improvements will also be completed during this closure: the existing aerial cables will be removed and replaced over the lift span.
6. Notice of Unscheduled River Closure. The Contractor shall be responsible to arrange with the U.S. Coast Guard for times and dates when work on the bridge shall require restrictions to the navigation of the waterway. A two-week (14 day) advance notice will be required for any unscheduled river closure for a period of 8 hours. The Contractor will also provide advance notice to the U.S. Army Corps of Engineers regarding unscheduled river closures.
7. River Level. Due to unpredictable weather conditions, work may have to be stopped due to high water elevations until the river level returns to normal pool stage. This decision will be made by the U.S. Coast Guard.
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8. U.S. Coast Guard Contact Person. The contact person from the U.S. Coast Guard for this rehabilitation project is: Mr. David Orzechowski U.S. Coast Guard Coast Guard 8th District 1222 Spruce Street St. Louis, Missouri 63103 Phone: (314) 269-2382 Email: [email protected]
9. U.S. Army Corps of Engineers Contact Person. The contact person from the U.S. Army Corps of Engineers for this rehabilitation project is: Mr. Roderick Gaines Phone: (501) 324-5563 Email: [email protected]
c. Measurement and Payment. All costs incurred by the Contractor in complying with the above requirements shall be considered as completely covered by the prices bid for the various items of work included in the contract.
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ELECTRICAL SPECIAL PROVISIONS
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ELECTRICAL REHABILITATION
a. Description. The work consists of providing all labor, materials and equipment for the complete electrical and control system rehabilitation as described herein and shown on the Plans, including all incidental work as shown and required by the Contract.
b. Applicable Standards. Comply with the following standards and specifications as applicable.
• NEC - National Electrical Code (NFPA 70)
• NFPA 70E - Electrical Safety in the Workplace
• NETA - International Electrical Testing Association Acceptance Testing Specifications
• NECA - National Electrical Contractors Association - Standard for good workmanship in Electrical Construction - NECA 1
• AREMA - American Railway Engineering and Maintenance-of-Way Association
• ASTM - American Society for Testing and Materials
• ANSI - American National Standards Institute
• AWS - American Welding Society
• AISC - American Institute of Steel Construction
• EASA - Electrical Apparatus Service Association
• EIA – Electronic Industries Alliance
• NEMA - National Electrical Manufacturers Association
• NESC - National Electrical Safety Code
• UL - Underwriters Laboratories
• MFMA - Metal Framing Manufacturers Association
• STINA - Steel Tube Institute of North America
• TIA - Telecommunications Industry Association
• ISO - International Organization for Standardization
• ICEA - Insulated Cable Engineers Association
• IEC - International Electrotechnical Commission
• ITU - International Telecommunication Union
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c. General Requirements.
1. Character of Work and Quality Control. Perform the work to not pose any danger to persons and/or property, and, in the judgment of the Engineer, to not expose persons and/or property to any danger because of normal service, including normal wear and tear.
Perform all work aesthetically, including neatness and cleanliness in accordance with NECA 1.
Coordinate all features, ratings, etc. of products as required to provide complete, operational, reliable, and safe system(s) and sub-system(s) in accordance with the requirements and intents of the contract.
Perform all coordination necessary to perform all work, including, but not limited to, coordination with and/or between suppliers, vendors, sub-contractors, trades, utility companies, and the USCG. Ensure proper interfacing between new and existing electrical systems and sub-systems, and the bridge operating machinery, the bridge structure, and miscellaneous equipment.
Verify all data, dimensions, and details at the site before proceeding with any work, purchasing any items, or fabrication of any custom components. All costs and/or damages that may result from the ordering or fabrication of any items or materials prior to such verifications will be borne by the Contractor.
Fully determine the nature and location of the work, the character, quality, and quantity of the materials that are required, the nature of equipment and facilities needed preliminary to and during the performance of the work, the general and local conditions, and of all other matters which can in any way affect the work for this project. Failure to comply with these requirements does not relieve the Contractor from responsibility for completion of all specified work and is not considered cause for delay or additional payment.
All products and work, including fabrication, erection, and/or installation procedures, will be always subject to inspection and testing by the Engineer. If any products and/or installations are found to be defective, coordinate repair or replacement at no additional cost. Under no circumstances will any inspection and/or test by the Engineer or his duly authorized representative, or any approval granted as a result thereof, relieve the Contractor from responsibility for full compliance with the requirements of the contract.
2. Field Measurements and Verification. Before commencing any work, ordering any materials, or fabricating any items, verify all relevant dimensions and other relevant characteristics at the job site and ensure their accuracy.
Verify field point-to-point wiring for connections of new installation, modifications of existing systems, and replacement. Verify all field measurements that are critical to the fabrication of new items, and clearly indicate to differentiate from other dimensions on working drawings that are submitted for review and approval.
The Railroad and the Engineer will not, as a part of shop drawings review, bear responsibility for verification of any field measurements made by the Contractor. Review of shop drawings by the Railroad and the Engineer does not in any way relieve the Contractor from responsibility
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for the accuracy of field measurements. Full responsibility for any errors that may result from inaccuracy of field measurements and verifications will be borne by the Contractor.
3. Brand Name Products and Substitutions. Provide identification by “brand name” to include manufacturer name and model name or number.
The identification of products, both on the plans and in this special provision, by brand name or equal description is intended to be descriptive, but not restrictive, and is to indicate the characteristics, performance, and quality of products that are satisfactory. Except when noted otherwise, the Contractor may propose "equal" products for consideration by the Engineer. Such "equal" products may be used only if the Engineer determines that the proposed product satisfies the requirements identified in the contract, is acceptable for the intended use, and is substantially equal in characteristics, performance, and quality to the specified product.
Where a product is identified by brand name, that brand name product was used as the design basis. Where the Contractor proposes to use an approved "equal" product, even if such a substitution is approved by the Engineer, responsibility for its proper installation, proper function and fit into the system is assumed by the Contractor. Responsibility for any resultant extra work, including products, labor, and related costs will be borne by the Contractor.
Supply to the Engineer all information required for the Engineer to determine the acceptability of a proposed "equal" product or procedure. The Engineer may request additional information, beyond what is explicitly required by the contract, to assist in determination of acceptability.
Full and final responsibility for selection of products that satisfy all identified requirements will be borne by the Contractor. In case of any discrepancy, or other conflict, between the salient requirements identified in the contract and products identified by brand name, the salient requirements will govern. Any such conflict, or other discrepancy, will not be considered cause for delay or additional payment.
4. Submittal Requirements. Obtain approval for all submittals prior to the purchase, delivery to the site, or commitment to this project of the respective equipment or materials. Provide neat and easily readable submittals, clearly show dimensions and pertinent ratings, and explicitly identify the intended use of each component on this project.
Each set of product submittal information must cover only one distinct product or similarly grouped products.
Submit the required component descriptive data and system shop drawings all together.
Do not use or install equipment or perform any work on this project without approved equipment, materials, and associated shop drawings by the Engineer and the Railroad.
Provide the following submittals in portable data format (PDF) for the required work and products as described herein:
A. Product information including, brochures, catalog cuts, manufacturer’s specification sheets, manufacturer’s recommended installation, maintenance, and troubleshooting, and other product literature for all equipment, components, and hardware
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proposed for installation as required by these Special Provisions. Specifically, submit product information for the following components:
(1) Bridge electrical system equipment including, but not limited to, power distribution equipment, general purpose conductors, conduits and raceways, aerial cables, pull and junction boxes, and accessories.
(2) Bridge control system equipment including, but not limited to, programmable logic controller (PLC) system components and related items, bridge limit switches, enclosures, communication and special cables, and accessories.
(3) SCADA (Supervisory Control and Data Acquisition) equipment and graphical user interface (GUI) and HMI hardware, software, and design information.
(4) CCTV system equipment including, but not limited to, CCTV management system hardware and software, cameras, and related items.
(5) Aerial Cable Support system components including, but not limited to, messenger cable data, cable supports, and material and finish information.
Where a catalog cut sheet is submitted with a table, listing or group of similar items with different catalog numbers and/or options, clearly mark the specific item(s) proposed.
B. Shop drawings including, but not limited to, the following:
(1) Installation and layout drawings showing the proposed locations and dimensions of equipment and clearances to floors, walls, ceilings, structural members, mechanical components, and other nearby objects and equipment. Verify through installation and layout drawings that equipment to be installed near rail tracks do not interfere with approaching rail traffic in accordance with AREMA. Clearly illustrate the physical relationship between new and existing components, critical dimensions, and modifications to be made to existing conditions and features. Clearly show the proposed method of attachment, mounting details, specific hardware, and holes to be drilled or cut in masonry. Detail custom or commercial mounting hardware and/or mounting brackets. Describe all installation procedures including alignment, testing, calibration, waterproofing, and as recommended by the manufacturer of the equipment being installed. Drawings need not necessarily be to scale but show items in their proper relative positions and provide dimensions. Field verify all pertinent information regarding existing features and dimensions prior to preparation of the drawings. Indicate dimensions obtained by field measurement as such on the drawings.
(2) Equipment enclosure, panel, and terminal cabinet layout drawings. On terminal cabinet layout drawings, clearly indicate all wires, including spares, to be terminated and coordinate wire numbering with wiring diagrams and other shop drawings.
(3) Conduit and raceway layout diagrams showing each raceway utilized, with all wire numbers installed therein. Tabulate all raceways, boxes, cabinets, and equipment enclosures, device served and function of each conductor and spare conductors with assigned wire numbers and present in tabular or spreadsheet format.
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Clearly indicate all wire numbers passing through or terminating in each raceway, box, cabinet, and equipment enclosure. Use different symbols to clearly distinguish between underground, concrete encased, in-wall, and exposed conduits, as well as cable trays, wire trough, flexible conduits, flexible cables, wireways, junction boxes, terminal cabinets, equipment, and enclosures. Fully coordinate drawings with all wiring diagrams, tabulations, and other shop drawings.
(4) Full schematic wiring diagrams depicting all required power and control wiring, including, if applicable, connections to existing wiring and equipment.
(a) On schematic wiring diagrams, show all circuit phase, neutral, and grounding conductors. Identify all conductors on the diagrams by wire numbers that match the same respective conductors or connections shown on other diagrams and shop drawings. Clearly indicate the size and type of all conductors on wiring diagrams. Wiring diagrams are not intended to be to scale, but must show all equipment, terminal cabinets, junction/pull boxes, and splices.
(5) Bridge control system graphical user interface (GUI) and HMI graphics. Include a menu structure tree showing screen navigation, example screens (color printouts), and color conventions.
(6) PLC and CCTV systems architecture with rack layouts, input/output/specialty card type and placement, and communications connections.
(7) CCTV camera field of view plan and description for each camera.
(8) Complete bill of materials for all components including spare parts. Present bill of materials in tabular format. Clearly identify all components by designation and/or description, along with manufacturer's name and complete model or catalog number.
(9) Mounting and support details for all electrical equipment. Specifically, provide shop drawing(s) for typical conduit support(s), junction and pull box(es) support(s), mounting of all wall-mounted style electrical enclosure(s), and light fixture and miscellaneous fixture mounting.
(10) Aerial Cable Support system attachment details including existing support structure details with modifications, cable supports, additional supports as required, and field assembly and cable attachment methods.
C. PLC program in ladder logic format (see section (e)(18)).
D. Certified prints with certified ratings and dimensions.
E. Certified drawings for products when requested by the Engineer, or as otherwise required by the contract. Certified drawings must clearly depict all critical dimensions, as well as all electrical and mechanical ratings. Manufacturer's standard catalog drawings are not acceptable in place of certified drawings.
F. Assembly drawings for fabricated items and assemblies.
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G. Material test certificates for raw materials when requested by the Engineer, or as otherwise required by the contract.
H. Testing procedures as described in the Construction – Electrical Testing and Measurements section of this Special Provision.
I. Power system study report including arc flash analysis. Report must include calculations and relevant code references to determine the degree of arc flash hazard labels for all electrical enclosures and terminal cabinets per the arc flash safety requirements of NFPA 70 and NFPA 70E.
J. Calculations.
(1) Aerial Cable Support system calculations to determine the messenger cable size and supporting devices. Include ice and wind loading data, in accordance with NESC 250B. Refer to sections (d)(1)(J), (d)(1)(K), (d)(1)(L) and (d)(1)(M) for additional requirements.
K. As-built drawings. Prepare and submit approved as-built drawings as described:
(1) Utilize a set of approved shop drawings (incorporate all review comments if approved as noted) and mark, in red, all circuit changes made in the field.
(2) Maintain these construction shop drawings as working drawings for the duration of construction. Required working drawings include all shop drawings as required by part B of Submittal Requirements. Make working drawings available to the Engineer, on request, for review of construction issues.
(3) Maintain a full set of working drawings on the job site at all times.
(4) Upon completion and final acceptance, prepare and submit for review and approval the final set of as-built drawings showing all modifications, field changes, revisions, and notes. Draft as-built drawings from the marked up working drawings in CADD format. Do not use existing drawings with mark ups in the as-built drawing set.
L. Operation and Maintenance Manuals. Upon completion and final acceptance, develop and furnish bridge operation and maintenance manuals. Both hardcopy and electronic portable document format (PDF) format versions must be provided. Hardcopy binder(s) must be hardback vinyl three ring loose-leaf type for binding of 8½ by 11-inch sheets. The manual(s) must contain at a minimum the following chapters:
(1) Table of Contents.
(2) Introduction, including a general description of the bridge and its facilities.
(3) A detailed description of the bridge sequence of operation and bypass switch functions. Include step-by-step raising and lowering procedures to operate the bascule leaves using the main drive system remote and local operation procedures and the diesel engine. Include a detailed alarm listing and corresponding operator level troubleshooting steps.
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(4) Maintenance troubleshooting procedures to be used by maintenance personnel for PLC and variable frequency drive fault and errors. Include a list of all drive fault and error codes with a detailed description and corrective action. Include GUI display information including screen menu structures and actual screen captures (in color) to illustrate the features and functions available from the GUI to identify problems.
(5) Complete drive parameter listings for the installed Variable Frequency Drive (VFD) and basic troubleshooting instructions including common drive HMI error messages.
(6) Complete, as-built, PLC program listing including descriptive address comments and symbols, line comments, and cross reference listing.
(7) SCADA information including hardware information, installed software with version and license information, network configuration, address information, and other relevant features and information.
(8) Catalog cut sheets and user manuals (including manufacturer recommended maintenance) for each type of new equipment including but not limited to PLC hardware, SCADA system hardware, CCTV and network equipment, power distribution equipment, raceways, cables, conductors, boxes and cabinets, bridge control components, lighting fixtures, navigation lighting, variable frequency drive hardware, and accessories.
(9) Network information for control system related items including architecture drawings showing all assigned network addresses for control system related devices, switch settings, and parameter listings for all programmable network switches and similar devices.
(10) Half-size (11x17) prints of as-built contract and shop drawings.
(11) Complete spare parts list.
Make a preliminary manual submittal (electronic PDF format) to the Engineer for review and approval.
M. Contractor experience and qualification logs required as described elsewhere herein.
5. Warranties. Warrant the work against defects in materials or workmanship for a period of 1 year from the date of final acceptance of the project. Perform all required corrections or adjustments to the electrical work during this period. All costs associated with this work are to be borne by the Contractor. Assign manufacturer’s warranties on products furnished and installed for the project to the Railroad in writing.
6. Execution. Employ electricians and helpers who are trained and experienced in the installation and maintenance of industrial electrical power and control systems to perform electrical work, and specialty technicians, mechanical and structural workers who are trained
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and experienced in the type of work they are performing. Ensure all electrical work is supervised by supervisory personnel.
Complete all work in a professional and safe manner in accordance with NECA 1. Verify all relevant dimensions prior to performing any work and comply with NEC required clearances (i.e., "Working Space", "Dedicated Equipment Space", etc.). Immediately inform the Engineer of any conflict between equipment locations shown on the plans and NEC required clearances. Ensure in the case of any such conflict, the equipment in question is relocated or similar remedial action taken, as directed by the Engineer. All costs associated with this work are to be borne by the Contractor.
Physically install all products in a secure manner as indicated and as required to provide a reliable installation. Inspect and test all installed products for correct installation, performance, and workmanship. Torque all terminals and other current carrying connections per the manufacturer's recommendations using calibrated tools. Provide nameplates and necessary warning labels for all equipment, cabinets, and boxes.
7. Electric Motor Service Vendor (EMSV). Engage a properly qualified EMSV to procure, provide, shop-assemble, and site-test the main drive motor. To be considered properly qualified, the EMSV must be primarily and regularly engaged in the procurement, service, installation, and maintenance of inverter duty gearmotors, and have been in the business of inverter duty gearmotors for at least 5 continuous years as of the bid date.
The EMSV must perform all this work and assist the Contractor in the installation of the main drive motors.
Provide start-up services. The EMSV must provide a factory-trained field service Engineer/Technician to check out all equipment and system installation on-site, including wiring interconnections to the main drive motors.
8. Control Systems Vendor (CSV). Engage a systems integrator as the CSV primarily and regularly engaged in the integration, installation, and maintenance of industrial control systems, with demonstrable experience in the integration, installation, and startup of movable bridge control systems. The CSV must have successfully completed five (5) movable bridge control systems in the past seven (7) years, three (3) of which must have incorporated a PLC system. In the five successfully completed control systems of movable bridges, at least one must involve a vertical lift span type movable bridge. The CSV must have the following applicable experience:
A. Providing relay-based, hardwired control systems.
B. Programming vector-controlled alternating current (AC) drive systems utilizing motors up to 75 horsepower.
C. Programming and integrating a GUI or HMI into a PLC and bridge drive system.
D. Networking and programming a web-based SCADA system and integrating the bridge PLC and controls into the SCADA system for remote monitoring and control.
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Concurrent with submission of the bid, identify the intended Control System Vendor, and submit a previous experience log to verify that the CSV meets the requirements listed herein. Include previous project references, including names of bridge owners and contact persons with phone numbers in the log. Control System Vendors unable to demonstrate compliance with the above requirements will not be accepted, which may be deemed cause for disqualification and rejection of the bid.
Engage a CSV to integrate all components necessary for a fully functioning, safe, and reliable bridge control system operating in accordance with the contract. The CSV must provide all equipment, accessories, and other materials required to produce the desired performance and functionality of the bridge control system, even if they are not specifically identified or implied in the contract. Engage a CSV to perform the following work:
A. Acquire and shop-assemble the bridge control system components.
B. Furnish equipment as part of the integrated control system including, but not limited to, the PLC system, SCADA system, CCTV system, network equipment, bridge control system, all bridge limit switches, and all miscellaneous bridge control components.
C. Develop the PLC program; develop and configure the GUI and HMI program and graphics.
D. Configure drive parameter settings, including matching the appropriate motor parameters to the main drive motor and tuning the variable frequency drive to the main drive motor to optimize the running and performance characteristics of the main drive motor.
E. Perform all interfacing and connections of the bridge control system and additional connections to the Signals Control System, as required.
F. Assist the Contractor in testing and in the development and execution of the as- built drawings and personnel training.
G. Perform the shop test as described elsewhere herein.
H. Provide start-up services by a factory-trained field service engineer/technician to check out all equipment and system installation on-site, including wiring interconnections to the PLC system and other equipment described herein. Provide start-up services prior to the initial operation of the bridge. The field service engineer/technician will remain or return on-site during system start-up and must return for at least one additional site visit immediately prior to final acceptance of the control system to make final adjustments to the control system as directed by the Engineer.
9. Delivery, Storage, and Handling. Properly store and protect all materials and products until installation, including during shipment and storage. Securely mount and store all large, bulky, and/or heavy items on skids or pallets of ample size and strength. Box all small parts in sturdy wood or heavy corrugated paperboard boxes. Provide weatherproof covers to protect materials from weather, when stored outdoors.
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10. Protection and Maintenance of Facilities and Work. Protect and always preserve all materials and work. Repair any damage to materials or work during construction to the satisfaction of the Engineer. All costs associated with this work are to be borne by the Contractor. Maintain all work, and the project site in general, in top condition. Keep the project site free of excess material, debris, and rubbish caused by the Contractor's operations at all times.
For any damage to any existing facility, repairs must begin immediately and must continue (24 hours a day, 7 days a week) until they are complete to the satisfaction of the Engineer. All costs and penalties that may be assessed against the Railroad associated with this work are to be borne by the Contractor. d. Materials. Provide UL listed or recognized equipment for all materials.
1. Wire and Cable.
A. Conductor for General Purpose Use. Provide type XHHW-2, 600 volts (V) rated, un-coated soft copper conductors meeting the requirements of ASTM B 3 and NEMA WC 70. Provide conductors, stranded in accordance with ASTM B 8. Insulate the conductor with cross-linked polyethylene insulation compound. Provide conductors rated 90 degrees Celsius (C) in wet and dry locations, heat, and weather resistant, and suitable for use in raceways.
B. Conductors for Installation within Control Cabinets. Provide ASTM B8, Class B stranded copper type THWN-2 or MTW rated 600 volts, 90 degrees Celsius. Provide minimum size 16 American wire gauge for control conductors. Size power conductors as required for the application.
C. Weatherproof Cable. Use type SEOOW or STOOW cable, rated for 600 volts, 105 degrees Celsius, outdoor use with oil, water, and sunlight resistant jacket.
D. Cable Connector. Use UL listed, stainless steel cable connector(s) with stainless steel mesh strain relief grip of size and type for compatibility with cable. Provide cable connector(s) with embedded O-ring or neoprene gasket for liquid-tight seal.
E. Ethernet Cable. Provide UL listed Ethernet cable rated TIA/EIA Category 6, NEC type CM, CMR, CMB or equivalent, and suitable for installation in raceways, with high density polyethylene insulation, and sunlight and oil resistant PVC outer jacket, rated 300 volts. Provide Ethernet cable with an overall foil shield, compatible with RJ45 connectors. Employ personnel with necessary training and use manufacturer recommended tools to terminate the cable and perform testing.
F. Fiber Optic Cable. Use loose tube, dry (gel-free), non-conductive, multimode fiber optic cable, suitable for aerial and conduit applications. Provide fiber optic cable to meet the following additional requirements:
(1) Number of fiber stands as indicated on the Plans.
(2) Polyethylene jacket with ultraviolet radiation, fungus, and abrasion protection.
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(3) OM3/OM4 – 50/125 µm laser optimized, 850/1300 nm operating wavelength.
(4) 3.0/1.0 dB/km maximum attenuation.
(5) 1 Gigabit serial Ethernet length of 1000/550 meters or better.
(6) Operating temperature range of -40 to 70 degrees Celsius.
(7) Minimum bending radius of 20 times its outside diameter during installation and 10 times its outer diameter during operation without changing the characteristics of the fiber optic cables.
(8) Color coding per TIA/EIA 598 B and design and test criteria per ANSI/ICEA/IEC/TIA.
(9) Manufacturer of fiber optic cable and related components must utilize the most advanced commercial materials and manufacturing process and must be ISO 9001 certified.
G. Fiber optic hardware. Use fiber optic hardware as required to properly splice, terminate, and/or pigtail fiber optic cable in all terminal cabinets and enclosures as described below:
(1) Provide hardware in aerial cable terminal cabinet(s) as required to splice fiber optic cable(s) with fiber optic cable(s) within aerial cable(s).
(2) Provide hardware as required in all other bridge enclosures to allow for easy access to connect bridge equipment to the fiber optic hardware via fiber optic patch cords.
Fiber optic hardware will include housings, modules, panels, cassettes, pigtails, and/or splice trays. Use hardware and connectors appropriate for each specific application meeting the requirements of ANSI/TIA/EIA-568. Coordinate characteristics of hardware with fiber optic cable and connectors. Use heat-shrink fusion splices.
H. Fiber Optic Patch Cords. Provide bend-insensitive loose tube fiber optic patch cords meeting the requirements of ITU and TIA. Provide connectors for fiber optic patch cords as required for compatibility with fiber optic hardware and equipment.
I. Encoder Cable. Provide shielded cable that is compatible with the factory mounted incremental encoder provided with the main drive motor. Cable shall meet the main drive motor manufacturer requirements and specifications.
J. Aerial Cables. Provide custom manufactured multi-conductor aerial cables suitable for installations in a horizontal position while being supported at both ends and designed to accommodate movement due to oscillation and vibration. Provide aerial cables with the following characteristics and features:
(1) Minimum content for aerial cables(s) shall be as shown on the Plans. Contractor shall review the aerial cable design with the Systems Integrator and all
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other involved parties to verify that the cable has adequate conductors, cables, and spares for the bridge control system, CCTV system, and all other supporting systems as shown on the Plans and required by these Special Provisions.
(2) Overall outer jacket shall be outdoor rated, heavy duty, and UV-resistant low- density polyethylene (LDPE) per ICEA S-95-658, NEMA WC-70.
(3) Insulation shall be ethylene propylene rubber (EPR) meeting the Type II requirements of ICEA S-73-532, NEMA WC-57 table 3-3 (22 to 16 AWG), 600 volt or ICEA S-95-658, NEMA WC-70, Table 3-1 (14 AWG or larger, 600 to 2,000V).
(4) Conductors shall be rated 600 volts, annealed, uncoated copper in accordance with ASTM B-172/174 for 10 AWG and smaller or ASTM B-172 for 8 AWG or larger, class K stranding, and section 2 of ICEA S-95-658.
(5) Individual conductors and component cables shall be identified with a surface printer legend with a unique identification number/label.
(6) Fiber optic cable as described in this Special Provision.
(7) Cable components are cabled together with non-hydroscopic fillers as required by application. The cable core is wrapped with moisture resistant binder tape.
(8) Cables shall be continuous with no splices.
(9) Each cable shall be wound onto a suitable reel capable of supporting the weight of the cable during transportation and normal handling. The ends of each cable shall be suitably sealed to prevent moisture ingress during shipment and storage.
(10) Each cable shall be supported to the messenger cable by an extra high strength grade galvanized strand messenger, noted as the support binder. The support binder shall be stainless steel Type 302 tape helically wound around the cable assemblies.
K. Aerial Cable Strain Relief Grips. Provide UL listed, NEMA 4X aerial cable grips (“Kellems” grips) to the support the aerial cables between the aerial cable terminal cabinets located on the tower tops and moveable span to the messenger cable. The relief grips shall be of heavy-duty construction, comprised of stainless-steel mesh, and rated for outdoor installation. Cables grips shall feature a straight male thread connector with liquid tight and dust-tight seat for attachment to terminal cabinet and installed such that the weight of the cables is supported by the entire mesh material. Length of the mesh shall be as required to support the load and per aerial cable diameter.
L. Messenger Cable Hardware and Components. Provide all hardware and components to secure the messenger cable(s) to the existing vertical support structure(s) located on the tower tops and moveable span. All hardware and components shall be of sufficient strength to exceed the breaking strength of the messenger cable guywire(s). Provide aerial cable hardware with the following characteristics and features:
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(1) Provide utility grade hardware and fittings for messenger. Hardware and fittings shall be made of galvanized steel, stainless steel, or non-corrosive metals.
(2) Deadends shall be heavy duty, bolted quadrant type or shall be assembled utilizing heavy duty pre-formed steel thimbles.
(3) Shackles, Turnbuckles, and similar components shall be forged steel, hot-dip galvanized construction. Pins and bolts shall be high strength steel, hot dip galvanized. Cotter pins and safety wire shall be stainless steel, sized as required.
(4) Wire rope clips shall be galvanized steel with drop forged base manufactured in accordance with Federal Specification FF-C-D, Type 1, Class 1.
M. Messenger Cable. Provide a messenger cable to support the aerial cable(s) between the existing vertical support structure(s) located on the tower tops and moveable span and between the existing support structures on the moveable span. The messenger cable shall be sized and designed according to requirements of NESC C2-2012. Ice and wind loadings shall be considered in the design with no overstress in cables or components. Cable shall be stainless steel, Type 302, Independent Wire Rope Core (IWRC).
2. Conduit, Raceways, and Accessories.
A. Rigid Galvanized Steel Conduit. Provide rigid galvanized steel (RGS) conduit meeting the following requirements:
(1) Nationally Recognized Testing Laboratory (NRTL) listed, threaded rigid metal conduit and fittings, and manufactured from high-strength steel, in accordance with ANSI C80.1, UL 6, and UL 514B. Use 3/4-inch diameter, minimum size.
(2) Manufactured from steel tubing having a wall thickness equivalent to Schedule 40 pipe with the entire length of the conduit hot-dip galvanized inside and out, threads hot-dip galvanized after cutting.
(3) Comply with the requirements of NEMA RN1.
(4) Unless otherwise shown on contract plans, use hot-dip galvanized steel channel, U-bolts and conduit clamps for conduit mounting.
(5) Provide components (couplings, elbows, fittings, etc.) of same material and manufacturer as the rigid galvanized steel conduit.
(6) Ensure all conduit installers are certified by the conduit manufacturer.
B. Polyvinyl-Chloride (PVC) Coated Rigid Galvanized Steel Conduit. Provide PVC coated rigid steel conduit meeting the following requirements:
(1) Nationally Recognized Testing Laboratory (NRTL) listed, threaded rigid metal conduit and fittings, and manufactured from high-strength steel, in accordance with ANSI C80.1, UL 6, and UL 514B. Use 3/4-inch diameter, minimum size.
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(2) Manufactured from steel tubing having a wall thickness equivalent to Schedule 40 pipe with the entire length of the conduit hot-dipped galvanized inside and out.
(3) Coat the exterior surface of the hot-dip galvanized conduit with a factory- applied PVC coating, at least 40 mil thick. Provide an exterior coating that is permanently fused to the hot-dip galvanized surface of the conduit. Ensure the adhesion of the PVC coating to the conduit is greater than the strength of the coating itself. Provide NRTL listed overall conduit with the PVC coating as the primary corrosion protection and the underlying galvanized coating as supplemental protection.
(4) Comply with the requirements of NEMA RN1.
(5) Coat the interior surface of the hot-dipped galvanized conduit with a factory- applied urethane coating at least 2 mils in thickness. The interior coating must afford sufficient flexibility to permit field bending of the conduit without causing cracking or flaking of the interior coating. After the PVC coating of the conduit, clean conduit threads and hot-dipped galvanize. Apply a urethane topcoat to the conduit threads after hot-dip galvanizing. Cap all threaded ends of conduit.
(6) Coat couplings, elbows, fittings, and conduit bodies used with the PVC coated steel conduit with the same coating as the conduit. Unless otherwise shown on contract plans, coat U-bolts and conduit clamps used for conduit mounting with the same coating as the conduit.
(7) Provide components (couplings, elbows, fittings, clamps, etc.) manufactured by the same manufacturer as the PVC coated steel conduit.
(8) Ensure all conduit installers are certified by the conduit manufacturer.
C. Polyvinyl-Chloride (PVC) Conduit. Provide PVC conduit meeting the following requirements:
(1) Schedule 80, ANSI/UL 651, NEMA TC-2, sunlight resistant, rated for 90 degree Celsius cable.
D. Conduit Bodies. Provide conduit bodies meeting the following requirements:
(1) NRTL listed, hot-dip galvanized cast iron alloy with threaded hubs and integral bushings, and with galvanized steel or iron alloy covers for use with RGS conduit. Use screw-in type covers. Do not use clip-in or other wedge type covers. Use stainless steel cover screws.
(2) Provide PVC coated conduit bodies and associated covers and screws for use with PVC coated rigid steel conduit. Provide PVC coating of the same manufacturer as the PVC coated steel conduit.
E. Liquid-Tight Flexible Metallic Conduit (LFMC). Provide NRTL listed LFMC, formed from a spiral wound strip of heavy gauge, corrosion-resistant, hot-dipped galvanized steel. Provide LFMC with rugged, flexible PVC, oil, mild acid and ultraviolet (UV) sunlight
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resistant outer jacket extruded over the steel core. Provide UL listed LFMC fittings of same make and material as the PVC coated rigid steel conduit with sealing gasket or sleeve. Provide heavy-duty stainless steel mesh support grips to support LFMC at all cabinet connection locations.
3. Pull Boxes, Junction Boxes, Terminal Cabinets/Boxes, Enclosures, and Accessories.
A. General. Size boxes and terminal cabinets as required by the NEC, and as appropriate to enclose all conductors and components and for the equipment served. Box sizes indicated on the Plans represent the minimum size required.
Use hinged doors pull/junction boxes. Provide bonding jumpers between the door and the box or cabinet body on boxes and cabinets with hinged doors. Provide drains in the bottom of all enclosures.
Provide aluminum or steel mounting panels with corrosion resistant finishes, heavy duty terminal blocks for wire terminations, and uninsulated ground bars. Use copper ground bars for use with copper conductors.
Where boxes contain both power and control conductors serving different devices, provide physical barrier(s) to separate the power and control conductors within the box.
In wet locations, use surface-mounted boxes meeting the requirements of NEMA 250, UL 50, and NEMA 4X Type 316 stainless steel with stainless steel hinges and hardware.
In damp locations, use surface-mounted boxes meeting the requirements of NEMA 250, UL 50, and NEMA 12 Type 304 stainless steel with stainless steel hinges and hardware.
B. Terminal Cabinets and Terminal Boxes. Provide freestanding or wall mount style NEMA 4X, constructed of 12-gauge type 316 stainless steel (NEMA 12 stainless steel for indoor locations only) terminal cabinets with an inner back plate for installing terminal blocks, fiber optic connector housings and panels, and other related components. Provide provisions for installing padlock with stainless steel hardware. Terminate all conductors, including spares, inside terminal cabinets. Provide all necessary mounting rails, end blocks, barriers, and accessories. Provide adequate space on each side of each terminal block to meet NEC wiring bending requirements. Provide a permanent barrier or listed divider where power cables are terminated within the same cabinet as fiber optic cable. The following enclosure sizes are provided below for bidding purposes only. The enclosure sizes provided shall be verified by the Contractor based on installation location, devices and terminations installed, and according to NEC requirements.
C. Machinery House Control Cabinet. Provide a freestanding style NEMA 12, constructed of 12-gauge steel cabinet for machinery house control and PLC equipment, minimum size as shown on the Plans and as required to house the equipment and meet NEC workspace requirements in machinery house. Provide inner back plate for installing terminal blocks and all internal equipment. Include thermostatically and humidistatically controlled heating and cooling via integrated HVAC unit provided by the cabinet manufacturer, internal cabinet light, terminal blocks, and other accessories as shown on the Plans. Install plastic wire duct to contain and organize internal control wiring. The
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front door of the cabinet shall feature the control panel layout with selector switches, pushbuttons, and indicator lights as shown on the Plans.
D. South Approach Control Cabinet. Provide a freestanding style NEMA 4X, constructed of 12-gauge type 316 stainless steel cabinet for South approach control and PLC equipment, minimum size as shown on the Plans and as required to house the equipment and meet NEC workspace requirements. Provide inner back plate for installing terminal blocks and all internal equipment. Include thermostatically and humidistatically controlled heating and cooling via integrated HVAC unit provided by the cabinet manufacturer, internal cabinet light automatically activated by a door switch, terminal blocks, and other accessories as shown on the Plans. Install plastic wire duct to contain and organize internal control wiring. The front door of the cabinet shall feature the control panel layout with selector switches, pushbuttons, and indicator lights as shown on the Plans.
E. North Approach Control Cabinet. Provide a freestanding or wall mount style NEMA 12, constructed of 12-gauge steel cabinet for North approach control and PLC equipment, minimum size as shown on the Plans and as required to house the equipment and meet NEC workspace requirements in the North approach bungalow. Provide inner back plate for installing terminal blocks and all internal equipment. Include humidistatically controlled heating, internal cabinet light, terminal blocks, and other accessories as shown on the Plans. Install plastic wire duct to contain and organize internal control wiring. The front door of the cabinet shall feature a panel mounted HMI; provide cutout and other accessories as required to mount the HMI on the front door of the cabinet.
(1) North Approach Control Cabinet HMI. Provide a purpose-built rugged, panel mountable HMI with 12” minimum full color resistive analog touchscreen. Provide HMI with rugged aluminum housing with operating temperature range of -20 to 60 degrees Celsius. Provide Ethernet, USB, and serial ports as required for communication with devices and support up to 20 simultaneous protocols. Provide built-in data logging with time stamp capability to store and display a complete history of bridge alarms and faults. Provide other accessories and options as required to satisfy all operational requirements as specified elsewhere herein. The HMI shall be capable of supporting and displaying the GUI screen(s) as described in the Construction – SCADA System section of this special provision.
F. North Approach Control Panel. Provide a wall mount style NEMA 4X, constructed of 12-gauge type 316 stainless steel cabinet with lockable hasp for the North approach control panel devices. The front door of the cabinet shall feature the control panel layout with selector switches, pushbuttons, and indicator lights as shown on the Plans.
G. Terminal Blocks. Use heavy duty, UL listed or recognized terminal blocks and power distribution blocks which are rated 600 volts (minimum 1000 volts for motor terminals), 90 degrees C, suitable for use with copper conductors, NEMA style, barrier type, tin plated copper, or aluminum, and Valox or phenolic insulated, with set-screw type terminals. Mount terminal blocks with stainless steel bolts or machine screws.
Within control enclosures, use finger safe, screw type connection with stainless steel corrosion resistant screws terminal blocks rated for minimum 300 volts, 15 amperes or terminal blocks as described above.
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Provide printed or engraved labels for all terminals. Use color coded grounding type terminal blocks for ground conductors.
H. Variable Frequency Drive (VFD) Cabinet. VFD cabinet must house the VFD and all related components as shown on the Plans and described herein. VFD cabinets must meet the following requirements:
(1) VFD cabinet must be heavy duty, free standing NEMA 12 industrial control enclosure constructed with a minimum of 12-gauge steel with a powder coated finish. Include thermostatically and humidistatically controlled heating and cooling via integrated HVAC unit provided by the cabinet manufacturer. A thermostat controller must be used to control the fan and heater operation. Both devices must be interlocked so that they cannot operate at the same time and cannot operate during bridge operation. Custom enclosure sizes and other creative solutions may be required to install new cabinets while providing working clearances as required by the NEC.
(2) Provide flange mounted disconnect switch for incoming power. Mechanically interlock the disconnect operator with the cabinet door and lock in the off position.
(3) Provide a cabinet 120-volt AC utility receptacle and door activated internal LED cabinet light.
(4) Provide a control power transformer mounted and wired inside the cabinet, sized as required by the cabinet components.
(5) Install plastic wire duct to contain and organize internal control wiring.
(6) Indicator lights must be as described elsewhere herein.
(7) Provide Input line contactor as shown on the Contract Plans.
(8) Provide Input line reactors, sized per drive manufacturer recommendation(s)
4. Mounting Brackets and Supports.
A. Fabricated Mounting Brackets and Supports. Use stainless steel type 316 for all stainless-steel plates, shapes (angles, channels, etc.), fabricated brackets, and similar items, unless indicated otherwise in the Plans.
For fabricated items which are constructed by welding, use steel per ASTM A 36, allow items to be thermally stress-relieved after welding and before any additional machining or finishing. Ensure welding complies with AWS standards appropriate for the material(s) and final product in question. Hot-dipped galvanize after fabrication.
Use type 316 stainless steel bolts, threaded rods, machine screws, nuts, washers, and similar hardware. Unless indicated otherwise in the contract, use type 316 stainless steel concrete anchors with adhesive (epoxy) type anchor. Use hot-dip galvanized hardware with hot-dip galvanized steel brackets and supports.
B. Strut Channel. Use strut channel meeting the following minimum requirements:
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(1) Strut channel and fittings manufactured in accordance with the requirements of the MFMA.
(2) Type 316 stainless steel.
5. Power Distribution Equipment.
A. Electric Service. The electric service, including all metering equipment shall be new 277/480 volt, 3-phase, 4-wire, grounded neutral service, sized as shown on the Plans. New service conductors and raceway shall be installed from the service transformers and metering equipment as indicated on the Plans. Electric service and metering materials and components shall comply with all applicable requirements of the electric utility company supplying the electric service. The Contractor shall be responsible for all coordination with the electric utility company.
(1) Service Main Disconnect. Provide a UL listed, NEMA 4X 316 stainless steel constructed, surface mount, circuit breaker enclosure, size and rating as shown on the Plans. Enclosure shall be rated for service entrance installation and provided with an exterior operating handle that can be padlocked in the OFF position and is interlocked to prevent the door from opening when the breaker is ON. Provide exterior visual indication for breaker trip. Disconnect shall be installed adjacent to the metering equipment, conforming to the requirements of the Utility Company. Circuit breaker shall be thermal-magnetic type and meet the requirements listed within this Specification and current ratings as shown on the Plans.
(2) Automatic Transfer Switch (ATS). Provide a UL listed ATS, suitable for the 480 volt, three-phase, four-wire, solidly grounded neutral, electrical power source. ATS shall be rated for 400A, 60HZ and housed in a NEMA 4x, stainless steel enclosure. Enclosure shall feature double doors, comprised of a dead front door and an internal front door. All controls shall be mounted to internal door. External door shall be pad lockable. The transfer switch shall be 4-pole type with silver allow contacts. The mechanism shall be electrically operated and mechanically held in position. Normal and generator contacts shall be positively interlocked electrically and mechanically to prevent simultaneous closing. The ATS shall have a microprocessor-based controller with a display for monitoring power conditions and adjusting transfer switch parameters. Features shall include programmable engine start delay timer, engine stop delay timer, transfer delay timers, transition timer, and generator exerciser. The ATS shall include indicator LED lamps for source availability, source connected, and exercise/test mode. The ATS shall have a maintenance bypass/isolation switch that permits manual selection and connection of either source of power or power directly to load. While isolated, interlocks prevent transfer-switch operation, except for testing or maintenance. ATS shall be compatible with existing generator control system and include all required external relays and contacts. The ATS shall contain internal transformers and fuses, sized in accordance with the NEC, to serve single phase loads in the existing generator, as required.
B. Motor Control Center (MCC). Provide a UL listed MCC, suitable for the 480 volt, three-phase, four-wire, solidly grounded neutral, electric power source. MCC construction shall be dead front, NEMA 12 with all components, devices, and hardware corrosion resistant to the extent possible. Doors and panels shall be constructed with 12 gauge, or
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heavier steel. Field power wiring shall connect directly to the device terminals; field control wiring shall connect to master terminal blocks located in each section. Control voltages shall be 120 volts AC, 60 hertz.
(1) General Construction: MCC section dimensions shall be as indicated on the Plans and meet the following requirements:
(a) The Contractor and Control System Vendor shall coordinate shipping splits and lifting provisions with the manufacturer so that the MCC can be safely transported to and installed in the machinery house without damage.
(b) Each unit shall be provided with an individual door giving access to only that unit. Doors shall have concealed hinges. Removable blank doors shall cover all unused openings.
(c) Circuit breaker for each combination motor starter units shall have flange mount external operating handles, lockable in the OFF position.
(d) Operating mechanisms shall be mechanically interlocked with the unit door.
(e) Vertical as well as horizontal wireways shall be included in each section. The horizontal wireways shall be continuous across the MCC. Separately removable hinged doors shall be provided for each vertical wireway. Wireways shall be fully isolated from all buses. Provide covers over all sharp edges in the MCC wireways and units to prevent damage to conductor insulation.
(f) The door to the unit housing the bus monitor and power monitor shall also contain a power monitor display module as specified elsewhere in this Special Provision.
(g) The incoming line section shall have an engraved nameplate with the MCC serial number, system electrical data, bus ampacity, and the bus short circuit rating.
(h) Engraved plastic nameplates with 1/4-inch white text on black background bearing the name of the equipment served shall be attached to each unit with stainless steel machine screws. Each contactor, relay, circuit breaker, etc. shall also be labeled with its own engraved nameplate located adjacent to the respective device.
(2) MCC Bus: Bus shall be tin plated copper, braced for 42,000 RMS symmetrical amperes. MCC shall include a vertical and horizontal ground buss bars. The main horizontal bus shall be continuous rated 600 amperes, vertical bus continuous rated 300 amperes, and the horizontal ground bus continuous rated 500 amperes minimum. Combination motor starter and branch circuit breaker units shall connect to the vertical bus via a single stab block on the back of the unit. Stabs shall be tin plated hardened copper and spring assisted.
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(3) Combination Motor Starter Units. Motor starter units shall be of the NEMA size, reversing or non-reversing type overload with manual reset, as indicated on the Plans and listed in this Special Provision.
Starter units shall be provided with thermal magnetic molded case circuit breakers, instantaneous trip breakers, or motor circuit protectors, sized in accordance with the NEC. Circuit breakers in combination starter units shall conform to the requirements for circuit breakers listed in this Special Provision.
Pilot light(s) shall be provided on the door of each starter unit, one for non-reversing and two for reversing starters, indicating the device function. One pilot light shall be provided on each start unit servicing a motor and illuminate when the overload relay is tripped.
Motor circuit protectors shall be magnetic trip type, paired with a
C. Circuit Breakers. Use UL listed, molded case circuit breakers, sized as shown on the Plans. Circuit breakers shall utilize toggle-type trip-free operating mechanisms, with quick-make, quick-break action, and positive handle indication. Circuit breaker operating handles shall assume a center position when tripped. Two-pole and three-pole breakers shall be common-trip.
Each thermal-magnetic type circuit breaker shall have a permanent trip unit containing individual thermal and magnetic trip elements in each pole. Circuit breakers shall be suitable for mounting and operating in any position. Connections to the bus for circuit breakers installed in panelboards on the bridge shall be bolt-on. Lugs shall be mechanical screw type, UL listed for copper conductors, and rated at 90 degrees C.
Motor Circuit Protectors (MCP) shall contain magnetic type circuit breaker with a permanent trip unit containing individual magnetic trip element in each pole. MCP’s shall be suitable for mounting and operating in any position. Lugs shall be mechanical screw type, UL listed for copper conductors, and rated at 90 degrees C. MCP’s shall be used to supply motor loads within a combination motor starter, as indicated in this Special Provision.
Individually mounted enclosed circuit breakers shall be NEMA 4X, type 316 stainless steel unless otherwise indicated on the Plans. Enclosures shall have hinged doors with provisions for attaching a padlock, external operating handles which are lockable in the OFF position, and mechanical door interlocks.
D. Full Voltage Contactors and Motor Starters. Use UL listed, electrically held, multiple pole contactor, NEMA type, with ratings and sizes as required for the equipment served. Starters smaller then NEMA size 1 shall not be used. Contactors for reversing starters shall be electrically and mechanically interlocked.
Electrically isolated auxiliary contacts shall be provided as required for control circuits, plus one normally-open and one normally-closed spare per contactor. Starters shall include overload relays with ambient compensated, Class 20, electronic user adjustable settings. Relays and overloads shall be manual reset type, with electrical isolated auxiliary
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contacts as required. Overload relays shall be sized per the equipment served. Contactor coils shall be 120-volt AC, 60 hertz.
E. Control Transformers. Provide totally encapsulated control transformers, where required, to limit control circuit loading from full voltage contactors and motor starters. Transformers shall be 65VA minimum, with primary and secondary fuses in accordance with the NEC. Transformers shall be fed from the load side of the contactor’s disconnecting means. Each transformer shall serve only one contactor.
F. Surge Protection Devices. Surge protective device (SPD) shall be heavy duty, UL 1449 listed and UL96A master label compliant. SPD shall provide line-to-line, line-to- neutral, line-to-ground, and neutral-to-ground protection. SPD’s shall include LED indicators for “Loss of Protection” and “Fully Operational”, an audible fault alarm with test/silence switch, and one set of normally open and normally closed dry contacts. SPD shall be UL labeled with 200kA short circuit rating, UL labeled as type 1 or 2, intended for use with need for external or supplemental overcurrent controls. Voltage protection ratings shall be as required per installation locations, listed below.
(1) Main Circuit Breaker: SPD (Type 1) for main service entrance area shall be installed integral to the main circuit breaker disconnect or provided in an external, NEMA 4X 316 stainless steel enclosure. Service entrance SPD surge current capability shall be at least 240,000 amperes per phase, or as required be NEC and NFPA requirements.
(2) MCC: SPD (Type 2) for MCC shall be integral to the MCC and mounted inside a designated unit. SPD surge current capability shall be at least 150,000 amperes per phase, or as required per NEC and NFPA requirements.
(3) Panelboards: SPD’s (Type 2) for panelboards shall be integral to the panelboard served directly bus connected between the mains and the branch circuit breakers. SPD surge current capability shall be at least 100,000 amperes per phase, or as required per NEC and NFPA requirements.
G. Lightning Protection System (LPS). All system components associated with the LPS shall be in accordance with UL 96, NFPA 70, NFPA 780, and are Certified/Listed by UL under the appropriate product category. The LPS system components and design shall be UL master label certified. Provide a LPS that meets or exceeds all UL, NFPA, Local, and State, and the following requirements:
(1) Air Terminal (lightning rods). Install air terminal(s) on the north and south tower tops at locations shown on the Plans and as required to meet the specifications listed above. Air terminals shall be of copper or aluminum construction and not be less than 24” long. Air terminal base support shall be of copper or aluminum construction and shall have connector fitting(s) for connection of the lightning (down) conductor.
(2) Down conductor. The down conductor shall connect the air terminal to the grounding electrode. Down conductor shall be of copper or aluminum construction and not be less than 115,000 circular mils at 375 lbs. per 1000 ft for copper and not less than 192,000 circular mils at 190 lbs. per 1000 ft for aluminum. Secondary or bonding conductors shall be of copper or aluminum construction and shall not be less than
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26,240 circular mils for copper and not less than 41,100 circular mils for aluminum. Provide beam clamps, suitable for use with down conductors, for attaching the down and secondary conductors to the existing steel structure. Provide brass round conductor clamp brackets for attaching the down conductor to the concrete pier. Utilize adhesive anchors, size and length per bracket manufacturer, to attach the bracket to the pier.
(3) Grounding Electrodes. The grounding electrode shall connect to the down conductor. The grounding electrode shall not be less than 5/8” diameter and 8 feet minimum in length. The electrode shall be of copper-clad steel construction and extend vertically not less than 10 feet into the earth. Provide copper or brass connectors for attaching the grounding electrode to the down conductor.
H. Power Monitor. Provide a UL listed, AC power monitor with build-in display, capable of measuring 3-phase voltage, current, and power, compatible for the 480 volts AC, 3-phase system of the bridge. Programming software shall be included. The device shall be mounted in a MCC unit with its display panel on the unit door. Potential transformers and current transformers shall be provided for connections of the device to the bridge AC power system. The power monitor shall contain internal relay contacts, double-pole, double throw (DPDT) style, rated at 10 amperes at 240 volts AC, 60 hertz, for use as inputs to the PLC in the event of a phase failure or phase reversal.
I. Mini Power Centers (MPC). Provide UL Listed MPC’s, housed in NEMA 4X enclosure for the North and South control platforms and a NEMA 12 enclosure for the machinery house. MPC’s shall be enclosed units and include a primary main breaker, encapsulated dry-type transformer, and a panelboard. All interconnecting wiring between the primary breaker or lugs and panelboard distribution section shall be factory installed. Access to interconnect wiring shall not be available when inspecting panelboard circuit breakers and schedule. Specifications for dry-type transformer and panelboard are provided within this Specification.
J. Panelboards. Provide UL listed, NEMA 12 surface-mounted for indoor use, and NEMA 4X rated for outdoor use, circuit breaker panelboards, with size and ratings as indicated on the Plans. Panelboards shall be equipped with thermal-magnetic molded case circuit breakers, with ratings as shown on the Plans. Access covers for panel shall be a pad lockable hinged door.
Bus bar connections to the branch circuit breakers shall be the “distributed phase” or “phase sequence” type. Single-phase, three-wire bussing shall be such that only one adjacent single-pole breakers are individually connected to each of the two different phases in such a manner that one- or two-pole breakers can be installed at any location. All current carrying parts of the bus assembly shall be tin-plated copper. Bus ratings shall be as shown on the Plans.
Each panelboard, as a complete unit, shall have a short circuit rating equal to or greater than the rating shown on the Plans. Panelboards shall be marked with their maximum short circuit current rating at the supply voltage. Terminals for conductors to the panelboard mains and branch circuit wiring shall be UL listed and rated for 90 degrees C. A circuit directory frame and a card with a clear plastic covering shall be provided on the inside of the door. The directory card shall provide a space at least ¼ inch high by three
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inches long, or equivalent, for each circuit. The directory shall be typewritten to identify the load fed by each circuit.
All panelboards shall be protected with a UL listed SPD, installed directly inside, or mounted immediately adjacent to the panelboard. The SPD shall be rated for the specific voltages of the corresponding panelboard and meet all the requirements listed within this Specification.
K. Transformers. Provide UL Listed dry-type transformers with sizes, voltage ratings, and primary/secondary arrangements as indicated on the Plans. Transformers shall be insulated with a 180 degrees C insulation system and rated at 115 degrees C temperature rise. Transformers shall be equipped with two 5% Full Capacity Below Nominal (FCBN) taps. Transformers shall be sealed, non-ventilated, surface mount, and housed in NEMA 12 enclosures for damp locations and NEMA 4X, type 316 stainless steel for wet locations.
L. Disconnect Switches. Provide UL listed, unfused, 3-pole, safety disconnect switches, sizes and ratings per the equipment served. Switches shall utilize quick-make, quick-break contacts, with terminals sized per the incoming and outgoing conductor(s) and rated at 90 degrees C. Disconnect switch enclosures shall be NEMA 12 for damp locations and NEMA 4X, type 316 stainless steel for exposed, wet locations. Enclosures shall have external operating handles, lockable in the OFF position, and mechanical door interlocks. Install disconnect switch at locations as shown on the Plans and as required to meet NEC requirements.
6. Lighting and Receptacles.
A. Maintenance Receptacle. Provide UL listed industrial specification-grade extra heavy-duty self-test GFCI (ground fault circuit interrupter) receptacles rated for 120 VAC, 60 HZ, 20 Amps, with NEMA 5-20R receptacle configuration. Provide tamper and weather resistant receptacles complete with all required accessories including while-in-use weatherproof cover and mounting hardware. Provide receptacles designed for wet/outdoor locations to meet the requirements of NEC section 406.9 for use in extremely corrosive, wet, dusty, hot and/or cold condition, with minimum operating temperature range of -35°C to +66°C.
B. Maintenance Lighting Fixtures (Stairway, Walkway, and Machinery House Interior and Exterior). Provide an UL 1598 listed heavy duty LED lighting fixture, style as detailed on the Plans. Provide fixtures complete with all required accessories including mounting hardware to supplement building structure for support of fixtures. Comply with the following additional features:
(1) Copper free aluminum housing.
(2) Marine and wet locations, NEMA type 4X, ingress protection (IP66).
(3) Minimum 1,500 lumen output.
(4) 5-year limited warranty.
(5) Vibration resistant.
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(6) 4000 Kelvin color temperature.
(7) Wide beam angle.
(8) Minimum 150,000 hours rated life.
(9) Minimum operating temperature range of -40°C to 55°C.
(10) Provide lens guard for additional protection.
C. Light Switches. Use extra heavy duty, corrosion resistant light switches rated for 20 amperes and 120 volts. Use NEMA 4X, stainless steel watertight box and cover.
D. Pier Navigation Lights. Provide heavy duty, marine type design pier navigation lights with rain-tight, fully gasketed, cast aluminum housing. Provide pier navigation lights that meet or exceed all Coast Guard recommendations and requirements.
Provide pier navigation lights with vandal resistant features including stainless steel tamper resistant external fasteners and lens guard formed of expanded stainless steel to provide protection from projectiles such as rocks or other thrown objects.
Include a tempered Fresnel glass lens red in color with nominal lens section of 180 degrees and inside and outside lens diameters of 7” and 8”, respectively.
Include a 120-volt, 8-Watt min. LED with 100,000-hour LED lamp rating and dual lamp arrangement with an automatic transfer relay to switch power to the backup lamp upon failure of the primary lamp.
E. Lift Span Navigation Lights. Provide heavy duty, marine type design lift span navigation lights with rain-tight, fully gasketed, cast aluminum housing with one red light over one green light in a vertical arrangement. Provide lift span navigation lights that meet or exceed all Coast Guard recommendations and requirements.
Provide lift span navigation lights with vandal resistant features including stainless steel tamper resistant external fasteners and lens guard formed of expanded stainless steel to provide protection from projectiles such as rocks or other thrown objects. Provide cast junction box with gasketed access cover of same material as light assembly.
Suspend the light heads from a 1-1/2” galvanized steel schedule 40 pipe. Provide a swivel design for all wiring to be completely contained within the light assembly. Provide gaskets and O-rings for a weather-tight assembly. Provide a swivel of heavy-duty construction, cast of the same material as the fixture head with a stainless-steel spindle.
Provide an automatic latch to hold the light securely in the normal operating and service positions. Ensure the service chain will automatically release the latch with a firm pull, allowing the light to pivot, and as the latch is raised, the latch will automatically engage to hold the light in the service position.
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Include a tempered Fresnel glass lens red in color with nominal lens section of 180 degrees and green in color with nominal lens section of 360 degrees. Inside and outside lens diameters shall be 7” and 8”, respectively.
Include a 120-volt, 8-watt min. LED with 100,000-hour LED lamp rating and dual lamp arrangement with an automatic transfer relay to switch power to the backup lamp upon failure of the primary lamp for each light.
F. Flashing Beacons. Provide red and amber AREMA compliant flashing beacons with operating temperature of -40 to 70 degrees Celsius and operating voltage range of 8 to 16 volts AC (alternating current) or DC (direct current). Provide 12-inch round uniform LED lamp rated to withstand 100 mile per hour impact from baseball. LED shall be 10 watts minimum. Provide an enclosure local to each flashing beacon location to house the following equipment:
(1) Provide a power supply or driver with 120-volt input voltage and output voltage as required for flashing beacons.
(2) Provide a flasher relay or module for flashing beacon if not integral to the flashing beacon unit/fixture.
7. Control System Components.
A. PLC (Programmable Logic Controller). Use Allen Bradley CompactLogix 5380 series by Rockwell Automation. Provide, at a minimum, the following features, and capabilities:
(1) Two identical PLC processors for redundancy, each with its own dedicated power supply. Provide a selector switch to manually select processor A or processor B as shown on the plans.
(2) Supports communication options for up to 60 Ethernet/IP nodes and up to 31 local input/output modules.
(3) 3 MB or greater user memory, as required for the control system as shown and specified.
(4) Provide SD card(s) with non-volatile memory for backup of PLC program in the event of a loss of power.
(5) Operating temperature and relative humidity range of 0 to 60 degrees Celsius and 5 to 95 percent noncondensing.
(6) Digital/discrete input and output, analog input and output, communications, special purpose modules, Resolver modules, cables, and power supplies as shown on the Plans and as required for a complete system.
(7) Input and output modules from the same product series as the PLC processor.
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(8) 120 volts digital input/output modules. Provide a minimum of 20 percent spare points for digital inputs and outputs or eight (8) digital input and eight (8) digital output points, whichever is greater, in each cabinet.
(9) Provide a dedicated and independent communication network from other communications network for I/O communications between racks.
(10) Install all necessary PLC programming software and accessory programs including communications drivers and programming documentation editors. License all software to the Owner.
B. Ethernet Switch. Provide UL listed, industrial managed type Ethernet switches with the following requirements:
(1) EIA-310 rack mount type or DIN rail mount with all necessary hardware and brackets for mounting.
(2) Provide minimum number of ports as shown on the plans plus one spare port per switch. Provide IEEE 802.3at class 4 PoE+ ports (as required) and sufficient wattage for each switch to power all PoE+ devices connected. Provide dynamic host configuration protocol (DHCP) and two LEDs status indicators for each port.
(3) Provide minimum of two small form-factor pluggable (SFP) fiber optic ports fully compatible with fiber optic cable and connector type(s).
(4) All Ethernet RJ45 and fiber optic ports must support Gigabit Ethernet speeds or higher.
(5) Supports the use of industrial automation protocol Ethernet/IP, rapid spanning tree protocol (RSTP) 802.1w, and other protocols as required for compatibility with PLC, CCTV equipment, and other connected devices.
(6) Supports the use of rapid spanning tree protocol (RSTP) 802.1w, IEEE 802.1x security standard for access control and authentication, simple network management protocol (SNMP) version 3, IEEE802.1q, quality of service (QoS) prioritization, internet protocol version 4 or version 6 (IPv4 or IPv6), command line interface (CLI).
(7) Provide ethernet switches capable of being configured via integrated web server.
(8) Provide alarm LED indicator and contact.
(9) Provide memory card slot to backup configuration data and to provide Layer 3 functions, with a spare configured card.
(10) Provide operating temperature range of 0 to 60 degrees Celsius.
C. UPS (Uninterruptible Power Supply). Provide rack or DIN rail mount uninterruptible power supplies (UPS) for PLC and CCTV system equipment. Provide UPS to sustain
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operation during short-term power failures and power for an orderly shutdown to prevent loss of data during power failure.
Size the UPS to sustain a connected full load for a minimum period of 5 minutes, or enough time for generator transfer, in the operating environment. Submit UPS sizing calculation with UPS product data submittal. For each UPS, include tabulation of connected load, run-time at full load, run-time at total connected load, and expected shut-down time for connected equipment in calculation. Provide a UPS with the additional requirements as follows:
(1) UL Listed.
(2) Suitable for standard EIA-310 rack mounting or DIN rail mounting as required.
(3) Microprocessor controlled with LED or LCD status display.
(4) Audible and visual alarms.
(5) Computer grade sine wave power with 5 percent or less total harmonic distortion.
(6) Regulated output to 120 V(ac) ± 3%
(7) Frequency regulation ± 5% synchronized to utility, ± 0.5 Hz on battery.
(8) Operating temperature range of -25 to 60 degrees Celsius for UPS located in outdoor/exposed enclosures; operating temperature range of 0 to 40 degrees Celsius for UPS in enclosures located in indoor (temperature controlled) areas.
(9) Relative humidity operation range 0-90%.
(10) Built in battery charger, with battery management to extend battery life.
(11) Internal maintenance free, sealed type batteries.
(12) Provisions for adding additional external batteries as required.
(13) Lightning and surge tested per ANSI/IEEE C62.41.
(14) Forced air cooled by an internally mounted fan(s).
(15) 10/100Mbit Ethernet communication option.
D. Indicator lights. Use UL listed industrial type with colors as indicated on the Plans. Indicator lights shall be size 30.5 millimeter, NEMA 4X rated. Lenses shall be interchangeable plastic Fresnel. Terminals shall be corrosion resistant screw type. Lamps shall be replaceable type, full voltage LED, 120VAC.
E. Pushbuttons. Use UL Listed industrial type, size 30.5 millimeter, with operation as indicated on the Plans. Pushbuttons shall be rated NEMA 4X with corrosion resistant
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contacts. Contact blocks shall be screw down stackable type. Contacts shall be rated 10 amperes at 120 volts AC. Terminals shall be corrosion resistant screw type.
F. Key switches. Use UL listed industrial type, size 30.5 millimeter, with operation as indicated on the Plans. Key switches shall be rated NEMA 4X with corrosion resistant contacts. Contact blocks shall be screw down stackable type. Contacts shall be rated 10 amperes at 120 volts AC. Terminals shall be corrosion resistant screw type. Provide min. 10 spare keys for key switches.
G. Limit Switches.
(1) Proximity Limit Switch. Provide UL listed, magnetic style proximity switch constructed of stainless steel with NEMA 4X or 6P corrosion resistant ratings. Provide double-pole double-throw (DPDT) contacts with minimum ratings of 10 amperes, 120 volts AC. Provide switch with operating temperature of -40 to 105 degrees Celsius. Proximity switch shall provide a min. ¼” sensing distance against ferrous materials. Provide a target magnet as required to increase sensing distance. Sensing face and orientation shall be as required for installation location. Provide factory installed cord set with matching quick disconnect connector.
(2) Lever Arm Limit Switch. Provide UL listed, heavy-duty NEMA style lever arm limit switches constructed of zinc die cast or stainless steel with NEMA 4X or 6P corrosion resistant and IP67 ingress protection ratings. Provide double-pole double- throw (DPDT) contacts with minimum rating of 10 amperes, 120 volts AC. Provide switch with operating temperature of -40 to 105 degrees Celsius. Provide corrosion resistant lever arm and use factory installed cord set with matching quick disconnect connector.
(3) Rotary Cam Limit Switch. Provide UL recognized, NEMA style rotary cam limit switch with number of cams/switches as shown on the Plans and integral resolver. Provide shaft configuration and gear reducer as required by application. Provide cam limit switch with 0 to 500 revolutions per minute (RPM) rated switching speed, bidirectional and snap action DPDT contacts, rated for 10 Amp / 120 volts AC. Provide the cam limit switch with an operating temperature rating of -50 to 185 degrees Fahrenheit and minimum cam adjusting temperature of -10 degrees Fahrenheit. Provide NEMA 4X, stainless steel enclosure for rotary cam limit switch. Provide resolver integral to the rotary cam limit switch assembly and enclosure. Provide industrial grade resolver with single turn and absolute position. Interface the resolver with the PLC control system.
Refer to the Mechanical Plans for rotary cam limit switch support details and requirements. The rotary cam limit switch support and incidentals shall be paid for under the Electrical Rehabilitation pay item, lump sum.
H. Interposing Relays. Use interposing (isolation) relays for interfacing with drives and motor controls, interfacing with other systems, and for isolating PLC inputs and outputs as shown on the plans and as required for the devices selected. Provide UL listed general purpose plug-in type tube or blade style relays with DPDT contacts rated 10 amperes at 300 volts AC, 60 hertz. Provide 120 volts AC, 60 hertz relay coils or as required by application. Provide DIN rail or panel mounting relay with retainer clips and
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LED indicator light, or a mechanical flag indicator for indicating when the relay is energized.
8. Boat Detection Sensors. Provide heavy duty microwave sensors, location and quantity as shown on the Plans, consisting of transmitters and receivers, capable of detecting marine traffic underneath the moveable span. Sensors shall meet the following requirements:
A. Min. range of 400’ (pier to pier)
B. Utilize frequency waves between transmitter and receiver that will not affect marine or RR radio traffic.
C. Unaffected by vibration, wind, fog, rain, snow, or dust.
D. Provide horizontal and vertical pattern width adjustment allowing for detection of marine vessels below sensor eye level.
E. Single-pole double-throw alarm output contacts rated 2 amps at 28 volts DC. Alarm output ON upon sensor failure and remote test.
F. Rated for outdoor installation, -40 to 66 degrees C operating temperature, and 0 to 100% humidity.
G. Provide stainless steel mounting hardware and sensor power supply.
9. Inclinometer. Provide a 2-dimensional, self-contained inclinometer for detecting span out-of-skew conditions, meeting the following requirements:
A. 4-20mA analog output for communication to the PLC
B. IP65, high impact, shock, and vibration resistant.
C. -18 to 70 degrees C operating range
D. Min. ±5-degree measurement range at .01-degree resolution
E. Quick disconnect connector and matching cord set.
F. Provide a local, digital tilt indicator compatible with Inclinometer, that provides live data of bridge angle. Install digital indicator on machinery house control panel. Include power supply and communication cables for inclinometer and digital tilt indicator. The digital tilt indicator display shall be replicated for display on the local HMI and at remote location(s) via the GUI.
G. Provide all necessary software and programing cables.
10. Machinery House Security System. Provide a complete alarm package that includes all required devices to detect unauthorized access inside the machinery house. The security system shall be provided by a single manufacturer and installed per their recommendations and as approved by the Engineer. The system shall meet the following requirements:
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A. Control Panel. Provide a control cabinet to house power supplies, battery backups and controller for the alarm system. The panel shall feature output relays, used to initiate an audible alarm and supply the PLC with a discrete signal used for remote monitoring. The panel shall also feature inputs for door switches and the keypad, described below.
B. Keypad. Provide a keypad display panel used for activating and deactivating the alarm system. The panel shall feature a digital display, indicating current alarm status and provide any fault indications.
C. Door Switch. Provide a door switch, compatible with the security system to detect when the machinery house door is opened and closed. The switch shall be heavy-duty and rated for outdoor installation.
D. Operation Specification. Entrance into the machinery house will require the user to enter a password into the control panel, which shall be determined by the Railroad. The security panel shall be installed near the machinery house entrance as shown on the Plans. If the authorized user does not enter the correct password under the allotted time, the control panel will set off an audible alarm inside the machinery house. Additionally, the control panel shall output an alarm to the PLC. The PLC, through the SCADA system, shall display an alarm indication for remote viewing and monitoring. The audible alarm shall maintain until the correct password has been entered into the keypad.
11. Machinery House Heater Thermostat. Provide a rugged, weather resistant mechanical thermostat used to regulate the temperature inside the machinery house. The thermostat shall be line or low voltage rated, as required to control the existing heater. Provide continuous adjustability between 40- and 100-degrees F.
12. CCTV System. Provide a CCTV system as shown on the Plans and as specified herein. Use the most current version of system protocol and software at the time of installation. Provide compatible system components that meet the following requirements:
A. Network Video Recorder (NVR). Provide a NVR configurable via the use of one central GUI (Graphical User Interface). Supply a standard mouse and keyboard with the NVR for system configuration and management. Provide additional devices and equipment for viewing and controlling CCTV system at the RR Springdale Dispatch Office. Provide an NVR that meets the following requirements:
(1) 16 or more IP video streams.
(2) Redundant RAID storage system for IP video streams, playback, and export.
(3) Solid state drive (SSD) for operating system storage to increase responsiveness.
(4) Support recording in JPEG, MPEG-4, and H.264 IP streams.
(5) Support H.264 Megapixel video streams up to 10 Megapixel resolution.
(6) Automatic detection of IP cameras.
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(7) Operation on a 4th Generation Intel Xeon processor or later and minimum 8 GB of RAM.
(8) Windows 10 (or later) Ultimate 64-bit operating system.
(9) Continuous scheduled alarm/event and motion recording. Pre and post alarm recording must also be available and must be fully programmable on a per channel basis.
(10) Archival of video data to computers or SAN storage devices over a network connection with the optional DS Archive Utility. The archival schedule must be either automatic at user-defined intervals or manual and must be configurable per connected camera.
(11) Support of Lightweight Directory Access Protocol (LDAP).
(12) System Requirements:
(a) Network Interface: Gigabit Ethernet (1000Base-T) ports (2x)
(b) Internal Storage: 12 TB min., RAID-5 hot swappable drives
(c) USB Ports: 2 USB 2.0 ports / 2 USB 3.0 ports
(d) Power Input: 100 to 240 V(ac), 50/60 Hz, auto ranging, internal power supply.
(13) Video Requirements:
(a) Video System: Intel HD graphics P4700 (shared memory)
(b) Maximum Resolution: 3840 x 2160 per DisplayPort output (2x) 1920 x 1200 @ 60 Hz on DVI-D output 1920 x 1200 @ 60 Hz on VGA output
(c) Video Standards: 60 Hz capable for NTSC; 75 Hz capable for PAL
(d) Video Decoding: MPEG-4 ASP; H.264 Baseline, Main, and High profiles
(14) Environmental Requirements:
(a) Operating Temp: 10°C to 35°C
(b) Operating Humidity: 20% to 80%, noncondensing
(15) Other Requirements:
(a) Remote viewing and monitoring of live and recorded video via desktop application or Web browser with all required security protocols.
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B. PTZ (Pan-Tilt-Zoom) Camera. Provide PTZ camera(s) with the following requirements:
(1) Use UL listed, outdoor vandal and tamper resistant dome type with an impact resistance rating of K10 (20 Joules). Camera shall contain interior heater and be IP66 Rated, -40°C to 60°C operating temperature, 5 to 90%, RH condensing operating humidity, and shock and vibration resistant.
(2) Provide multiple simultaneous video streams with 2 megapixel (MPx), 1920 x 1080 resolution (or higher) at 30 frames per second, auto iris and built-in varifocal lens type, f/1.6, 3.5-10mm focal length. Provide H.264 and MJPEG compression formats available for primary and secondary streams with selectable Unicast and Multicast protocols.
(3) Provide built-in video motion detection algorithm for detecting movement on presets or for alarm signaling. Alarm detection shall display through web server for user display.
(4) Provide min. 20x optical zoom and 12x digital zoom and delivering full frame rate HD images over the entire zoom range. Include a variable hi-speed pan and tilt drive, with 360° continuous pan and +5° to -85° tilt with additional features allowing user programmable preset viewing angles. Preset accuracy for pan and tilt function shall be within ±1⁰.
(5) Provide true wide dynamic range (WDR) up to 120 dB with local contrast enhancement (defog). Provide automatic IR cut filter mechanism for increased sensitivity in low-light installations. Configure set points for the IR cut filter feature through an embedded Web browser. Provide auto or manual exposure settings for adjusting the amount of light detected by the camera sensor.
(6) Provide supported network protocols as required for integration into CCTV system. Provide a full function web server, allowing complete administrative and operator control capabilities. Administrative features shall include configuring network settings, user password assignments, setting video stream properties, configuring camera imaging properties, and assigning camera ID labels.
(7) Provide compatible camera mounting accessories as required for pole mount and other camera installation as shown on the Plans.
(8) Provide image stabilization assuring a steady, clear image for installations subject to wind or vibration, allowing existing bridge structures to be used for camera mounting.
(9) Support industry standard Power over Ethernet (PoE+) IEEE 802.3at, Class 4 to supply power to the camera (with heaters on) over the network with RJ-45 connector for 100Base-TX.
C. Wall Mount Monitor. Provide an industrial high-definition LED or LCD monitor for viewing cameras at the Springdale dispatch office. Coordinate with the Railroad for
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mounting location and position. Ensure the wall mount monitor meets the following requirements:
(1) Minimum 42-inch diagonal screen with LED backlight.
(2) Full HD (1920 x 1080) resolution, 16:9 aspect ratio.
(3) Response time of 8ms or faster.
(4) Ultra-wide 178° (H) / 178° (V) viewing angle.
(5) Minimum brightness rating of 450 cd/m2.
(6) Operating temperature: 0°C to 40°C (32F to 104F).
(7) HDMI, DVI, VGA, and S-Video inputs (coordinate with NVR outputs).
(8) 100–240 volts, 50/60 Hz power.
(9) VESA mountable.
Provide heavy duty ceiling or wall mount mounting bracket as required for location, with mounting hardware. Secure mounting bracket to a sturdy structural member. Provide power and video cables and all required accessories.
D. Surge Protection Device. Provide a PoE surge protection device rated for Gigabit PoE (802.3at) for each camera power over ethernet connection with the following minimum requirements:
(1) UL497B listed and IEEE 802.11 approved.
(2) Provide transmission speeds up to and including 1000BaseT.
(3) Total discharge current rating of 10 kiloamperes at 8/20 microseconds.
(4) Nominal discharge current rating of 100 amperes (line-line) and 2 kiloamperes (line-earth per signal pair) at 8/20 microseconds.
(5) Response time of 1 nanosecond or less (line-line) and 100 nanoseconds or less (line-earth)
(6) Operating temperature range of -25 to 60 degrees Celsius.
E. Ethernet Switch. Provide ethernet switches as described in the Materials – Control System Components section of this special provision.
F. VPN Router. Provide a VPN router at the local network connection entrance point, capable of supplying a secure, Virtual Private Network (VPN) connection to the PLC, CCTV, and Signals control system. In addition, the router shall meet the following requirements:
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(1) Min. 2 VPN tunnels with required username and password for web-based access and management.
(2) Integrated managed ethernet switch with min. 4 RJ45 ports, 10/100BASE interface.
(3) USB connection programming port
(4) Supports Dynamic Host Configuration Protocol (DHCP) and Network Time Protocol (NTP)
(5) DIN rail mountable
(6) IPSEC protocol on Layer 3 security protection
G. Thermal Camera (FOR ALTERNATIVE BID OPTION ONLY).
(1) Use UL listed, outdoor vandal and tamper resistant dome type with an impact resistance rating of K10 (20 Joules). Camera shall be IP66 Rated, -40°C to 60°C operating temperature, 5 to 90%, RH condensing operating humidity, and shock and vibration resistant.
(2) Provide multiple video stream capability; two independently configured H.264 streams, an H.264 with MJPEG output, or an H.264 with analog output. Control functions shall be accomplished over IP.
(3) Provide min. 20x optical zoom and 12x digital zoom and delivering full frame rate HD images over the entire zoom range. Include a variable hi-speed pan and tilt drive, with 360° continuous pan and +5° to -85° tilt with additional features allowing user programmable preset viewing angles. Preset accuracy for pan and tilt function shall be within ±1⁰.
(4) Provide a dual thermal/visible imager, cable of displaying both low and high light images. Imager resolution shall be 320- or 640-pixel in either low frame rate (<9 Hz) or high frame rate (30/60Hz). Provide thermal imaging by a high-performance uncooled vanadium oxide microbolometer thermal imager and a 1/2.8-in progressive scale day/night visible imager.
(5) Thermal camera shall feature object motion detection with the ability to follow moving objects using the PTZ functions, in low and high light environments. Minimum object detection distance shall be 1000 feet. Provide built-in video motion detection algorithm for detecting movement on presets or for alarm signaling. Alarm detection shall display through web server for user display. Provide additional alarm indication for use as PLC input(s) and incidental wiring and integration into the PLC program.
(6) Thermal camera(s) shall be compatible with the NVR.
(7) Provide image stabilization assuring a steady, clear image for installations subject to wind or vibration due to passing train, allowing existing bridge structures to be used for camera mounting.
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(8) Provide compatible camera mounting accessories as required for pole mount and other camera installation as shown on the Plans.
(9) Provide supported network protocols as required for integration into CCTV system. Provide a full function web server, allowing complete administrative and operator control capabilities. Administrative features shall include configuring network settings, user password assignments, setting video stream properties, configuring camera imaging properties, and assigning camera ID labels.
(10) Support industry standard Power over Ethernet (PoE+) IEEE 802.3at, Class 4 to supply power to the camera (with heaters on) over the network with RJ-45 connector for 100Base-TX.
13. Main Drive Motor. Provide a main drive inverter duty rated gearmotor with the features and ratings as shown on the Mechanical drawings, Main Motor Specifications, and as follows:
A. 460 volts AC, 3 phase, 60 Hertz.
B. Minimum duty cycle rating of 5 minutes at 3 to 5 Hertz, 15 minutes at 6 to 15 Hertz, and 60 minutes at 16 to 60 Hertz, with a service factor of 1.15 at constant speed.
C. Optimized for operation with a variable frequency flux vector drive.
D. Meet or exceed the requirements of NEMA MG 1, Part 31.
E. Include factory mounted incremental encoder with at least 1024 pulses per revolution and output interface for compatibility with the supplied variable frequency drive.
F. Include 120-volt internal space heater.
14. Variable Frequency Drive. Variable frequency drive (VFD) shall be IP54, NEMA/UL type 12, flux vector AC drive featuring true field-oriented flux vector control. VFDs shall be suitable for operation on 480 volts AC, 60 hertz, three-phase systems. VFDs shall be rated for 75 horsepower, heavy duty, and be capable of providing true closed loop (encoder feedback) flux vector speed and torque control. VFDs must also meet the following requirements:
A. Microprocessor based control.
B. Operator interface, with backlit LCD display and keypad, usable for drive status monitoring and entry of all drive parameters. The operator interface must include all necessary cables and hardware required to mount it on the VFD cabinet door. All parameters must be viewable and adjustable through the drive operator interface and with the drive manufacturer’s software package. Parameters must be stored in nonvolatile memory. Mount VFD operator interface on cabinet door to use and view without opening the VFD cabinet.
C. Include built-in communications capability, including Ethernet with common industrial protocol. The Ethernet communications connection must be used for VFD configuration.
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D. Three preset speeds selectable via external discrete control inputs, independently adjustable acceleration and deceleration times, and adjustable torque limit selectable via external discrete control input to allow for a reduced bridge seating torque.
E. Internal, adjustable electronic thermal overload relay for motor overload protection.
F. Self-tuning feature allowing the VFD to optimize its performance parameters to the main drive motor.
G. 0 to 40 degrees Celsius operating temperature without derating and 5-95% relative humidity operation range, non-condensing.
H. Speed regulation with slip compensation in sensor less vector mode of 0.5% of base speed across 40:1 speed range, 40:1 operating range.
I. Adjustable carrier frequency with a minimum of four settings.
J. Safe torque off function, to safety category 3, Safety Integrity Level (SIL) CL3 or higher.
K. 150% rated motor full load torque for 60 seconds, 180% for three seconds.
L. Provide the drive manufacturer’s software package and necessary programming cables for the configuration, backup, and restoration of drive parameters. Install the software package on the laptop computer and license to the Owner.
M. Provide a VFD output filter that meets the following requirements:
(1) Drive output filters must be UL listed, 3% impedance reactors with inductance- capacitance (LC) filter (dv/dt filter) suitable for operation on 480 volts AC, 60 hertz, three phase systems.
(2) The dv/dt filters must be harmonically compensated and rated to handle full rated fundamental current plus an additional 50% of fundamental current due to harmonics.
(3) Reactors must include IGBT protection and have a dielectric system which satisfies the requirements of UL 508.
(4) Filters must be sized and supplied by the drive manufacturer.
15. Drive Braking Resistors. Provide braking modules and appropriately sized braking resistors sized to provide a braking torque of at least 150 percent rated motor full load torque for a duty cycle consisting of 30 seconds on at 150 percent, then four and one-half minutes off, or as required by the VFD manufacturer.
Braking modules must be the same manufacturer as the VFD and designed for use with the VFD, including all inputs and outputs required for proper interfacing with the VFD. Converter protective features must include module overload.
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Braking resistors must be edge-wound stainless steel, mounted in ventilated enclosures. Openings must be screened or otherwise protected to prevent entry of small rodents. Use stainless steel or similarly corrosion resistant hardware. Wire braking resistors to terminal blocks with high temperature silicone or Teflon wire rated for 150 degrees Celsius or higher. Interconnect braking module fault contact and resistor built-in over-temperature sensor to the VFD to initiate an alarm and drive stop in the event of a resistor over-temperature condition.
16. Labels and Identification. Provide one piece engraved plastic type legend plates for indicator lights, selector switches, pushbuttons, and exterior cabinet and enclosure labels with black text on a white background. Include text as shown on plans. Fasten exterior cabinet labels with stainless steel machine screws. Labels mounted inside cabinets and enclosures are permitted to use adhesive backed labels.
17. Spare Parts. Provide the following minimum spare parts:
A. One (1) main drive motor.
B. One (1) main drive motor encoder.
C. One (1) variable frequency drive (pre-programmed), including braking resistor(s) and input line reactor(s)
D. One (1) disconnect switch of each type used.
E. Two (2) of each type of surge protective device used.
F. Two (2) of each type of PLC module used.
G. Two (2) of each type of limit switch used.
H. One (1) rotary cam limit switch with resolver.
I. One (1) inclinometer.
J. Ten (10) maintenance lighting fixtures.
K. Four (4) of each type of relay and other control devices used.
L. Six (6) of each type of fuse used.
M. Two (2) of each pushbutton, key/selector switch, and indicator light used.
N. One (1) complete pier navigation light assembly.
O. One (1) complete lift span navigation light assembly.
P. Six (6) red and six (6) amber flashing beacons. e. Construction.
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1. General Requirements. Provide all miscellaneous products, tools, equipment, and labor necessary to properly complete all work in accordance with the requirements and intent of the plans and special provisions.
Install all machinery components by certified millwrights experienced in precision machinery alignment.
Install all products in accordance with their manufacturers' recommendations and the requirements of the NEC and the contract. Physically install all products at the indicated and approved locations, and in a secure manner as indicated or as required to provide a reliable installation. Inspect and test all installed products for correct installation, performance, and workmanship.
Coordinate with the US Coast guard (USCG), the US Corps of Engineer (USCE), the local Department of Environmental Protection, and other local agencies, and acquire permits and/or permission for the Work performed in and/or over the navigable waterways. Obtain explicit permission and/or permit from the USCG for any bridge closure or delay of the marine traffic. Maintain the bridge navigation lighting system in continuous operation, 24 hours a day for the duration of the project. All penalties assessed against the Railroad due to the non-operation of the navigation lighting system will be borne by the Contractor. Notify the USCG and the Engineer of any change to the Contractor’s work schedule.
Spillage of oil and hazardous material is prohibited. Properly maintain construction equipment, and carefully and properly handle fuel and hazardous material so as not to cause any spillage in the waterway. Notify the Engineer immediately of any spillage of oil/hazardous material in the waterway. Instruct personnel not to dispose of oil/hazardous material into the waterway directly or indirectly and have plans to remove any spillage of such materials, should it occur. The removal method must be as authorized by the State and Federal laws and regulations. All costs of cleanup shall be borne by the Contractor.
2. Removals. The Contractor shall give the Railroad the option of salvaging all electrical equipment which is to be removed. Unless otherwise noted, unused or unsalvaged materials from the removal that is unwanted by the Railroad will become the property of the Contractor who must dispose of them away from the construction site in accordance with all local, state, and federal laws and regulations.
When instructed to replace, remove the existing components, and furnish and install new components as specified on the Plans and elsewhere herein.
3. Installation. Prior to commencing installation verify that all surfaces upon or in which equipment and devices are to be mounted, are properly prepared.
Before mounting of enclosures, ensure that all required wire pulling has been completed and all wires are properly tagged. Take corrective action, if necessary.
Verify that mounting provisions are suitable for the intended mounting. Make corrective adjustments, if necessary.
Where new mounting brackets and supports are to be mounted on existing structural members, prepare mounting surfaces by cleaning and painting surfaces of the existing steel
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before mounting new brackets and supports. Refer to structural specifications for cleaning and painting requirements. Field drilling of structural members is prohibited; mount to members via clamp-on methods only.
4. Operation and Maintenance of Bridge During Construction. The Contractor is responsible for operating the bridge any time that a bridge operation is required from the time the construction starts until all required testing and training is complete, the construction of the bridge is complete, and final acceptance of the project has been issued, including any necessary bridge operation during the bridge outage period for construction. Depending on site conditions or stage of construction, the Contractor may be required to operate the bridge using the stand-by generator for power, auxiliary diesel engine as the prime mover, and/or manually actuating the brakes and span-locks. The Contractor should be familiar with this procedure should it be necessary. During this time, the Contractor is responsible for maintenance of the lift span. Maintain and provide any required adjustments and corrections to all work during construction and until all required training and the period of Contractor supervised operation is complete.
The Contractor is responsible for maintaining the functionality and proper sequence of all bridge navigation lighting per the USCG approved plan as indicated in the Code of Federal Regulations (CFR) for the bridge. This is required from the time construction starts until all required testing and training is complete, the construction on the bridge is complete, and final acceptance of the project has been issued, including as required during any necessary bridge outages for construction. The navigation lighting must be always functional. All penalties assessed against the Railroad due to the non-operation of the navigation lighting system will be borne by the Contractor. Notify the USCG and the Engineer of any change to the Contractor’s work schedule.
Provide at least one operator available to always operate the bridge during this construction phase. Maintenance of the lift span includes performing all required machinery lubrication and any adjustments or corrections required to maintain the bridge operational.
Always provide at least one “on-call” individual available while Contractor personnel are not working on-site. This individual must be available and able to resolve any issues that are a result of work performed by the Contractor on-site.
Follow OSHA Lockout/Tagout procedures when Contractor personnel are working on-site. The bridge operating machinery must be always locked out by the Contractor’s Employee responsible for coordination of bridge operations unless bridge operations are required. The Contractor will be fully responsibility for all fines, fees, and damages resulting from non- compliance with the requirements of this section, caused by the Contractor work, non- compliance with USCG regulations and requirements, or any other applicable local, state, or federal laws and regulations. The Contractor must immediately reimburse the Railroad for any fines, fees, and damages assessed against the Railroad due to the Contractor's activities.
5. Wiring. Use conductors with green colored insulation only for grounding conductors. The re-identification of conductors with green colored insulation, such as with colored tape, is prohibited.
Supply a dedicated neutral conductor for all branch and feeder circuits requiring a neutral. Ensure a dedicated neutral conductor is not shared by phase conductors of other circuits.
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Provide equipment grounding conductors in all conduit and cable runs. Unless otherwise shown on the Plans, size equipment grounding conductors equal to the largest circuit conductor in the conduit or cable. Coordinate all wire and cable requirements with manufacturers of the equipment served.
Handle and install wires and cables with care to avoid damage to conductors, insulation, jackets, armor, etc. Replace at no additional cost any wire or cable which is found to be damaged.
Permanently label all conductors, cables, and terminal blocks at every terminal or connection, splice, and tap. Assign each conductor or cable with one identifying number (including spares) throughout the entire electrical and control system. Coordinate identification numbers for consistency and accuracy with conductor numbers on the Contractor's approved wiring diagrams and shop drawings, field wiring diagrams, and any other diagrams containing the same respective conductor or cable.
Label all conductors with machine printed self-sealing, adhesive-type labels. Use water and smudge resistant text. Coordinate label text with shop drawings and wiring diagrams. Handwritten labels are prohibited.
6. Conduit and Cable. Unless specifically indicated otherwise, install connections of conduit and cable entrances only in the bottom of cabinets and enclosures which are located outdoors and in damp locations.
To the extent practical, maintain at least a 4-inch separation between power wiring and communication and/or instrumentation cables.
Use weatherproof cable(s) only where the final connection to equipment requires the use of a cable and final connection via conduit or flexible conduit is not feasible. Use cable connectors where weatherproof cable(s) transition from conduit and where weatherproof cable(s) enter box(es) or enclosure(s).
Provide insulated throat bonding bushings or bonding nuts where conduits or metal armored cables enter metal boxes or enclosures. Properly bond/ground conduit to the bonding/grounding hub. Connect bonding bushings and bonding nuts to the equipment grounding conductor included in the conduit or cable.
Install metal conduit and tubing in accordance with the Steel Tube Institute of North America's Guidelines for Installing Steel Conduit/Tubing.
Make bends in rigid conduit with tools which are specifically designed for bending the type and size of conduit in question. When bending conduit maintain proper internal diameter and wall thickness.
Do not make more than three quarter bends, equivalent to 270 degrees, in one conduit run between pull points such as conduit bodies, junction/pull boxes, terminal cabinets, and enclosures.
Make field cuts square to conduit and ream conduit ends to remove burrs. Field cut threads must have same length, dimensions, and taper as factory-cut threads. Clean field cut threads
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with an appropriate degreasing solvent after cutting and coat with a touch-up compound as recommended by the conduit manufacturer and a urethane topcoat. Similarly treat any area on the interior of the conduit which has been disturbed by reaming.
Install PVC coated rigid metal conduit using tools and methods which will not cause damage to the PVC coating, and in accordance with installation instructions provided by the conduit manufacturer. Coat any area on the exterior of the conduit which has been damaged during installation with an exterior patching compound as recommended by the conduit manufacturer.
Repair, by replacing the entire section of conduit, any defect (nick, scar, cut, tear, abrasion, etc.) to the PVC coating of PVC coated rigid metal conduit that is 3 inches or more in length. Repair any defect to the PVC coating which is less than 3 inches long with an appropriate repair compound as recommended by the conduit manufacturer and approved by the Engineer. However, the Engineer may, at his discretion, alternatively require that defects 3 inches long or less be repaired by replacing the entire section of conduit. Any costs associated with required replacement of conduits due to damaged coating, including if such replacement requires the removal and re-installation of conductors will be borne by the Contractor. Submit proposed conduit repair details for approval.
Unless explicitly indicated otherwise, install conduits as follows:
A. All outdoor (wet) locations: use PVC coated rigid metal conduit and liquid-tight flexible metal conduit (LFMC).
B. Inside the machinery house and indoor locations: use galvanized steel conduit and LFMC.
Use liquid-tight flexible metal conduits in accordance with the following conditions:
A. In lengths not to exceed 18 inches for final connection to motors and similar equipment subject to vibration.
B. Where flexibility is required, lengths must not exceed 18 inches, unless explicitly indicated otherwise or with the special permission of the Engineer. Do not use liquid-tight flexible metal conduit in lieu of bends in rigid conduit, except as may be allowed by the Engineer by special permission.
7. Wire and Cable Pulling. Thoroughly swab raceway system before installing conductors. Use pulling lubricant to facilitate installation of wire and/or cable in conduits. Ensure lubricant is NRTL listed, environmentally friendly, Teflon based lubricant which is safe for use with all cable types and does not harden in conduit.
Replace conductors and cables, which are damaged during shipping, handling, storage or during the installation, or due to high pulling tension during the installation as revealed during any inspection or tests, as required, or as directed by the Engineer to his satisfaction. Such replacement will not be considered cause for delay or additional payment.
8. Low Voltage Splices, Terminals, and Terminal Blocks. Splice and tap conductors only in equipment enclosures, cabinets, or junction boxes, and on terminal blocks or with insulated
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compression crimping-type connectors or as described herein. Do not terminate more than two conductors per terminal block. Make splices and taps at equipment or in locations which do not permit the use of terminal blocks with crimp or mechanical type connectors with the Engineer’s permission.
Make connections to motor terminal leads only with means which will allow for disconnection without cutting motor leads, such as two crimp type lugs bolted together or mechanical type connectors. The use of wire nut connectors is prohibited.
After the installation, insulate all splices made with crimp or mechanical type connectors with rubber and vinyl tape, or an insulating cover specifically designed for use with the connector. The Engineer may require the use of special splices or splice kits to address specific application considerations.
For splices without integral insulating sleeves, tightly apply a minimum of one half-lapped layer of rubber tape, tacky side up, over entire splice and extending onto the conductor insulation at least one tape width on both sides of splice. Apply a minimum of two half-lapped layers of vinyl tape completely over rubber tape and extending onto conductor insulation past ends of rubber tape.
For splices which are provided with integral insulating sleeves, apply a minimum of two half- lapped layers of vinyl tape completely over splice and extending onto conductor insulation, past ends of splice.
9. Grounding and Bonding. Provide grounding and bonding in compliance with the requirements of NEC Article 250 for grounding and bonding.
Do not use raceways and metallic cable armor/sheaths as the sole grounding or bonding conductor for any circuit.
Solidly connect all electrical equipment to the equipment grounding conductor serving that equipment.
Bond the ground buses of all equipment to the nearest substantial structural steel member. Size bonding jumpers equal to the equipment grounding conductors serving the equipment. Install the bonding jumper in accordance with the requirements for grounding electrode conductors given in the NEC. Ensure bare ground wire is used when installing a bonding wire in junction boxes, terminal cabinets, and enclosures.
Where bolted connections are used for connection of equipment grounding conductors to equipment, clean the area around the connection down to bare metal prior to making the connection. Touch-up the area with paint after the connection is made in accordance with the equipment manufacturer recommendations.
10. Conduit and Cable Supports. Support rigid conduits near each elbow and within 18 inches of each box, enclosure, conduit body, or similar termination, and at regular intervals not to exceed 6 feet.
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Support flexible conduits near each elbow and within 12 inches of each box, enclosure, conduit body, or similar termination, and at regular intervals not to exceed 3 feet, except where flexibility is required.
11. Aerial Cable Support System. Provide all necessary components and materials to utilize the existing support structures located on the North and South tower tops and the moveable span. Aerial cable and messenger cable length shall be field verified and designed by the Contractor to minimize cable droop when the bridge is fully open and seated, as well as prevent interference with any part of the existing bridge structure. Messenger cables, mounting hardware and components shall be designed by the Contractor as specified in the NESC, C2-2012. Ice and wind loadings on messenger and aerial cables shall be considered in the design with no overstress in the members or components. Cables and hardware shall be installed to eliminate interference between the cables due to wind loading. The Contractor shall provide and design additional support structure(s) as required to aid the existing vertical supports on the tower tops and moveable span to properly secure the new messenger and aerial cables.
12. Conduit Penetrations. Provide conduit penetrations through walls, floors, and ceilings as necessary for the installation of conduits. Following the installation, restore floors, walls and ceilings with materials equal to the original construction and finish to match surrounding surfaces. Materials used will be subject to the approval of the Engineer for appropriateness. The Engineer will advise the Contractor regarding the method to be used at each penetration location.
13. Equipment Cabinets and Enclosures. Where equipment cabinet or enclosure sizes are shown on the plans, this indicates the minimum size required. Upsize the box or enclosure for the internal components used per manufacturer recommendations.
14. Mounting Brackets. Fabricate mounting brackets as required by the contract, or for the specific equipment and devices, or as proposed by the Contractor to accommodate the specific mounting locations and equipment. Submit to the Engineer, for approval, shop drawings and details of mounting brackets proposed for installation with indicated dimensions, materials, type, and materials of anchorage.
15. Touch-up Painting. Touch-up paint all scratches and damage to factory-applied finishes on electrical equipment and enclosures, raceways, and boxes, as required to repair the damage to the factory finish. Use touch-up painting at least one coat of primer, and two coats of finish paint. Use primer and paint as supplied or recommended by the manufacturer of the item being painted.
16. CCTV System. Install CCTV system in accordance with the manufacturer’s instructions. Install CCTV cameras at locations shown on the Plans. Aim, adjust, align, focus, and perform all necessary system set-ups to achieve required viewing image performance. Mount and aim each camera to achieve the field of view as described on the plans. Coordinate final camera field of views with Railroad.
Use water-tight fittings for connection to cameras. To the extent practical, do not permanently install cameras until major construction activities on the bridge have been completed. Provide means of protection from damage and debris for installed cameras while construction is still underway.
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17. Variable Frequency Drive. The CSV must perform the manufacturer recommended sequence for tuning the variable frequency drive to the main drive motor. Adjust any other main drive settings necessary to ensure fully functional and reliable bridge operations.
See the Special Provision for Mechanical Rehabilitation for additional construction requirements and hardware required for the installation of the main drive motor.
18. PLC Programming. Ladder logic shown on the Plans is conceptual only. Provide additional logic development and program writing necessary for complete programs suitable for operating the bridge. Use ladder logic type programming language/format.
Provide descriptive address names/tags for all used and reserved addresses for input and output points and internal memory locations. Use line comments to provide additional explanations for complex logic, calculations/scaling and to identify sections of logic for specific purposes.
Provide PLC function(s) to allow drive faulted conditions to be reset from the SCADA System main drive configuration screen. Password protect user ability to acknowledge, reset, and clear drive faults.
19. SCADA (Supervisory Control and Data Acquisition) System. Provide a web-based SCADA system with a graphical user interface (GUI) for remote monitoring and operation as described herein. Configure the SCADA system with the following features and characteristics:
A. SCADA system shall provide the ability to monitor and control the CCTV camera and PLC system, through a web-based software, protected through a Virtual Private Network (VPN). The VPN shall provide secure web-based access to the PLC and CCTV system and meet the requirements as listed under section “VPN Router”.
B. The SCADA system shall provide the user with the ability to replicate all data that could be accessed locally at the bridge.
C. Provide the viewer with real time and historical data though the GUI, as listed below, for the CCTV and PLC system.
D. Provide multi-user and multi-workstation capability without operator restrictions other than password and access rights.
E. Provide standard interfaces to monitor and control a variety of SCADA field equipment from a variety of manufacturers.
F. Provide industry standard protocols to support communications with PLC’s and other facilities management devices.
G. The systems integrator shall provide the Railroad with a non-exclusive, perpetual, irrevocable, royalty-free license to use the SCADA software and related third-part software. This software shall contain no license key or other mechanisms preventing the user from expanding or utilizing the software to its fully licensed capabilities, nor allow for additions of workstations, SCADA control devices, graphics, reports, etc. To protect the
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Railroad against lack of future support, all source code for the core of SCADA software owned by the vendor shall be provided to the customer under the terms of confidentially agreement.
Configure the GUI with the following graphic screens, features, and characteristics:
A. Configure the GUI to automatically default to display the main bridge overview screen upon startup. Utilize a simple menu type system to organize graphic screens and to allow the user to quickly navigate between screens.
B. Main Bridge Overview Screen. On the main bridge overview screen, provide a simplified graphical representation of the bridge with position/height status, angle via inclinometer data, status of brakes and span locks, main drive speed and direction, automatic transfer switch status, and links to all configured screens.
C. Bridge Control Panel Screen. On the bridge control panel screen, mimic the control panel layout(s) local to the bridge. Include height status and main drive speed on this screen and configure graphical indicator lights to appear grey when not on and to change color to the respective indictor light color when on. Mimic the appearance and operation of the selector switches and pushbuttons. Remote operation of the span from this screen shall be limited to sending the lower request to lower the span, or as directed by the Railroad. This operation will mirror the lower request command from signals and follow the same operating sequence as if the lower request were received from signals. Password protect user access to this screen.
D. Main Drive Status Screen. On this screen, mimic the main drive cabinet HMI panel display and show, at a minimum, drive speed, torque, current, and frequency. Configure the drive HMI panel graphic to display a real-time pop-up if an error or fault occurs at the drive. Provide a link with the pop-up to navigate the user to the fault/alarm history screen.
E. Fault/Alarm History Screen. Configure this screen to keep a complete history of bridge PLC and main drive faults and alarms. Provide date/time stamps for each fault and alarm to show the date and time it was activated, acknowledged, and cleared. Password protect user ability to acknowledge and clear faults and alarms. List the fault/alarm history in chronological order with the most recent item listed first. Color code each item to distinguish between active unacknowledged (flashing red), active acknowledged (solid red), and cleared faults and alarms. Provide option to sort faults and alarms by status, date, or alphabetically. For each possible PLC and drive fault/alarm, pre-configure in the program the name of the fault/alarm, a brief description, and a recommended action for the user (i.e. contact maintenance). Configure the program to display these when a fault/alarm is active. Provide a password protected link for each fault/alarm item to navigate the user to a diagnostic/troubleshooting screen.
F. Diagnostic/Troubleshooting Screen(s). Configure a password protected screen (linked from the fault/alarm history screen) for each possible fault/alarm to display a recommended action for diagnosing and troubleshooting the fault/alarm. Provide options for the user to acknowledge and clear the fault/alarm on this screen.
G. CCTV Camera Screen(s). Configure a main CCTV camera screen to show all camera views on one screen. Configure each camera view to enlarge to a full screen
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single camera view when selected. Include additional links on this screen to navigate to other preconfigured camera group screen(s). Each camera group screen will show larger views of one or multiple cameras as requested by the Railroad. Coordinate with the Railroad for desired group camera screen(s).
H. Configure all HMI screens to display a new fault/alarm, with description and recommended action for the bridge operator, with link to navigate the user to the fault/alarm history screen.
I. Configure all screens with links to navigate back to the previous screen and the main bridge overview screen.
J. Coordinate with the Railroad and the Engineer and provide other screens and features as requested and for setup of all password protected user access and abilities.
Configure the North approach control cabinet HMI with the following graphic screens, features, and characteristics:
A. Configure the GUI to automatically default to display the main bridge overview screen upon startup. Utilize a simple menu type system to organize graphic screens and to allow the user to quickly navigate between screens.
B. Main Bridge Overview Screen. On the main bridge overview screen, provide a simplified graphical representation of the bridge with position/height status, angle via inclinometer data, status of brakes and span locks, main drive speed and direction, automatic transfer switch status, and links to all configured screens.
C. Main Drive Status Screen. On this screen, mimic the main drive cabinet HMI panel display and show, at a minimum, drive speed, torque, current, and frequency. Configure the drive HMI panel graphic to display a real-time pop-up if an error or fault occurs at the drive. Provide a link with the pop-up to navigate the user to the fault/alarm history screen.
D. Fault/Alarm History Screen. Configure this screen to keep a complete history of bridge PLC and main drive faults and alarms. Provide date/time stamps for each fault and alarm to show the date and time it was activated, acknowledged, and cleared. Password protect user ability to acknowledge and clear faults and alarms. List the fault/alarm history in chronological order with the most recent item listed first. Color code each item to distinguish between active unacknowledged (flashing red), active acknowledged (solid red), and cleared faults and alarms. Provide option to sort faults and alarms by status, date, or alphabetically. For each possible PLC and drive fault/alarm, pre-configure in the program the name of the fault/alarm, a brief description, and a recommended action for the user (i.e., contact maintenance). Configure the program to display these when a fault/alarm is active. Provide a password protected link for each fault/alarm item to navigate the user to a diagnostic/troubleshooting screen.
E. Diagnostic/Troubleshooting Screen(s). Configure a password protected screen (linked from the fault/alarm history screen) for each possible fault/alarm to display a recommended action for diagnosing and troubleshooting the fault/alarm. Provide options for the user to acknowledge and clear the fault/alarm on this screen.
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F. Configure all HMI screens to display a new fault/alarm, with description and recommended action for the bridge operator, with link to navigate the user to the fault/alarm history screen.
G. Configure all screens with links to navigate back to the previous screen and the main bridge overview screen.
H. Coordinate with the Railroad and the Engineer and provide other screens and features as requested and for setup of all password protected user access and abilities.
20. Electrical Testing and Measurements.
A. Submittals. Submit as specified to meet the following minimum requirements:
(1) Submit proposed testing procedures, including test instruments, up-to-date instrument calibration proof, and other equipment to be used for approval at least 15 working days prior to testing.
(2) Accurately record the results of all tests in a neat and orderly manner along with time and date of test(s), environmental conditions (temperature, humidity, general weather conditions, etc.), testing equipment used, conditions of test(s), and the name(s) of person(s) performing the test(s).
(3) Submit all test results with all text in typewritten format no later than 10 working days from date of test(s). The results of these tests must be deemed acceptable by the Engineer prior to acceptance of the work in question.
(4) Submit the following:
(a) Insulation resistance testing of the new main drive motor at the time of installation and at final acceptance.
(b) Insulation resistance testing of all newly installed power and control conductors (including aerial cable conductors), except for instrumentation conductors.
(c) Results of operational testing after installation. Operational testing must include three-phase motor current measurements for at least one complete bridge operation (raise and lower).
B. General Requirements. Perform all testing, inspections, and any resulting corrective work to ensure that, after the installation of the electrical materials and equipment for the required work, the entire bridge power and control systems properly function as intended and as recorded by the Contractor prior to the removals and as modified and required by the contract.
In addition to the specific tests described herein, perform all additional testing, and make any necessary repairs or adjustments to provide a complete, functional, and reliable installation. All testing, inspections, and demonstrations, and any resulting remedial work,
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will be deemed solely the responsibility of the Contractor and will not be considered cause for delay or additional payment.
Use test procedures and equipment in accordance with manufacturer’s recommendations, NETA Acceptance Testing Standards, any other applicable industry standards, and appropriate for the specific test being performed.
Use true root mean square (RMS) type voltmeters and ammeters. Maintain in proper calibrated condition and use all tools and instruments specifically designed for measuring the quantity in question.
C. Shop Testing. Perform a shop test for the control system prior to shipment from the CSV’s shop. Ensure the shop test is witnessed by the Engineer or the Engineer’s designated representative. Include a complete run through of the operating sequence and confirm all safety interlocking.
Prepare a detailed testing procedure for shop testing of the installed work. Submit the shop test procedure at least 3 weeks in advance for approval before beginning shop testing. Coordinate with the Railroad and schedule the test at a time agreeable to all parties involved. Determine the schedule at least 2 full weeks in advance of the proposed start date for the testing. If an approved shop testing procedure is not documented prior to the scheduled time of the test, the Railroad retains the right to reschedule the test. In the event a reschedule is required, the Contractor will bear any costs associated with delay and rescheduling of travel arrangements.
Note that not all components will be present at the shop test; use simulation of these components to perform the most complete shop test as practical. Utilize temporary indicator lights and control switches as required. Demonstrate the user screens and operation of the GUI during the shop test.
Wire and assemble all PLCs, relays, and other related control system components to the extent practical in the proper cabinet(s) and make ready for shipping pending any corrections or adjustments necessitated by testing results, before performing such tests.
Correct any errors found in the system and rerun the respective portion of the test.
D. Testing and Inspection after Installation. After all wires have been installed and prior to connections of any circuit, test to verify that all installed conductors are free of shorts, opens, or unintentional grounds, and properly terminated.
Measure and record the insulation resistance of the new main drive motor. Make measurements at the motor, or at the local disconnect switch. Measure and record the insulation resistance of all newly installed power and control conductors, except for instrumentation conductors. The minimum acceptable resistance is 100 megohms (at 500V DC).
Measure the contact resistance of all new circuit breakers and contactors. Deviation of 50 percent or more between contacts of any device, or between contacts of similar devices, is considered a failure.
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Perform tests after energizing any circuit and prior to connections to equipment or motors to verify the following conditions:
(1) Correct no-load voltage for the equipment to be powered.
(2) Correct phase sequence.
(3) Correct polarities.
After all connections have been made to all equipment and devices, visually inspect all electrical connections, and verify that all lugs, connectors, and terminals are tightened and torqued to the levels recommended by the manufacturer.
E. Testing of Motors and Machinery. Prior to first operation of any motor or motor driven machinery, confirm proper motor rotation with all driven machinery disconnected or otherwise suitably arranged to prevent damage in the event of incorrect rotation. After confirming proper rotation, record the correct circuit phase to motor terminal connections on the as-built plans and working drawings.
Visually inspect all motors and motor driven machinery, including, but not being limited to, checking for excess mechanical or electrical noise, for excessive heating, for vibration, verifying proper tightening of all mounting bolts and coupling connections, and observation of any other physical indications of improper installation and operation.
Following final acceptance, measure and record the motor terminal voltage and three- phase currents for the main drive motor through one complete bridge operation (raise and lower). Take measurements at the outputs of the VFD and continuously record with suitable computer-based recording equipment at a data sampling rate of at least 20 samples per second.
F. Operational Tests and Demonstrations. Prior to attempting to test-run the bridge, test and verify that all PLC input/output wiring has been installed correctly. Verify the correct operation of all limit switches and sensors.
When the installation of all systems is complete and ready for testing, test-run the lift span. Demonstrate a trouble-free bridge operation, meeting all specified requirements with all interlocks properly functioning through the PLC control system.
Perform additional miscellaneous operational tests as requested by the Engineer, or the Railroad’s representative to demonstrate and establish that the work as installed meets all specified requirements and is operating in a reliable manner.
G. Final Field Acceptance Testing. Perform a final field acceptance test for the bridge operation, control system, and other components as described herein after all required components are installed and initial operational tests and demonstrations are complete. Ensure the final field acceptance test is witnessed by the Engineer or the Engineer’s designated representative. The final field acceptance test must include, at a minimum, the following demonstrations:
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(1) Include a complete run through of the operating sequence for the main drive mode. A minimum of 10 consecutive, successful, error free, and full bridge operations are required, including 8 consecutive bridge operations with the main drive motor and 2 bridge operation with the diesel engine (complete from fully raised to fully seated to fully raised). At least one bridge operation with the main drive motor must be performed using the GUI for remote operation. At least one bridge operation must be performed using the North control panel, South control panel, and machinery house control panel (total of 3 bridge operations). At least one bridge operation with the main drive motor on generator power must be performed. Perform all bridge operations within one single day. In the case of any error or required adjustment, ensure the count of successful operations is started over.
(2) Perform one complete check of proper bridge safety interlocking.
(3) Confirm with the Railroad the final field of view of all CCTV cameras.
(4) Demonstrate that all bridge lighting, navigation lighting, automatic transfer switch and backup generator, and other miscellaneous systems are operating satisfactorily.
(5) Perform additional tests and demonstrations to demonstrate to the Engineer and the Railroad’s representative that the installed systems satisfy the requirements and intents of the plans and special provisions.
Prepare a detailed testing procedure for final field acceptance testing of the installed work. Submit the final field acceptance test procedure at least 3 weeks in advance for approval before beginning final field acceptance testing. Coordinate with the Railroad and schedule the test at a time agreeable to all parties involved. Determine the schedule at least 2 full weeks in advance of the proposed start date for the testing. If an approved final field acceptance testing procedure is not documented prior to the scheduled time of the test, the Railroad retains the right to reschedule the test. In the event a reschedule is required, the Contractor will bear any costs associated with delay and rescheduling of travel arrangements.
Correct any deficiencies revealed during testing and repeat the test until such time as the Engineer is satisfied with all test results and the overall performance of the bridge control system.
For final acceptance by the Railroad, the minimum 10 consecutive bridge operations must be successful and error-free, and operation and maintenance training must be completed.
H. Operation and Maintenance Training. After all systems are installed and tested, the bridge and its control and drive systems are proven to operate reliably, and the 10 bridge operations, as described above are successful, provide operation and maintenance training for maintenance personnel. Provide training for a minimum of two full 8-hour working day, with a minimum of 1 week notice to the Railroad. Training must include, at a minimum, the following:
(1) Using and navigating the GUI and HMI interface(s), including viewing drive and bridge status, viewing CCTV cameras, remote operation via the bridge control panel
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screen, and interpreting common VFD and PLC errors and faults and respective corrective actions.
(2) Overview of PLC equipment, including basic troubleshooting and recommended maintenance.
(3) Overview of CCTV system, including basic operation and navigation of the NVR, switching between preloaded camera views on the GUI, and basic troubleshooting and recommended maintenance.
(4) Overview of bridge operating sequence and interlocking.
(5) Basic newly installed device troubleshooting instructions.
(6) Include additional training at the request of the Railroad.
21. Corrective Actions. For any test failure, or for any test result which fails to meet the specified requirements or the stated acceptable values or conditions, or the Engineer finds unacceptable, the Contractor must investigate the cause of the failure, take appropriate corrective actions, and repeat the test(s). Repeat this procedure until such time as all test results are deemed acceptable by the Engineer.
22. Contractor Supervised Lift Span Operation. Provide a minimum of one person to supervise the operation of the bridge for a period of 7 calendar days after final acceptance by the Railroad (after final field acceptance testing and operation and maintenance training is complete) and provide one person on call for an additional 7-day period. Ensure these people can operate the bridge, to supervise its operation, and to make any adjustments or corrections that may be required in the electrical, PLC, and control equipment of the bridge. They must instruct and qualify the Railroad employees in the operation of the bridge. Any adjustments or corrections required during the two 7-day periods must be at no additional cost.
f. Measurement and Payment. The completed work, as described, will be measured as a lump sum and paid for at the contract price using the following pay item:
Pay Item Pay Unit
Electrical Rehabilitation ...... Lump Sum
Electrical Rehabilitation (Alternative Bid Option) * ...... Lump Sum
*Electrical Rehabilitation (Alternative Bid Option) includes all Electrical Rehabilitation Items plus the thermal cameras, as provided within this Special Provision and noted in the Contract Plans.
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MECHANICAL SPECIAL PROVISIONS
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SECTION M100 - GENERAL MECHANICAL SPECIFICATIONS a. Description. The work consists of providing all labor, materials and equipment for the work as described herein and shown on the plans, including all incidental work as shown and required by the Contract. b. Applicable Standards.
1. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only. The latest revisions only shall be used for all references.
2. Where not otherwise specified herein, workmanship, materials, fabrication, and erection of the bridge components shall be in accordance with the requirements of the latest revision of The American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Chapter 15, Part 6, “Movable Bridges”.
3. Other applicable standards:
. AREMA - American Railway Engineering and Maintenance-of-way Association
. ASTM - American Society for Testing and Materials
. ANSI - American National Standards Institute
. ASME – American Society of Mechanical Engineers
. AGMA - American Gear Manufacturer's Association
. SAE - Society of Automotive Engineers
. AWS - American Welding Society, Bridge Welding Code, D1.5
. ABMA - American Bearing Manufacturers Association
. AISI - American Iron and Steel Institute
. AISC - American Institute of Steel Construction
. AMPP – Association for Materials Protection and Performance c. General Requirements.
1. Submittals
A. Submittals for machinery work shall include shop and working drawings, layout drawings, catalog cut and specification sheets, installation details, test procedures and results, and other items as necessary for the fabrication and installation of machinery work, and as may be required by these Contract Documents.
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B. Submittals shall be in Portable Data Format (PDF). All shop drawings generated in computer-aided design and drafting software (CADD) shall be submitted as an original PDF generated from the CADD software package. All catalog cuts and other documents shall be text searchable PDF documents when possible. Scanned catalog cuts and other documents shall be scanned using 300 dpi resolution, and in 8-bit up to 24-bit color.
C. Certified drawings shall be submitted for approval prior to purchase of all standard or semi-standard machinery components including, but not limited to: gearmotors, brakes, couplings, turned bolts, wire ropes, and similar items.
D. Shop drawings shall fully define all details and assemblies, indicate the methods and sequences to be employed in the assembly and installation of bridge machinery, and present the installation of necessary utilities, support, and service facilities. Ensure submittals are neat and legible, clearly show dimensions and pertinent ratings, and be marked to explicitly identify the intended use of each component.
E. As-built drawings shall be maintained on site by the Contractor and shall be a full-size set of shop drawings, erection layouts and plans, marked-up with changes/revisions to reflect the as-built, or as-installed condition. Such plans and drawings shall be updated weekly, so that no changes or deviations are more than one week old without being correctly documented. These working drawings shall be the basis for the deliverable as-built drawings.
F. As-built drawings shall present complete details of all parts as installed on the bridge and shall be submitted to the Engineer as finished, formal drawings within 30 days after completion of all work. This recognizes that there may be differences between shop drawings approved for manufacture and adjustments required based upon actual field conditions.
G. The Contractor shall submit copies of producer or manufacturer data, e.g. ratings, specifications, tests results, catalog cuts, and installation instructions for the following items, but not excluding other items or materials not specifically mentioned:
(1) Mill reports, inspection reports, and physical tests of all metals
(2) Bolts, nuts, washers, and other fasteners
(3) Paint
(4) Lubricants as endorsed by machinery manufacturers
(5) Lubricants as endorsed by wire rope manufacturers
(6) Results of required rope tests presented herein.
(7) Standard and custom-manufactured purchased components or stocked items.
(8) Buy America Certification for all iron and steel products.
H. The Contractor shall prepare a complete list of all new machinery items which require lubrication. The list shall be maintained through construction and contain the type of
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lubricant used and the date it was installed and lubricated by the Contractor and shall be given to the Engineer prior to start up and testing of the machinery.
I. Submittals shall be neat and legible, clearly show dimensions and pertinent ratings, and be marked to explicitly identify the intended use of each component on this project. Where a catalog cut sheet is submitted with a table, listing or group of similar items with different catalog numbers and/or options, the specific item(s) being proposed shall be clearly marked.
J. The Contractor shall submit shop drawings to the Engineer for review and approval in accordance with these specifications. These shall include complete details, classification of materials, schedules for fabrication and shop assembly, weld procedures and qualifications, procedures and diagrams showing sequence and details for erection and approval. The Contractor is responsible for providing all field measurements and erection layouts necessary to fully define the details of all fabricated components. Reformatted contract drawings, without complete manufacturing and erection information as set forth herein, shall not be considered satisfactory shop drawings.
K. Shop drawings will show all external dimensions and clearances necessary for installation and operation of each item of machinery.
L. Shop drawings with erection-dependent data, required from the Contractor, may be conditionally approved by the Engineer for material allocation or procurement. The Contractor shall be fully responsible for providing final details to the supplier for fabrication.
M. Variations between the conditionally-approved shop drawings and installed components shall be recorded and submitted on the as-built drawings.
N. Shop drawings for fabricated detail parts shall be given a suitable title to describe the parts detailed thereon. These drawings shall be so complete that parts may be duplicated without reference to patterns, other drawings, or individual shop practice. Each drawing shall be identified by the complete project name and number. Shop drawing submittals shall be complete and organized to allow the review and evaluation of logical groups of items, including the interfaces between adjacent or connected parts, and shall include the following information:
(1) Dimensions, call-outs and notes to completely define the form, fit, function, manufacturing process and allowable deviations for each feature of each item.
(2) Material specification for each item.
(3) Heat treatment, specific hardness, and/or mechanical properties requirements when mandated.
(4) The surface finish of machined surfaces and tolerances for each dimension for which a specific fit is required. A general tolerance block shall be used to define the tolerances of all other dimensions. Fits and finishes shall be the more rigorous of AREMA or manufacturer specifications.
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(5) Quantity required. Quantities of all details required for their associated assemblies and quantities of complete assemblies for the entire bridge.
(6) Computed weight. Component weights shall be shown on the same shop drawing as the component detail to facilitate material handling planning.
O. All submittal items must be approved by the Engineer prior to purchase, fabrication, or installation of the items.
P. Shop drawings for manufactured or purchased assemblies shall be given a suitable title to describe the parts detailed thereon and shall include:
(1) Complete data on the design and construction of all detail components furnished as part of the machinery under this Contract.
(2) All proprietary items (e.g. enclosed gearboxes, brakes, etc.) shall be shown in outline on shop drawings.
(3) Complete assembly diagrams shall be provided for proprietary components that show each part contained within the item and its corresponding manufacturer's part number. The diagrams shall be sufficient to enable complete disassembly and re-assembly of the subject component and enable the definition and procurement of proper spare/replacement parts.
(4) In the event that any part is modified in any manner from the way it is described or delivered by its original manufacturer, the Contractor shall deliver a drawing which details each modification, and the part shall be assigned a unique part number to assure procurement of proper spare/replacement parts.
(5) Component assembly drawings shall include:
(a) Dimension of all principal elements within the item
(b) Certified external dimensions and clearances affecting interfaces or installations
(c) Gross weight
(d) Capacity and normal operating ratings
(e) Method and recommended type and quantity of lubrication, including location and type of fittings and provisions for adding, draining and checking the level of each lubricant employed
(f) Inspection openings, seals, and vents
(g) Details of all turned bolts used to mount the machinery to its supports (all fasteners used to mount the equipment to its foundation)
(6) The Contractor will furnish complete data on the design and construction of any
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unit furnished as part of the machinery under this Contract, including material specifications, cross-section assembly drawings, detail drawings, and dimensions of principal elements.
(7) Complete shop bills of materials shall be included for all machinery parts. If the bills are not shown on the shop drawings, prints of the bills shall be furnished for approval in the same manner as specified for the drawings. The computed weight of each piece of machinery shall be stated on the shop drawing upon which it is detailed.
(8) Fully detailed and complete assembly and erection drawings shall be furnished. These drawings shall provide identification of, and essential locating dimensions for each part or assembly with respect to the bridge or foundation and shall indicate the methods and sequences to be employed in the installation and tensioning of the wire ropes.
(9) The Contractor shall determine the final dimensions of parts involving commercial products, such as gearmotors, brakes, bearings, electrical equipment, hydraulic equipment, etc., from certified drawings of the commercial products before making shop drawings.
Q. Shop drawings, which have not been approved or require correction, shall be resubmitted until they are approved by the Engineer. This approval procedure shall not be considered a cause for delay. The Contractor shall bear all costs or damages which may result from the ordering or fabrication of any materials prior to the acceptance of the shop drawings. As a means of expediting delivery prior to acceptance of the shop drawings, the Contractor may request from the Engineer, approval to order raw materials of the correct type for later fabrication from accepted shop drawings. Such approval by the Engineer shall be in writing. After acceptance of the shop drawings, the Contractor shall supply the Engineer with additional copies of the accepted drawings as may be required.
R. Material certifications and component test reports shall be submitted for approval as required by the standards.
S. The Contractor shall submit detailed procedures for installation, alignment, testing, and indexing of components. Such procedures include, but are not limited to trunnion bearing alignment and installation, counterweight wire rope removal and installation, counterweight jacking, span balancing, machinery brake removal and installation, motor removal and installation, motor coupling alignment, span lock removal and installation, etc. These procedures shall be submitted to the Engineer for approval prior to construction. d. Products.
1. General
A. All materials shall be as called out on the Contract Drawings and as indicated in the Specifications.
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B. The current issue of all material specifications and standards shall be those in effect on the date of the bid for this project.
C. All mechanical components and materials shall be new, except as noted, clean, and free of defects, and conform to standard ASTM and other specifications included previously and indicated on the drawings and herein, or as may be otherwise applicable.
D. Brinell hardness tests shall be made, and included on inspection reports, for all castings and forgings.
E. Steel for weldments and miscellaneous components shall be ASTM A709 Grade 50, unless otherwise specified on the contract documents, fine grain practice is mandatory, and always weldable grades as designated by applicable ASTM standards. Welding materials and methods shall conform to the AWS Bridge Welding Code D1.5, current edition.
F. No item shall be fabricated, machined, welded, cast, or forged without sufficient advance notification to the Engineer to permit scheduling of required inspection. The Contractor shall furnish all facilities and provide for the free access at the plant or shop for the inspection of material and workmanship. Inspection and testing shall conform to the following requirements:
(1) Inspection at the plant or shop will not relieve the Contractor from responsibility for furnishing satisfactory materials and workmanship. Acceptance of a material or item shall not prevent subsequent rejection if material is found defective. The Contractor shall remedy defects due to workmanship, erection, materials, or design for a period of one year after final tests and acceptance have been made, at his own expense. The Contractor shall furnish a satisfactory guarantee to ensure correction of defects. When written notification of a defect or malfunction is given and no satisfactory corrective action is provided after 14 days, such defects may be corrected by others at expense to the Contractor.
(2) The Contractor shall furnish the Engineer with the number of copies of purchase orders as may be required.
(3) Unless otherwise provided, the Contractor shall furnish without charge, test specimens required herein, and all labor, testing machines, tools, and equipment necessary to prepare the specimens and to make the physical tests and analyses. Two copies of test reports and chemical analyses shall be furnished to the Engineer.
G. Proposed substitutions to the specific manufacturers and/or models shown on the contract drawings must satisfy all listed requirements, be appropriate for the intended application, and be approved by the Engineer as substantially equivalent to the specified item(s). The Contractor shall be responsible for all design modifications, engineering analysis, and documentation required by the Engineer as may be necessitated by his proposed substitution.
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2. Manufacturer's Recommendations
A. When installation procedures for an item or component are required to be in accordance with the recommendation of the manufacturer, printed copies of the recommendations shall be furnished to the Engineer prior to installation. Installation of the item will not be allowed to proceed until the recommendations are received. Failure to furnish these recommendations can be cause for rejection of the material.
3. Standard Products
A. Materials and equipment shall essentially be standard, current production, cataloged products of established manufacturers regularly engaged in production of such materials or equipment, and have at least two years of satisfactory commercial or industrial use prior to bid opening and the latest design that complies with the requirements on these contract documents. Where two or more units of the same class of equipment are required, these units shall be products of a single manufacturer; however, the component parts of the system need not be the products of the same manufacturer. Each major assembled component shall have a conspicuous, durable, permanently affixed nameplate that includes at least the following information: the manufacturer's name, address, the component model number, serial number, rated capacity, and pertinent factory setting(s). The nameplate of the distributing agent will not be acceptable. Copies of nameplates and/or equipment tags shall be furnished as part of the shop drawing and included in the Operation and Maintenance Manual for future reference on all machinery.
B. Materials of equal or greater strength and corrosion resistance than shown on the contract drawings may be proposed and are subject to approval by the Engineer. Similarly commercial components proposed to be supplied by alternative manufacturers shall be submitted to the Engineer for approval. The Contractor will be responsible for proving equality with the originally specified component.
(1) Electrodes for Welding: Electrodes for welding shall comply with AWS Bridge Welding Code D1.5, current edition and be compatible in strength and composition with the materials joined.
(2) High Strength (H.S.) Bolts, Nuts and Washers: High Strength (H.S.) Bolts shall conform to ASTM F3125 Grade A325 Type 1. The recommended nut and washer, listed in the aforementioned specification, shall be used in conjunction with all high strength bolts, unless noted otherwise. All bolts shall conform to the dimensions specified in F3125.
Threads for bolts, nuts, and cap screws shall conform to the unified thread standards, coarse thread series with a Class 2A tolerance for bolts and Class 2B tolerance for nuts, in accordance with ASME B1.1, unless otherwise specified.
(3) High Strength Turned Bolts: Turned bolts up to and including 1-1/2 inches shall conform to ASTM F3125 Grade A325, Type 1, or SAE Grade 5, unless otherwise specified on the contract drawings. Turned bolts greater than 1-1/2 inches shall conform to ASTM A449 Type 1 unless otherwise specified on the contract drawings. For this paragraph, specification conformance refers to material,
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chemistry, and mechanical properties.
(4) Socket Head Cap Screws: Alloy steel socket head cap screws shall comply with ASTM A574. Stainless steel socket head cap screws shall be Type 316, with a minimum tensile strength of 80,000, and shall meet or exceed ASTM F837, Alloy Group 2, Condition CW, unless otherwise specified. Dimensions shall conform to ASME B18.3.
(5) Hex Cap Screws: Hex cap screws up to and including 1½ inch diameter shall conform to ASTM F3125 Grade A325 Type 1. Hex cap screws greater than 1½ inch diameter shall conform to ASTM A449, Type 1. Heavy hex nuts and hardened washers shall be used with hex cap screws and shall conform to A563 Grade DH, and F436 Type 1, respectively. Stainless steel hex cap screws shall be Type 316 with a minimum tensile strength of 85,000 psi and shall meet or exceed ASTM F593, Alloy Group 2, Condition CW. Locking shall preferably be by use of double nuts. Hole clearances shall be governed by ASME B18.2.8. Screw length shall be sufficient to allow a minimum of two threads to extend beyond the nut.
(6) Flat Countersunk Head Cap Screws: Flat countersunk head cap screws shall conform to ASTM F835. Stainless steel flat countersunk head cap screws shall be Type 316, with a minimum tensile strength of 80,000 psi, and shall meet or exceed ASTM F879, Alloy Group 2, Condition CW, unless otherwise specified. Dimensions shall conform to ASME B18.3.
(7) Stainless Steel: Stainless steel for fasteners shall comply with the preceding paragraphs, unless otherwise specified. Stainless steel fasteners shall be used in conjunction with stainless steel washers (Type 316) and hex nuts of Type 316 stainless steel with a minimum proof strength of 85,000 psi and shall meet or exceed ASTM F594, Alloy Group 2, Condition CW. Stainless steel pins shall be ASTM A276, Type 316, Condition S, cold finished.
Stainless steel bolts shall generally be tightened to produce a tension of 70% of the proof load. Include friction coefficient data for any thread lubricant with installation procedures to confirm torque magnitudes.
(8) Shims: Where shown on the drawings, all machinery shims required for leveling and alignment of equipment, including tapered shims, as necessary for trunnion bearing alignment, shall be stainless steel, ASTM A240, Type 316.
(9) Keys: Unless otherwise specified herein or on the contract drawings, keys for all components shall be made from cold-finished carbon steel squares or flats that meet the requirements of ASTM A668, Class K, with a minimum tensile strength of 105,000 psi, and minimum yield strength of 80,000 psi, or approved equal.
(10) Steel Castings: Steel castings shall conform to ASTM A148, Grade 80-50, unless otherwise specified in the plans.
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(11) Bushings and Liners: Unless otherwise specified on the plans, material for bushings shall conform to ASTM B22 C91100 or C91300, and liners shall conform to AMS-DTL-22499 Comp 2.
(12) Shafts: Unless otherwise specified, shafting shall be forged steel conforming to ASTM A291 alloy steel with a minimum tensile strength of 95,000 psi and a minimum yield strength of 70,000 psi. Substitution of cold-finished steel shafting (ASTM A108) for forged steel shall be acceptable if of equal or greater strength and ductility. e. Details and Workmanship.
1. The machinery shall be finished, assembled, and adjusted in an approved manner using best machine-shop practice. The limits of accuracy, which are to be observed in machining the work, and the allowances for all metal fits, shall be placed on the Contractor's shop drawings. Fits and finishes of machinery parts shall be as called for on the contract drawings or as specified in the AREMA Manual, Chapter 15, Article 6.5.1.
2. Where surface finishes are indicated on the contract drawings or specified herein, the symbols used shall conform to ASME B46.1, "Surface Texture". Values of roughness height are specified in micro-inches as an arithmetical average deviation from the mean line. Roughness specified is the maximum value, and any smoother finish will be satisfactory. Compliance with specified surface roughness will be determined by trained sense of feel and by visual inspection of the work compared to standard “roughness comparison specimens" in accordance with the provisions of ASME B46.1. Values of roughness width and waviness are not specified, but shall be consistent with the general type of finish specified by the roughness height. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable will be cause for rejection.
3. Unspecified surface finishes shall conform to AREMA, Chapter 15, Section 6.5.1. Mating surfaces shall be machined to provide even, true bearing. Surfaces with rotating or sliding contact shall be highly polished and finished true to the given dimensions. Surfaces to be machine-finished shall be indicated on shop drawings by symbols, which conform to ASME B46.1.
4. So far as practicable, all work shall be laid out to secure proper matching of adjoining unfinished surfaces. Large discrepancies between adjoining unfinished surfaces shall be remedied to realize proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown on the shop drawings and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or function of the parts may be filled in a manner approved by the Engineer.
5. Mechanical Component Requirements
A. Fits and Finishes
(1) Fits and surface finishes, when not included in these contract documents, shall be in accordance with AREMA specifications for movable railroad bridges or vendors’ recommended specifications, whichever is more rigorous, and as modified below.
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(2) Surface finishes are given as the roughness height in micro-inches.
Part Fit Finish Machinery base on steel - 250 Machinery base on masonry - 500 Shaft journals RC6 8 Journal bushings RC6 16 Split bushing in base LC1 125 Solid bushing in base (to 1/4" wall) FN1 63 Solid bushing in base (over 1/4" wall) FN2 63 Hubs on shafts (to 2" bore) FN2 32 Hubs on shafts (over 2" bore) FN2 63 Turned bolts in finished holes LC6 63 Hubs on main trunnions FN2 63 Sliding bearings RC6 32 Keys and keyways (top and bottom) LC4 63 Keys and keyways (sides) FN2 63 Machinery parts in fixed contact - 125
(a) The above fits for cylindrical parts shall also apply to the major dimensions of non-cylindrical parts.
B. Shafting and Pins
(1) Rounds and shafts shall be true, straight, and free from flaws, piping, laps, seams, or cracks. All shafts shall have finished ends with a 60-degree lathe center with a clearance hole at the exact center of the shaft. Stepped shafts shall have fillets finished smoothly to adjacent surfaces without tool marks or scratches. Surface finish for fillets shall have a maximum roughness of 63 micro- inches according to ASME B46.1 unless a finer finish is required.
(2) All forged shafts shall be reduced to size from a single bloom or ingot until perfect homogeneity is secured. The blooms or ingots, from which shafts or pins are to be made, shall have a cross-sectional area at least three times that required after finishing. No forging shall be done at less than red heat. Forged rounds for shafts and pins shall be true, straight, and free from any defect.
(3) All shafts and pins shall be accurately finished, round, smooth, and straight; and when turned to different diameters, they shall have rounded fillets at the shoulders. Each shaft or pin having a uniform diameter of 8 inches or more and each shaft or pin having several diameters, of which the smallest is 8 inches or more, shall be bored lengthwise through the center to a diameter approximately one fifth the smallest diameter. The wall of the center bore shall be examined for cracks and fissures. Shafts and pins exhibiting defects will not be accepted. Shafts that are bored with an inspection hole shall have the ends prepared for the attachment of a centering device equivalent to the lathe center. All such devices shall be furnished as part of the work.
(4) Turned, ground and polished shafting straightness tolerance shall be 0.002 inches per foot for shafts up to and including 1-1/2 inches in diameter and 0.003 inches per foot for shafts over 1-1/2 inches in diameter. All shafts shall be free
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from camber and shall run without vibration, noise, or chatter at all speeds up to and including at all operating speeds.
(5) All journal bearing areas on shafts and pins shall be accurately turned, ground, and polished with no trace of tool marks or scratches on the journal surface or adjoining shoulder fillets. The journal bearing area shall have an 8 micro-inch finish or better. Journal diameters shall be finished to the limits of an ANSI Class RC6 running fit, unless otherwise noted.
C. Keys, Keyways, and Set Screws
(1) Keys and keyways shall conform to the dimensions and tolerances for square and flat keys of the ASME Standard B17.1, "Keys and Keyseats," unless otherwise specified. Keys shall be machined for an FN2 side fit (Class 3) and an LC4 fit on top and bottom with keyways in shafts and hubs and a 63 micro-inch finish or better. Keyway corners and key chamfers shall be cut with the fillet radius and chamfer as suggested by ASME B17.1. All keys shall be effectively held in place, preferably by setting them into closed-end keyways milled into the shaft. The ends of all such keys shall be rounded to a half circle equal to the width of the key. Keyways shall not extend into any bearing. Keys shall preferably not extend past the end of the hub of the keyed element. If two keys are used, they shall be located 120 degrees apart. Custom keys shall be provided as necessary for manufactured components to meet the required key fits and finishes.
(2) Set screws shall not be substituted for keys for transmitting torsion; they may be used only for holding keys or light parts in place. They shall be safety-type headless set screws with cup points set in counterbored seats. Unless otherwise noted, they shall be secured in place by use of self-locking threads.
D. Bearings and Bushings
(1) Bronze bushings shall be made of ASTM B22 Alloy C91300, unless otherwise specified on the plans. All bushings shall be grease lubricated and shall be grooved on the inside diameter for lubrication through the bolts or shafts, at the centerline of the bushing, or fed from a central housing passage at the intersection of the lubrication grooves. Use of “Double Oval” grooving is preferred, unless otherwise shown on the plans. All grease grooves will be machine-cut and smooth. The corners of all grooves will be rounded to a radius of not more than half the width of the groove or as shown, with all radii tangent to adjoining surfaces. Small inequalities can be removed by chipping and filing.
(2) Brass liners having a total thickness of 1/4” consisting of one solid piece 1/8” thick and one laminated piece 1/8” thick with 0.003” laminations shall provide the proper fit between shafts and bushings at split pillow block housings.
E. Hubs and Bores
(1) The hubs of all couplings shall be finished on both faces and polished where the hub face performs the function of a collar to prevent shaft movement. The hubs shall be bored concentric with the outside of couplings. Unless otherwise noted or recommended by the manufacturer, all hubs shall have a 32 micro-inch finish
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or better for 2 inch or smaller bore, or a 63 micro-inch finish or better for a bore larger than 2 inches. All hubs shall have an ANSI Class FN2 medium force fit on the shafts unless otherwise specified.
F. Shims
(1) Where shown on the contract drawings, all machinery shims required for leveling and alignment of equipment shall be stainless steel, neatly trimmed to the dimensions of the assembled parts, and drilled for all bolts that pass through the shims. Bolt holes in shims may be drilled 1/16” oversized to aid in installation. Slotted shims shall not be used, unless noted otherwise on the contract drawings. In general, total shim thickness available shall be no less than equal to twice the nominal thickness shown on the contract drawings, and sufficient varying thicknesses shall be furnished to secure 0.003-inch variations of the shim allowance including one shim equal to the full allowance. The Contractor shall provide shims with less than 0.003-inch variations if required to meet proper machinery installation alignment tolerances. Shims shall be placed to provide full contact between machinery and machinery supports. Shims shall be shown in detail on the shop drawings. Shim packs shall be individually packed to prevent damage from handling during shipment to the project site. Packaging shall be clearly marked with the plan sheet number and item number of the part for which the shim pack was fabricated.
(2) Solid tapered shims shall be provided as necessary to achieve proper trunnion bearing alignment. Full contact shall be provided across the tapered shim mounting surface with the bearings and the bearing supports. Starting thickness of the tapered shim plates shall be 1 inch, prior to final machining, and shall have a minimum thickness of 3/8" inch. Tapered shims shall have a multidirectional lay top and bottom and shall have all surfaces machine-finished to 125 micro-inches. Tapered shim bolt holes shall be drilled in the field, after final alignment, and may be oversized 1/16” to aid in installation.
G. Turned Bolts
(1) The dimensions of turned bolts shall conform to ASME B18.2.1 for heavy hex structural bolts, except as noted in these contract documents. The fillet under the bolt head shall be 1/32” and the transition from the shank to the threads shall be a 30° to 45° chamfer. The bodies of turned bolts shall be finished to 63 micro- inches or better, as defined by AREMA. Threads for the turned bolts and nuts shall conform to the Unified Thread Standards, coarse thread series with a Class 2A tolerance for bolts and Class 2B tolerance for nuts, in accordance with ASME B1.1, unless otherwise specified. Turned bolts are designated by their nominal thread size. The turned bolt body shall be 1/16” larger in diameter than the nominal size specified and shall have an LC6 fit with holes reamed after final alignment. Bolt head and nut bearing surfaces shall be flat and square with the axis of the bolt holes and shall be spot faced if necessary. Unless otherwise noted, bolt holes in machinery parts required for connecting to supporting steelwork shall be sub-drilled (in the shop) smaller than the turned bolt diameter and shall be reamed together with supporting steel either during assembly or at erection, after the parts are correctly assembled and aligned. Positive type
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locking shall be provided. Double heavy hex nuts are preferred. Where double heavy hex nuts are not used, heavy hex and jam nuts shall be used. Alternate locking methods shall be submitted to the Engineer for approval. Turned bolts shall be installed with a hardened plain washer meeting ASTM F436 at the head and nut ends.
H. Castings
(1) All castings shall be cleaned free of all loose sand and scale. All fins, seams, gates, risers and other irregularities shall be removed. All unfinished edges of castings shall be neatly cast with rounded corners and all inside angles shall have ample fillets. Dimensions of castings shown on the approved shop drawings will be the finished dimensions. Deviations from the dimensions and the thicknesses of the castings, as shown on the drawings, will not be permitted to exceed such amounts as will, in the opinion of the Engineer, impair the strength of the casting as computed from the dimensions shown. Warped or otherwise distorted castings, or castings that are oversize to such an extent as to interfere with the proper fit with other parts of the machinery, will be rejected. All castings shall be manufactured in accordance with ASTM A781 and shall be tested for internal defects using the applicable examination method prescribed under Supplementary Requirements of ASTM A781.
I. Welding
(1) Welding required for machinery shall comply with AWS D1.5, current edition. Welded steel machinery parts shall be given a stress relief heat treatment prior to machining. The Contractor shall submit a schedule of the proposed stress relief heat treatment to the Engineer for approval. The schedule shall include a description of the part and an explanation of the proposed heat treatment, including the rate of heating, the soaking temperature, the time at the soaking temperature, the rate of cooling, and the temperature at which the part is to be withdrawn from the chamber. Soaking times of less than one hour will not be approved. Completely test all welds used to fabricate machinery by ultrasonic inspection using the methods given by ASTM E164, according to AWS D1.5 for tension members, unless noted otherwise.
(2) All welds shall be complete joint penetration (cjp) welds unless otherwise noted or shown on the Contract Drawings. No feather edges allowed on weldments. All free edges of stiffeners, webs, and gussets must be welded.
(3) All welding shall be by certified welders.
(4) Welding for stainless steel shall conform to AWS D1.6.
(5) Welding for aluminum shall conform to AWS D1.2.
(6) Submit all weld procedures and welding qualifications prior to the start of work.
(7) Unless otherwise specified, welds shall meet minimum weld sizes per AWS D1.5. The Contractor shall select preheat and soak times accordingly to provide the
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required heat input and shall submit to the Engineer for approval.
(8) All fillet welds shall be 100% magnetic particle tested and all groove welds shall be 100% UT tested.
J. Machinery Guards and Covers
(1) Provide each motor brake and machinery brake with a NEMA 3R stainless steel brake cover, with slots for drive shafts, and access to brake release lever without removal of cover. Cover must have a hinged lid for inspection purposes. Provided brake covers must not interfere with any new or existing machinery components including brake limit switches and wiring.
K. Couplings
(a) Gear-type, full-flexible (double engagement) couplings or semi-flexible (single engagement) couplings with floating shafts shall be used to connect all machinery components, except where other types of flexible couplings are called for on the contract drawings. The couplings shall be made of forged alloy steel, have exposed bolts, curved face teeth, and provide for at least a 3/4- degree misalignment per gear mesh. Installation misalignment should be limited to no more than 1/8 degree per gear mesh.
(b) Gear-type couplings shall be the standard product of an established manufacturer.
(c) Coupling hubs shall be bored by the coupling manufacturer to the required size and tolerances, including keyways, and each hub shipped to the proper location for installation on its shaft by the manufacturer of the connected component or by the Contractor’s machine shop. f. Shop Inspection, Assembly, and Testing.
1. All shop testing and shop alignment verification shall be performed in the presence of the Engineer. The Engineer shall be given at least two weeks notification prior to all testing.
A. All machinery components on a common weldment shall be shop aligned and assembled with undersized bolts, verifying their correct fit prior to shipment. The alignment of all components within each subassembly shall be within the individual manufacturers’ allowable installation tolerances and shall be measured and recorded. Components to be shop installed on a common support include; the main motor and motor brake. Any components requiring selective assembly shall be match-marked for future assembly. g. Lubrication.
(1) The Contractor shall furnish a lubrication plan for all machinery for approval. The plan shall be developed from recommended practice of the machinery manufacturers. The Contractor shall coordinate the lubrication plans for the various machinery elements and minimize the number of different lubricants. The Contractor shall furnish copies of letters from the various machinery
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manufacturers endorsing the lubricants which have been finally selected. Lubricants shall be selected for year-round exposure at the bridge.
(2) The Contractor shall provide pipe extensions where necessary. These pipe extensions shall be kept as short as practical and shall be rigidly supported at the fittings and at intermediate points. Pipe shall be 1/4-inch seamless threaded red brass with cast bronze threaded fittings, unless noted otherwise. Fittings on proprietary parts shall be replaced if necessary, with fittings that have been selected as standard for the bridge.
(3) The Contractor shall furnish a lubrication diagram which shall show all points requiring lubrication on the bridge (new, rehabilitated, and existing machinery), the type of lubricant to be used at each point and the frequency of lubrication. The diagram shall be submitted to the Engineer for approval and the approved diagram shall be mounted in the operator's house with a suitable and approved frame and glass cover.
(4) A reduced size copy of the Lubrication Diagram shall be included in the Operating and Maintenance Manuals. h. Quality Control and Assurance Program.
1. Quality Control
A. The Contractor shall maintain and be responsible for the Quality Control of the work detailed herein. The Contractor’s Quality Control Manager shall perform QC inspections for all mechanical components included in this section, including witnessing required testing, monitoring installation and alignment work, and ensure that all work is performed in accordance with the contract documents, specifications, manufacturer’s installation procedures and all applicable codes and standards.
B. The Contractor’s Quality Control Manager shall maintain documentation of all required mechanical testing and shall turn over said documentation to the Engineer in a timely manner.
C. The Contractor’s Quality Control program shall be responsible for notifying the Engineer immediately for clarification whenever any portion of the work is not clearly or accurately defined.
D. Warranty. The Contractor shall remedy defects due to workmanship, erection, materials or design for a period of one year after final tests and acceptance have been made, at his own expense. The Contractor shall furnish a satisfactory guarantee to ensure correction of defects. If necessary, such defects may be corrected by others at expense to the Contractor if written notification is given and no satisfactory corrective action is provided after 14 days.
2. Quality Assurance
A. The Engineer shall, at his discretion and as he deems necessary, inspect and verify the procedures and operations being performed during the work.
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(1) Inspection. Materials and fabrication procedures are subject to inspection and testing in the mill, shop and field by the Engineer. Such inspections and tests will not relieve the Contractor of responsibility for providing materials and fabrication procedures in compliance with specified requirements.
(2) Design of Items and Connections. All details shown on the contract drawings are typical and apply to similar conditions unless otherwise indicated. All dimensions and details shall be verified at the site before proceeding with any work, obtaining final approval of any shop drawings by the Engineer, to avoid causing subsequent delay in work.
B. The Engineer shall be responsible for reviewing all QC records and test reports submitted by the Contractor’s Quality Control Manager.
(1) Certified Test Reports. As used herein, certified test reports refer to reports of tests conducted on previously manufactured materials or equipment identical to that proposed for use.
(2) Mill/Factory Tests. As used herein, mill or factory tests refer to tests required to be performed on the actual materials or equipment proposed for use. Results of the tests shall be submitted in accordance with the provisions of this Contract for laboratory test results.
C. The Engineer shall have the authority to reject materials and workmanship that do not conform to the requirements of the contract. Inspection of material and workmanship may be conducted before, during, and after fabrication, as deemed necessary by the Engineer. Materials and workmanship which are “in the process” of being fabricated and are found to contain defects, or to have been subjected to damaging fabrication procedures, shall be rejected while still in process. The Engineer will have the right to perform, at the expense of AMRR, non-destructive tests of material and workmanship. At the discretion of AMRR, QA functions may be exercised on site and at the mill and shop. The Contractor shall furnish means and assistance for testing materials and workmanship.
D. AMRR’s Quality Assurance (QA) program, including a review of tests reports, and mill, shop, or field inspections, will not relieve the Contractor of the responsibility for providing materials and fabrication procedures in compliance with specified requirements.
E. The Engineer will have free and safe access at all times to any portion of shops and field where work is being done under these specifications.
3. Contractor Experience
A. The Contractor, suppliers, and onsite supervisory personnel of the installation and operation of the new machinery shall each have performed similar work on a minimum of one vertical lift bridge in the last ten years.
B. The Contractor shall submit to the Engineer for evaluation, a tabulation of experience in the installation of movable bridge operating machinery, specifically for vertical lift
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bridges. The list of experience submitted to the Engineer, shall include experience of the machinery suppliers and subcontractors, specifically for vertical lift bridges. The machinery suppliers and subcontractors shall have performed similar work for a minimum of one vertical lift bridge in the last ten years.
C. The counterweight rope tensioning subcontractor shall have experience in measurement and directing the adjustment of counterweight rope tensions on a minimum of five vertical lift bridges.
D. The strain gauge testing subcontractor shall have experience in strain gauge balancing a minimum of five vertical lift bridges with at least three span drive vertical lift bridges. i. Execution.
1. Shop Assembly and Operation
A. Machinery components mounted on common weldments shall be shop assembled with undersized bolts to verify their correct fit prior to shipment. Any components requiring selective assembly shall be match-marked for future assembly. Components not mounted on a common base will then be disassembled for shipment.
B. The various parts of units or groups, such as shaft couplings, before leaving the shop shall be marked according to mating, location and correct relation to facilitate reassembling at the bridge site. Stamp markings shall be made in areas of the part or assembly that are not subjected to significant stress during operation.
2. Delivery, Storage and Handling
A. Components and materials shall be properly packaged and protected from weather, dirt, and all other injurious conditions during manufacture, shipment, and while awaiting erection from initial shipment until the time of installation.
(1) All machinery shall be cleaned of dirt, chips, grit, and all other injurious material prior to shipping.
(2) Prior to shipment from the manufacturer’s and/or fabricator’s plant or plants, the Contractor shall prepare the various elements for shipment. All large, bulky and/or heavy items shall be securely mounted on skids or pallets of ample size and strength to facilitate loading and unloading. Skids or pallets should be crafted for protection during shipment and storage. All small parts shall be boxed in sturdy wood or heavy corrugated paperboard boxes. A packing list enclosed in a moisture proof envelope and indicating the contents of each such box shall be securely attached to the outside of the container. The skid/pallet mounting and boxing shall be done in a manner which will prevent damage to the equipment during loading, shipment, unloading, storage and any associated and/or subsequent handling. Weatherproof covers shall be provided during shipment to protect any and all items shipped in open railway cars, trucks, or barges. Any eyebolts, special slings, strongbacks, skidding attachments or other devices used
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in loading the equipment at the manufacturer’s and/or fabricator’s plant or plants shall be furnished for unloading and handling at the destination.
(3) Finished and unpainted metal surfaces that would be damaged by corrosion, shall be coated with a .030" minimum film thickness, as soon as practicable after finishing, of No-Ox-Id, A-Special, as manufactured by San-Chem Company, Chicago, Illinois, or approved equal. This coating shall be removed from all surfaces prior to lubrication for operation and from all surfaces prior to painting after erection. If the anti-rust coating on any part becomes compromised prior to part installation, the coating shall be restored immediately.
(4) Shaft journals that are shipped disassembled from their bearings shall be protected during shipment and before erection by a packing of oil-soaked waste secured in place by burlap and covered with heavy metal thimbles or heavy timber lagging securely attached; an alternate method may be submitted for approval. Every precaution shall be taken to ensure that the bearing surfaces will not be damaged and that all parts shall arrive at their destination in satisfactory condition.
(5) All shipping units shall have lifting eye bolts or lifting holes properly sized for safe working loads and located to provide a balanced lift.
(6) All wire ropes shall be shipped on reels, the diameter of which shall not be less than 26 times the diameter of the ropes, which shall be mounted on skids or otherwise crated for protection during shipment and storage.
B. Material storage on site shall afford easy access for inspection and identification, protection from the ground and prevent, condensation buildup, distortion, or damage.
3. Erection
A. Erection work shall not commence until the required items have been completed and approved for installation, and until preparations by others where required have been satisfactorily completed.
B. The Contractor shall provide personnel and supervising engineers familiar and experienced in the installation of movable bridge machinery, especially for vertical lift bridges. The Contractor shall provide all the precision equipment that may be required for the proper and accurate installation of the machinery.
C. Prior to erection, all finished surfaces, which were coated by a rust-inhibiting coating, shall have the coating removed with an approved solvent. While machinery parts are being erected, and work is interrupted, they shall be covered by a sound tarpaulin or other durable waterproof covering. Prevent soil and waterway contamination by appropriate containment. Collect and dispose of waste solvents, coating, and expendables per state and federal regulations.
D. The machinery: motors, brakes, bolsters, shafts, couplings, ancillary electrical equipment connected to the operating machinery, sheaves, trunnion bearings, bearing bolsters, span locks, and the like shall be erected and adjusted by competent
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mechanics and millwrights skilled in the type of work involved. Representatives of the machinery manufacturers shall be present during final assembly, alignment, and testing. They shall be provided with all necessary precision measuring and leveling instruments as may be required. The machinery shall be erected with exactness so the various parts are truly aligned in their proper positions and, when entirely assembled, will operate smoothly without binding or undue looseness of the components.
E. All parts of the machinery shall be erected in accordance with erection marks and match-marks. When the final position of the machinery will change upon application of the full dead load, the final adjustments shall be made after the dead load is fully applied. Before final drilling or reaming, all parts shall be adjusted to exact alignment by means of shims furnished for each part. After final alignment and bolting, all components shall operate smoothly.
F. Bolt holes in structural steel for connecting machinery with turned bolts shall, in general, be drilled from the solid after final alignment of the machinery. Sufficient erection holes, sub-drilled 1/4 of an inch undersize for temporary bolts, may be used for erection and alignment of the machinery. When the machinery is aligned in its final position, full-size holes for the permanent turned bolts shall be drilled and reamed; full- size bolts installed; and the temporary bolts removed.
G. ASTM A449 bolts shall be torqued to the same tension required for the identical size ASTM A325 bolts using the turn-of-nut method.
H. Torques for double nuts shall be as follows: If a jam nut is used, place the jam nut on the bolt first. Holding the head of the bolt, torque the first nut to 50% of the target torque. Place the second nut on top of the first nut. Holding the first nut, torque the second nut to 100% of the target torque.
I. Torques for other grades of bolts shall be proportioned to their strength and shall be indicated on the erection drawings.
J. Throughout the installation, bolts and nuts shall be adjusted or tightened only with wrenches that fit; tightening with chisels and hammers will not be permitted.
K. Installation and alignment of all mechanically-connected machinery and electrical equipment shall be conducted under supervision of the machinery manufacturer's field engineer.
L. The machinery and all machine-like elements or parts, especially all sheave/trunnion assemblies and their bearings, shall be assembled, erected, aligned, and adjusted at the bridge site under the direct and continuous supervision of the Engineer, to whom the Contractor shall afford every opportunity and facility to satisfy himself that the work is being done in accordance with the contract drawings, specifications, and acceptable construction practices.
M. Field Inspection and Testing: All field testing and alignment verification shall be performed in the presence of the Engineer. The Engineer shall be given at least two weeks notification prior to all testing.
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4. Painting
A. Manufactured or purchased machinery items shall be painted with the manufacturer’s premium, high performance, epoxy paint system, recommended for outdoor applications in harsh marine environments, which shall be submitted to the Engineer for approval. If the manufacturer does not have a recommended high performance paint system, the components shall be painted according to the paint system and requirements specified herein. Factory painted machinery items shall either be painted with a top coat color matching as close as possible to the top coat color, as discussed herein, or shall be hand tool and solvent cleaned and overcoated with the top coat of the specified paint system in the appropriate color as discussed herein. The Contractor shall coordinate required paint colors with the machinery component manufacturers. Manufacturer’s paint system and coat colors shall be submitted to the Engineer for approval.
B. The paints shall be of one manufacturer and shall conform to the chemical and performance requirements of the manufacturer’s published technical data application information, and the referenced specifications.
C. All metalwork shall receive the 3-coat specified paint system in the shop with the exception of the finished, bearing, and lubricated surfaces.
D. The Contractor will not be allowed to clean or paint at night. All cleaning and painting shall be performed only during daylight hours.
E. Cleaning and painting of existing steel surfaces at areas of steel removal, modification or repair shall be in accordance with AREMA Chapter 15, Section 8.7. Existing steel at these areas, except for surfaces to be in contact with new steel, shall be prepared in accordance with the degree of cleaning for overcoating as defined in AREMA Chapter 15, Section 8.7.2.d.5. Existing steel surfaces that will be in contact with new steel (faying surfaces), shall meet the Class A surface preparation and coating requirements as defined in AREMA Chapter 15, Table 15-1-11a.
F. Coatings application shall be in accordance with the manufacturer’s recommendations, SSPC-PA 1 Paint application Specification No. 1 and these specifications, whichever is more stringent.
G. Coatings shall be applied only to surfaces prepared in accordance with the manufacturer’s recommendations and these specifications.
H. Paint systems may be applied by conventional air spray, airless spray equipment or brush in accordance with the manufacturer’s recommendations and these specifications.
I. The painted surfaces shall be free from dry spray, over spray, runs, sags, drips, excessive paint build-up, ridges, waves, laps, streaks, brush marks and variations in color, texture and finish (glossy or dull). The coverage shall be complete and each coat shall be so applied as to produce an even film of uniform thickness, completely coating corners and crevices, and bonded to the underlying surface. When spot repairs are necessary, the edges of the surrounding coating shall be feathered, leaving surfaces prior to painting, tapered and free of loose or damaged coating. Care shall
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be exercised to avoid over spraying or spattering paint on surfaces not to be coated. Damage to surfaces not to be coated shall be repaired by the Contractor at the Contractor's expense.
J. All items not to be painted shall be covered or protected from cleaning and painting and shall be cleaned of overspray. The coverage and protection measures shall be submitted to and approved by the Engineer.
K. Color for the top coat will be Federal Safety Orange ANSI Z53.1 for all moving parts in the machinery room including shafts, couplings, and brake wheels. Bearing and lubricated surfaces shall not be painted. Color for the top coat of stationary parts in the machinery house shall be Federal Safety Green. All machinery located outside of the machinery house and requiring painting, including the bearings, trunnions, and sheaves, shall be painted with the same top coat color as specified for the structural tower metalwork and shall be submitted to the Engineer for approval.
L. Before application of paint in the shop, surfaces which require painting shall be cleaned of all chips, burrs, dirt, rust, mill scale, sand, grease, and other extraneous materials by employing methods such as chipping, grinding, wire brushing, solvents, followed by the required abrasive blast cleaning and residual dust removal by compressed air. Finished machined surfaces not to be painted shall be masked or shielded from abrasive blasting operations. After cleaning, surfaces requiring paint shall be painted with the three coat paint system. After coupling hubs are installed on all shafts in the shop, the remaining exposed portion of shaft shall be painted, with care to protect any adjacent bearing or seal. Bearing or sliding surfaces that are not to be painted will be coated with temporary protective materials as previously specified and approved by the Engineer. Nameplates shall be protected to remain clean and free of paint.
M. After the machinery items have been installed in final position on the bridge, all surfaces which require paint, including bolts and portions of shafts remaining exposed after assembly, shall be cleaned of grease, oil, and loose materials by the use of solvents and compressed air, and all unprimed or damaged shop coated surfaces shall be repaired with the touch-up primer followed by a full intermediate coat. The Contractor shall take special care to avoid painting of machinery bearing and sliding surfaces and to mask and protect from paint these surfaces and all nameplates, legend plates, and escutcheons mounted on machinery.
N. After completion of the operating tests and acceptance of the machinery, all oil, grease, dirt, and other foreign matter shall again be cleaned from the exposed machinery surfaces which require the third coat of paint, including bolts, and those shop painted surfaces that were damaged and repaired with field applied primer and intermediate coat. The exposed surfaces shall then be given a third field coat, the top coat, which shall color-code the machinery to identify fixed and moving parts in the machinery room or match the tower color as indicated previously and as shall be shown on the shop drawings.
END OF SECTION M100
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SECTION M101 - SHEAVES, TRUNNIONS, BEARINGS a. Description
1. Description of Work
A. The work shall include fabricating, furnishing, shipping, assembling, erecting, installing, aligning, lubricating, testing, and placing into satisfactory service, four sheave and trunnion assemblies, and eight trunnion bearing assemblies, and all other necessary parts required for installation of these components per this section. All other materials, lubricants, labor, bearing shims, and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. All parts furnished by the Contractor shall be new and shall be as shown or an approved equal. In cases where a substitution is proposed, it will be the responsibility of the Contractor to prove equality of the substitution with the original contract drawings, including the submission of a sample for Engineer examination and/or a visit by the Engineer to the proposed manufacturing facility, all at the cost of the Contractor. The Contractor will also provide, at no additional cost, engineering analysis, and design modifications as may be necessitated by his proposed substitution.
B. Sheaves
(1) Each sheave is assembled with a trunnion shaft and two trunnion bearings. The sheaves shall be fabricated by welding and made of structural steel plate and carbon and alloy steel forgings, as specified on the contract drawings. The rim shall be fabricated from no more than three pieces of plate, welded into a complete ring and welds ground on all sides before being welded into the remainder of the sheave weldment. The hub shall be made from a one-piece forging. Each web shall be fabricated from not more than two pieces of plate. Welds connecting the web plate section shall be full penetration welds and shall be ground on both sides. Full penetration welds shall be used to weld the web and full length stiffeners to the rim and hub pieces. Welds on partial depth stiffeners shall be 100% magnetic particle tested. Welds shall be made with low hydrogen procedures and automatic submerged-arc welding shall be used to the greatest extent practical. After completion of welding and before final machining, the sheave shall be stress relieved. The stress relief heat treatment shall be in accordance with the requirements of the AWS D1.5 Bridge Welding Code for tensions members. All welds shall be treated as welds on main members in a tension zone and shall be inspected by ultrasonic methods in accordance with AWS D1.5.
(2) Groove Tolerance and Concentricity: The machining procedure for the sheaves and trunnions shall be such that the pitch circles of the completed rope grooves shall be concentric to the centerline of the installed trunnion shaft to within 0.005 inches. The finished diameters at the bottoms of all rope grooves shall not vary by more than plus or minus 0.010 inch. All grooves shall be checked by the Engineer upon completion of machining and prior to the application of the protective anti-
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rust coating. A record of the sheave diameters at the bottom of the grooves and of the groove radii and concentricity for all grooves of all sheaves shall be made and submitted to the Engineer.
C. Sheave Trunnion Shafts
(1) The trunnions shall be made of forged steel, as shown on the contract drawings (finished all over). The journal ends of each trunnion shall be detailed, dimensioned, surface finished, machined and toleranced as specified by the contract drawings. The ends of each trunnion shall be fit into the trunnion bearing so the two sheave trunnions for each tower will be in exact alignment under full dead load. The journal ends of each trunnion shall be turned with extreme care to the diameter as specified by the contract drawings. One end of each trunnion shaft shall be machined to accommodate a machined disk for alignment purposes.
D. Sheave-Trunnion Assembly
(1) The trunnions shall be fit into the sheave hub with a shrink fit as specified on the contract drawings. The Contractor shall submit procedures for inserting the trunnion into the sheave to the Engineer for approval. The trunnion shall be inserted into the sheave hub and then drilled and doweled in place using high- strength dowel pins, 155,000 psi tensile strength minimum. The dowel holes are to be peened after assembly.
E. Bearings
(1) Each sheave trunnion bearing consists of a steel base fitted with a bearing bushing and a cap.
(2) Mounting feet on bearing housings shall be solid, or drilled for undersized holes, and shall be drilled and reamed in the field, by the Contractor, after final installation and alignment, with high strength turned bolts that have an LC6 fit with the holes.
3. Erection
A. The new trunnion bearing assemblies shall be carefully adjusted so that all new sheaves are accurately aligned. Prior to the start of construction, the Contractor shall establish the exact location of the existing trunnion centerline at each tower. At each tower, the new trunnion centerline must be within 1/16” of the existing trunnion centerline. The trunnion bearings must be installed and aligned so the axes of the new trunnions are as near to a straight horizontal line as possible when the full dead load of the lift span and the counterweight is carried by the sheaves. The Contractor shall place a level on the journals of each trunnion and adjust the alignment until the slope is less than 0.002 inches per foot at all locations. Vertical adjustment shall be obtained by use of full size shims. Shim material shall be stainless steel, ASTM A240, TYPE 316. In setting the sheave assemblies and bearing assemblies, allowance shall be made for the anticipated transverse and longitudinal movement of the assemblies under the deformation of all the supporting members due to the total dead load of the span, counterweights, sheaves, ropes, bearings and machinery. Solid tapered shims shall be provided as necessary to achieve proper bearing alignment. The Contractor
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shall submit a detailed assembly and alignment procedure for installation of the sheave assemblies to the Engineer for approval. The procedure must include measurements of the existing trunnion centerlines and measuring the slope of the trunnions at every bearing before and after the counterweights are jacked.
B. The alignment of the trunnions to their bearing assemblies shall be obtained vertically and horizontally such that, when the full dead load of the lift span and counterweights is carried by the sheave assemblies, the clearances between the bearing sides and the mating trunnion does not vary by more than 0.005” along the length of the bearing, and the clearances between the bearing cap and the mating trunnion does not vary by more than 0.002” along the length of the bearing.
C. Drill bearing mounting bolt holes undersized in the shop based upon field measurements. Drill and ream holes for LC6 fit with new turned bolts after final alignment in the field.
D. After each sheave assembly and bearing assembly are installed and bolted in place, but before the counterweight ropes are reinstalled, the bearings shall be lubricated and tested to see that the sheave assemblies turn freely. If not, the reason shall be determined and the necessary corrections made.
E. The Contractor shall provide all apparatus, tools, devices, materials and labor to install, erect, align, adjust, lubricate, and test the counterweight sheaves and bearings and associated components in an approved manner as provided herein. Any apparatus, tools, devices, materials and labor not specifically stated or included, which may be necessary for the work, shall be furnished by the Contractor. b. MEASUREMENT AND PAYMENT
A. MEASUREMENT - The work in Section Sheaves, Trunnions, Bearings shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
B. BASIS OF PAYMENT - Payment for the work in Section M101 Sheaves, Trunnions, Bearings will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions.
DESCRIPTION UNIT
M101 Sheaves, Trunnions, Bearings Lump Sum
END OF SECTION M101
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SECTION M102 - COUNTERWEIGHT WIRE ROPES a. Description
1. Description of Work
A. This work shall consist of jacking the counterweights and replacing the counterweight wire ropes. All other materials, lubricants, labor, bearing shims, and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. Counterweight Wire Ropes
(1) Counterweight wire rope shall be in accordance with the latest revisions of AREMA Chapter 15, Part 6, Section 6.6, and Federal Specification RR-S-550.
(2) Wire rope assemblies shall be finished, assembled, and adjusted in an approved manner and according to the best shop practice as defined by the latest edition of the Wire Rope Users Manual. The limits of accuracy that are to be observed in machining the work, and the allowances for all metal fits shall be placed on the contractor's working drawings. Fits and finishes of machinery parts shall be as called for on the contract drawings or as specified by AREMA.
(3) All counterweight wire ropes shall be 2" diameter, made of extra-extra improved plow steel (EEIPS), drawn galvanized, with a minimum ultimate tensile strength of 434,000 pounds, and shall be 6 x 25 filler wire construction with an independent wire rope core (IWRC), right regular lay. The wire ropes shall be preformed. The wire ropes shall have a line painted down the length of the rope to aid in verifying there is no twist in the ropes at installation. The wire ropes shall comply with ASTM A1023, A1007, and these contract documents.
(4) Wire rope shall be manufactured by one manufacturer, whose facilities and experience have been approved by the engineer. Ropes shall be laid in accordance with the best practice. Every effort shall be made to obtain ropes of uniform physical properties. The ropes shall be fabricated in the greatest length practical and shall be cut from ropes manufactured with one setting of one stranding machine, and one setting of one closing machine.
(5) The wire ropes shall be prestretched in accordance with AREMA Chapter 15, Part 6, Section 6.6.10.
(6) The actual diameter of the wire rope shall be defined as the diameter of the circumscribed circle. The actual diameter of the rope, measured with the rope unstressed, shall not be less than its nominal diameter and not more than 3/32" in excess of its nominal diameter.
(7) The actual length of each wire rope assembly shall not vary from the specified length by more than 1/8” when measured under a tensile load of 38,800 lb. All wire ropes shall be right regular lay. The maximum length of the rope lay shall
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not exceed 7-1/4 times the nominal rope diameter.
(8) All portions of the wire rope shall be lubricated during fabrication with a lubricant containing a rust inhibitor.
(9) No splicing of the ropes or individual strands will be permitted.
(10) Rope sockets shall conform to these contract documents. Rope sockets shall be spelter block sockets made from forged alloy steel, conforming to ASTM A668, Class H. Each socket shall be magnetic particle and ultrasonic inspected. Sockets shall be selected at random for testing, which shall be in accordance with the provisions of this specification, and in accordance with AREMA Chapter 15, Article 6.6.11. Assemble in accordance with provisions in the AREMA Manual.
(11) All sockets shall be attached to the ropes in accordance with AREMA Chapter 15, Part 6, Section 6.6.11.
(12) Sockets shall be galvanized in accordance with ASTM A153.
(13) Shims must be furnished and installed by the Contractor as necessary to achieve the rope tension described herein. Shims must be solid, shims of multiple plies are not permitted, and must be made from 316 stainless steel. Finger shims are permitted and must be installed with the open end of the slot against the keeper plate.
3. Shop Inspection, Assembly, and Testing
A. The wires and wire rope assemblies shall conform to the testing requirements of AREMA Chapter 15, Part 6, Section 6.6. Provide a minimum quantity of 3 wire rope assemblies for testing. Test assemblies must be at least 10 feet in length. All tests shall be conducted in the presence of an inspector designated by the engineer.
B. The length of each rope, between load-bearing faces of the sockets identified on the contract drawings, shall be measured while the rope is twisted to the correct lay, and supported throughout its length in a straight line and under a tension equal to 38,800 pounds, which is approximately equal to its dead load in service. The method of measurement shall be such to guarantee measurement of all ropes under identical conditions, and shall be satisfactory to the Engineer. The length variation shall be as previously stated.
C. When each rope assembly is under tension of 38,800 lbs for measurement, it shall be marked with a longitudinal streak of brightly colored paint or other marking so as to determine the exact relation of rope strands and sockets with each other, and when erected, care shall be taken to see that the rope has no twist, but that they occupy exactly the same relation to each other which existed when the rope was measured. Each rope shall be suitably marked or tagged for identification and erection. The final rope length (socket to socket) shall be stamped on the socket at a location recommended by the socket manufacturer.
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D. The manufacturer shall provide facilities for making the tests, and shall make, at his own expense, the tests required. Tests shall be made in the presence of an inspector representing the Engineer. The manufacturer shall make those tests normally made by the manufacturer and shall provide all necessary and proper facilities and shall otherwise cooperate as necessary in the making of tests which are to be in the presence of an inspector.
4. Erection
A. Rope length shall not be adjusted after shipment from the manufacturer.
B. The counterweight ropes shall be carefully removed from reels or coils by revolving them and shall be erected as to avoid any kinks or bends. The ropes shall not be pulled through dirt or water. The stripe painted on each rope in the shop shall be straight and facing outwards after the rope is installed. The painted stripe shall indicate a rotation of the rope less than 7-1/2° per 50 feet of rope length. The Contractor shall submit to the Engineer for approval and show the erection procedure for the counterweight ropes on the shop drawings, including the transfer of load onto the ropes.
C. The counterweights shall be jacked and placed on bolsters to permit the installation of the wire ropes. See Structural Specification “Counterweight Jacking and Support” for jacking procedures. See Structural Plans for counterweight jacking details.
D. Clean the rope connection points and remove all sharp edges prior to the installation of the new counterweight ropes. The new ropes are the same nominal diameter as the existing, but some minor grinding of the rope anchor casting may be required to seat the ropes in the grooves. Lubricate rope contact areas. Paint all other exposed surfaces.
E. After the lift span is in operating condition, the Contractor shall properly clean all ropes of all foreign material and shall furnish and apply hot, in an approved manner, and when weather conditions are suitably dry and warm, one coat of the lubricant compatible with the factory applied rope dressing. Lubricant compound for field dressing the wire ropes shall be recommended and certified by the manufacturer in writing. The wire rope lubrication shall be recommended for long term (at least 12 months), year-round, outdoor, marine environment, use with consideration to ambient temperature ranges between 0°F and 100°F. The field dressing must be compatible with the lubricant used during fabrication and suitable for application by hand brushing, hand pouring, swabbing, or spray can. The wire rope lubrication shall include a rust inhibitor.
F. Rope Tensioning
(1) After each rope has been placed on the sheave, with the painted stripe straight and facing outward, and has been connected to the counterweight and lift span, the Contractor shall initially adjust the ropes to proper tension.
(2) After the counterweight has been lowered onto the ropes, and after the Contractor has conducted the preliminary span balance testing as specified herein and after the span has been operated through no less than 10 operating
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cycles, the Contractor shall measure rope tensions. This section presents a recommended method to measure individual rope tension by counting vibrations. The Contractor may propose alternative methods to the Engineer for approval.
(a) Place the entire weight of both counterweights onto their counterweight ropes and place the span in the seated position.
(b) Induce vibrations in each wire rope, one at a time. Using a stop-watch and touching or holding the ropes, record the time for twenty vibrations (first order “free vibrations”). Conduct three separate tests for each rope and calculate the average number of vibrations per second. Variation between tests shall be less than 0.1 seconds. Any approved method may be used to establish the vibrations in the ropes; the frequency of the vibrations does not depend upon the method used. Useable vibrations will be noticeable to the touch and must be first-order.
(3) If a rope varies by more than 5% from the average frequency of the corner, jack the counterweight and adjust the thickness of shims used at the lift span connections to equalize the tensions. Submit for approval detailed plan of the equipment and procedure proposed to adjust the ropes via the shims at the lift span connection.
(4) After tension adjustments are made, the span shall be operated at least three times followed by retesting each rope. This shall be repeated as required until the average frequency for each individual rope is within 5% of the average frequency for all of the ropes at each corner.
(5) All tension measurements, including any tension adjustments performed, shall be submitted to the Engineer in a report containing graphs showing the distribution of the rope tensions.
(6) Rope Tension Re-Measurement and Re-Adjustment
(7) After the bridge has been in regular service for at least six months, but prior to the end of the Contractor’s warranty period, the Contractor shall re-measure the rope tensions and re-adjust the rope tensions using the same approved methods used during construction or by an alternate method approved by the Engineer. Rope tension re-adjustment shall be performed iteratively until all rope tensions meet the above criteria. The Contractor shall coordinate the work schedule and rail interruptions with AMRR and shall submit a maintenance and protection of rail traffic plan to AMRR for review and approval. The work shall be performed during off-peak or over-night hours, at the option of AMRR. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT - The Counterweight Wire Ropes shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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2. BASIS OF PAYMENT - Payment for work in Section M102 Counterweight Wire Ropes will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including temporary counterweight jacking and support, painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M102 Counterweight Wire Ropes Lump Sum
END OF SECTION M102
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SECTION M103 - COUNTERWEIGHT BALANCING a. Description
1. Description of Work
A. This work shall consist of measuring and adjusting the counterweight balance. All other materials, labor, and equipment necessary to perform the work shall be provided by the Contractor.
2. Execution
A. Initial strain gauge balancing shall be performed by the Contractor prior to beginning construction. Strain gauges shall be mounted to record torsional strain which shall be converted into operating rope loads to each side of the bridge. The Contractor shall submit a method to determine the individual corner reactions for approval. The microstrain shall be recorded on a digital data acquisition system along with lift span height indication for a minimum of three complete lift cycles. Span imbalance for each corner of the lift span shall be determined. The percentage of full load torque of the span drive motor(s) and the friction for the vertical lift system measured for the full operating cycles shall also be determined and submitted. The initial balance will be determined by the Contractor, and the results will be submitted for review.
B. The Contractor shall develop and maintain a spreadsheet that will track, throughout the duration of the work, the lateral and longitudinal center of gravity locations, relative to the bridge/span centerlines, of all items (temporary or permanent) added or subtracted to/from the lift span and/or counterweights. The spreadsheet will reflect the actual construction schedule and shall be updated daily. The Contractor shall document and weigh all materials removed from the counterweights and replace with new material equal to the removed weight during the same work shift. All additions and removals shall be recorded in the balance spreadsheet. Temporary adjustments will be made to maintain an acceptable balance condition as required below. The Contractor shall provide, install, and remove temporary balance materials as needed. Copies of the daily balance sheet report shall be made available to the Engineer for verification of stability and balance each day after any weight distribution has been affected. If at any point there is an imbalance exceeding the acceptable limits, the Owner shall be immediately notified.
C. After completing all work, the Contractor shall perform final strain gauge balance testing indicating that the balance condition is within the requirements. A written report of the results of this test shall be submitted to the Owner.
D. The Contractor is responsible for determining the final balance conditions of the lift span, per corner, by utilizing the strain gauge procedure described below. Strain gauge balancing of the lift span shall be performed by the Contractor after all construction is completed, including the main motor control system, and after preliminary balance adjustments to the span and/or counterweight have been made. Exercise the lift span through a minimum of 3 full operating cycles prior to strain gauge balance testing.
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E. Prior to performing strain gauge measurements, the Contractor shall submit full documentation of the proposed procedure, including instrumentation equipment, strain gauge mounting and wiring arrangements, method for zeroing static torque, and specific formulas and equations to be utilized for data analysis. The method of measuring and determining lift height shall be completely detailed in this documentation. This documentation shall be submitted to the Engineer for review and approval.
F. Prior to recording strain, the strain readings shall be zeroed and all static torsional loading shall be relieved from the machinery. The Contractor shall submit the proposed procedure to relieve the static torque to zero strain gauges.
G. Strain gauge measurements shall be taken only on a dry, calm day, with wind loads less than 10 mph, when there is no extraneous equipment, debris, rainwater, ice, snow, or other material on the bridge that would affect the balance of the span.
H. The lift span shall be tested through at least three (3) complete operational cycles powered by the main motor and a permanent record of each test shall be maintained.
I. The Contractor shall submit a report of the results of the balance determination. From the strain data, shaft torque and bridge imbalance, per corner, shall be computed and plotted against feet of lift from full closed to full open, and from full open to full closed. A plot of raw data strain against lift height shall also be included. Also included in the results presentation shall be a discussion on the peak operating torques as a percentage of the full load motor torque (when they occur and their magnitude) and system friction.
J. Initial balancing shall establish the existing balance baseline for use in the balance spreadsheet. If the results of the initial balancing determine that the bridge balance is outside of the acceptable balance condition, the Contractor shall coordinate with the Engineer the means and methods to bring the bridge into an acceptable balance. Final balancing shall be performed to verify that an acceptable final balance has been obtained after the adjustments.
K. If the final balancing results indicate that an acceptable final balance condition has not been obtained after the adjustments have been made, the Contractor shall make additional adjustments and repeat the balance testing as required until the desired balance conditions have been achieved.
L. The Contractor may first utilize any spare balance blocks owned by AMRR. All additional balance blocks shall be furnished by the Contractor. The number of balance blocks to be provided shall be such that an acceptable final balance condition is achieved and there are 100 spare balance blocks for future use. Balance blocks shall meet the requirements as described in the Mechanical Plans.
M. The testing and all balance calculations shall be performed by a Professional Engineer. The Contractor shall provide evidence of successful strain gauge balancing experience on a minimum of three (3) vertical lift bridges within the previous five years. A complete test procedure, along with the resume of the Professional Engineer
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conducting the tests, shall be submitted for review and approval by the Engineer prior to the initial balancing test.
N. The test procedure shall include the following:
(1) Test method (2) List of equipment (3) Sample calculations (4) Torque zeroing method (5) Report format
O. After the balance tests have been completed, the Contractor shall submit a formal report signed and sealed by the Professional Engineer who conducted the tests. The report shall include the following:
(1) Introduction (2) Test procedure and equipment (3) Method of analyzing recorded data (4) Presentation of results (5) Conclusions (6) Calculations (7) Graphical representation of torque, strain, and span balance plotted against lift height
P. Balance Requirements: The balance of the lift span shall be adjusted to meet the following requirements (all reactions listed are dead load only, no live loading):
(1) During Construction, Bridge Operation Not Permitted. Bridge is in the Closed Position, with Span Locks Engaged:
(a) The lift span must be span heavy in the closed position, with a minimum positive reaction at each corner of 3,000 lbs.
(2) During Construction, Bridge Operation Permitted:
(a) The lift span must be span heavy in the closed position, with a positive reaction at each corner between 3,000 lbs and 6,000 lbs.
(3) Final Balance Condition of Bridge Following Construction:
(a) The lift span must be span heavy in the closed position, with a positive reaction at each corner between 3,000 lbs and 4,000 lbs. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Counterweight Balancing shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M103 Counterweight Balancing will be made at the contract lump sum price bid. Price and payment shall be full compensation
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for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M103 Counterweight Balancing Lump Sum
END OF SECTION M103
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SECTION M104 – MACHINERY BEARING LINERS a. Description
1. Description of Work
This work shall consist of adding or removing liner shims, as necessary, to achieve the required fit between the shaft and bushing at the upstream operating drum’s inboard bearing. Also measure the total bearing clearance in both inboard final pinion (P1) bearings and adjust liner shims, as necessary, to achieve the required fit. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. New liner shims shall be brass AMS-DTL-22499 ,1/8” solid, 1/8” laminated in 0.003- inch layers. Details of shims to match Mechanical Plans.
3. Execution
A. The Contractor shall verify all required details in field prior to fabrication.
B. This work shall be completed with the bridge in the seated position.
C. Add or remove liner shims, as necessary, to achieve an RC6 (0.0035 to 0.010 clearance) fit between the shaft and bushing at the upstream operating drum’s inboard bearing. Clearance measured in October 2020 was approximately 0.085 inches.
D. Measure the total bearing clearance in both inboard final pinion (P1) bearings with a dial indicator, or other approved method. Adjust liner shims, as necessary, to achieve and RC6 (0.004 to 0.0113 clearance) fit.
E. With the bearing cap(s) removed, inspect the journal and bushing for unusual wear. Hand dress areas to at least a 16 micro-inch finish, as necessary. Prior to operation, thoroughly clean any metal shavings and debris, and lubricate the bearing. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Machinery Bearing Liners shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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2. BASIS OF PAYMENT - Payment for work in Section M104 Machinery Bearing Liners will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M104 Machinery Bearing Liners Lump Sum
END OF SECTION M104
94 Arkansas River Lift Bridge, MP 410.6
SECTION M105 – WIRE ROPE SOCKET KEEPERS a. Description
1. Description of Work
A. This work shall consist of removing all existing rope socket keeper plate screws and installing new screws and washers at every tapped hole location (192 total). All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. New screws shall be Ø3/8”–16 x 1¼” stainless steel hex cap screws and matching stainless steel flat washers.
B. Thread-locking compound shall be Loctite Blue 242, or approved equal.
3. Execution
A. The Contractor shall verify all required details in field prior to fabrication.
B. Remove all rope socket keeper plate screws. Use hand tools or wire brush drill attachment to clean tapped holes of all dirt/debris and blow out holes with compressed air. If threads have become damaged, the Contractor shall re-tap the hole, or tap for the next largest size screw.
C. Install new hex cap screws in clean tapped holes to retain rope socket keeper plates. Apply Loctite to the threads of screws prior to installation.
D. Perform this work of removing, cleaning, and installing screws while the counterweight is supported, and the ropes are removed. There are six (6) screws per keeper plate, four (4) keeper plates per rope anchor casting, and eight (eight) rope anchor castings for a total of 192 screws. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Wire Rope Socket Keepers shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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2. BASIS OF PAYMENT - Payment for work in Section M105 Wire Rope Socket Keepers will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M105 Wire Rope Socket Keepers Lump Sum
END OF SECTION M105
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SECTION M106 – AUX DRIVE SHIFTER ASSEMBLY a. Description
1. Description of Work
A. This work shall consist of rehabilitating the auxiliary drive shifter assembly. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. New screws shall be Ø1/2” shoulder diameter, Ø3/8”–16 alloy steel socket head shoulder screws meeting the requirements of ASTM A574 and ASME B18.3.
B. New nuts shall be Ø3/8”-16 heavy hex nuts meeting the requirements of ASTM A563 Grade C or DH.
C. Thread-locking compound shall be Loctite Blue 242 or approved equal.
3. Execution
A. The Contractor shall verify all required details in field prior to fabrication.
B. Remove both the bolts connecting the auxiliary shifter yoke to the auxiliary shifter shaft and the set screw connecting the auxiliary shifter lever to the auxiliary shifter shaft. With mating components together, drill and ream existing holes for Ø1/2” shoulder screws. Drilled and reamed holes shall have a tolerance of Ø0.500” to Ø0.502” and shall completely clean up existing holes.
C. Install hex nuts on shoulder screws with Loctite.
D. The auxiliary drive pinion must be fully engaged with its mating gear when the auxiliary shifter lever is in the engaged detent. Similarly, the auxiliary drive pinion must be fully disengaged with its mating gear when the auxiliary shifter lever is in the disengaged detent.
E. After the work is complete, test operate the auxiliary shifter assembly by shifting the auxiliary shifter lever from the engaged position to the disengaged position five times. Verify the pinion position as described above. The lever must move without excessive force or slop. After successful completion of the no load test, operate the bridge on the auxiliary drive and verify that proper engagement is maintained throughout the entire bridge operation. This test will need to be done, or repeated, after the electrical limit switch work to verify the proper interlocking. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Aux Drive Shifter Assembly shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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2. BASIS OF PAYMENT - Payment for work in Section M106 Aux Drive Shifter Assembly will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M106 Aux Drive Shifter Assembly Lump Sum
END OF SECTION M106
98 Arkansas River Lift Bridge, MP 410.6
SECTION M107 - MACHINERY BRAKE a. Description
1. Description of Work
A. This work shall consist of replacing the existing machinery brake, machinery brake support, and machinery brake wheel with a new machinery brake, machinery brake support, and machinery brake wheel. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. Span drive machinery brakes shall be electro-hydraulic thruster type Pintsch Bubenzer Ø250mm drum brake, catalog no. EBN 250-80/6, or approved equal. The brake shall have a low force hand release lever that will permit release of the brake without energizing the thruster motor. The brake shall be adjustable to regulate the time for setting of the brake. The brake shall be factory set for 885 foot pounds of braking torque. The brakes shall be supplied with stainless steel pivot pins, bearings at all main pivots, lube fittings, and any other optional features necessary for corrosion protection. The brakes shall be painted with a finish coat of Federal Safety Orange prior to final assembly.
B. The machinery brakes shall operate at 460 volts, 3 phase, 60 Hz. Each machinery brake shall be equipped with three separate limit switches for interlocking span control supervision and indications. Two brake limit switches shall provide for sequence interlocking on span control operation and for indication of the set and release status of the brakes. The other brake limit switch shall provide for lock-out of the span control circuitry when the brake is hand released and for indication. Brake limit switches shall be NEMA 4 rated, oil-tight and furnished and mounted on each brake frame by the manufacturer.
C. The machinery brake shall operate on a Pintsch Bubenzer, or an approved equal, Ø250mm, 95mm wide symmetric brake wheel with a custom hub per the manufacturer’s recommendation. The brake wheel shall be bored for an FN2 fit with the existing shaft S5. A custom keyway shall be machined in the bore with fits, as described elsewhere, for a new 7/8” parallel square key. All exposed surfaces shall be painted as specified elsewhere herein.
D. The machinery brake shall be supplied with a set delay valve. Brake set delay shall be initially set at 2 seconds. This delay may be adjusted in the field at the discretion of the Engineer.
E. The machinery brake shall have the manual low force brake release lever mounted on the side of the brake that provides the most access for operation.
F. Provide each machinery brake with a Type 3R stainless steel brake cover, with slots for drive shafts, and access to brake release lever without removal of cover. Cover shall have a hinged lid for inspection purposes. Provided machinery brake covers must
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not interfere with new or existing machinery components including brake limit switches and wiring.
G. Provide a new 7/8” parallel square key, conforming to ASTM A668 Class K, to connect the new machinery brake wheel to the existing shaft S5.
3. Erection
A. Press the machinery brake wheel onto shaft S5 so that the end of the shaft is flush with the brake wheel hub.
B. Machine a new 7/8” parallel square keyway into the end of the existing shaft S5 where the new machinery brake wheel will be mounted. The new keyway shall completely clean up the existing keyway while keeping it as short as practical. See M100 – General Mechanical Specifications for fit and finish requirements.
C. The machinery room floor plates will need to be temporarily removed to remove and install the machinery brake support. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Machinery Brake shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M107 Machinery Brake will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M107 Machinery Brake Lump Sum
END OF SECTION M107
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SECTION M108 - SPAN GUIDE a. Description
1. Description of Work
A. This work shall consist of replacing the existing longitudinal span guide assemblies with new longitudinal span guide assemblies. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. Provide new longitudinal guide weldments consisting of ASTM A709 Gr. 50 plates welded with 3/8” double fillet welds or groove welds ground flush, as required. Stress relieve weldments with heat prior to machining and clip corners per AWS D1.5.
B. Provide new longitudinal and transverse guide shoes meeting the requirements of ASTM B22 C91300 with a surface finish as described in M100 – General Mechanical Notes and on the Plans.
C. Provide new high strength bolts, nuts, and washers for the structural connection of the longitudinal span guide assembly to the lift span.
3. Erection
A. The Contractor shall verify all required details in field prior to fabrication.
B. The longitudinal span guide assembly shall be aligned to the guide rail with 1/8” clearance transversely and longitudinally with the span in the seated position.
C. The existing longitudinal span guide castings are bolted to the structure with 20 bolts top and bottom. The new longitudinal span guide assemblies shall be aligned to the guide rail and field drilled to match the 20 existing mounting holes top and bottom.
D. Remove all burrs, lips, ridges, and metal flow from the guide rail to produce a flat bar with perpendicular faces on three sides where the guide shoes will contact.
E. All hex cap screws and lifting eyes shall be installed with Loctite Blue 242, or approved equal.
F. See Structural Plans and Special Provisions for modifications to the span guide mounting arm.
b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Span Guide shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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2. BASIS OF PAYMENT - Payment for work in Section M108 Span Guide will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M108 Span Guide Lump Sum
END OF SECTION M108
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SECTION M109 - MAIN MOTOR a. Description
1. Description of Work
A. This work shall consist of replacing the existing main motor, motor support, and motor coupling. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. New gearmotor shall be Nuttall G365T76S, TEFC, 75 hp, 1170 rpm input, 640 rpm output, floor mounted unit with an oil sight gauge, or approved equal. The motor shall have a rear shaft extension approximately 9” long that provides at least 2” of clearance between the back of the motor and the motor brake cover. The gearbox shall have a welded plate steel construction. The gearmotor shall meet the additional requirements as listed in the Electrical Rehabilitation Special Provisions.
B. New motor and motor brake support weldment shall consist of ASTM A709 Gr. 50 plates welded as described in the Mechanical Plans. Stress relieve weldments with heat prior to machining and clip corners per AWS D1.5.
C. New motor coupling shall be a Falk 1025G20 double engagement gear coupling with a minimum torque rating of 66,150 lb-in, or approved equal, with bores and keyways to match mating components.
D. New clamping two-piece shaft collar shall be McMaster-Carr PN 6436K245 stainless steel collar, 7/8” wide, with stainless steel socket head cap screws, or approved equal.
3. Shop Assembly and Operation
A. After alignment and bolting into place in the shop, the assembly shall be lubricated per manufacturer recommendations and test run in place at full speed and 100% FLT for a period of 30 minutes in each direction with the motor brake hand released. Parts shall have a minimum amount of play consistent with their free operation where not otherwise specified. The reducer housing shall be checked for leaks at bearing covers, seals, inspection covers, oil drains, bolts, and welds. Noise level of each reducer shall not exceed 90 dB while operating at maximum speed when the microphone is located 3 feet from the reducer housing. Temperature rise of any component shall not exceed 100°F over ambient. Monitor all bearings for excessive noise, temperature, and lubrication leaks. Record and submit, to the Engineer, all test activities and results.
4. Erection
A. The Contractor shall verify all required details in field prior to fabrication.
B. The final gearmotor location will be set by aligning the machinery with the required coupling gaps as specified by the coupling manufacturer.
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C. Subdrill the motor and motor brake support for machinery mounting bolt holes. At the shop assembly, align the motor and motor brake on the support with undersized bolts. In the field, clamp and/or bolt the machinery support in place and install the motor coupling. Confirm coupling alignment is within manufacturer recommended tolerances. One at a time, remove the temporary undersized bolts, drill and ream for final turned bolts, then install and torque the turned bolts.
D. Machine a new 7/8” parallel square keyway into the end of the existing shaft S7 where the new motor coupling will be mounted. The new keyway shall have an overall length of 3-11/16”. See M100 – General Mechanical Specifications for fit and finish requirements. Fill the unused portion of the existing keyway with metal epoxy and smooth the profile to match the shaft O.D.
E. The machinery room floor plates will need to be temporarily removed to remove and install the motor and motor brake support.
F. Install, align, and lubricate the motor coupling per the coupling manufacturer’s recommendations. No operation will be permitted until the Engineer has verified proper coupling alignment and lubrication. Alignment measurements as well as lubrication type and date shall be submitted for record. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Main Motor shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M109 Main Motor will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M109 Main Motor Lump Sum
END OF SECTION M109
104 Arkansas River Lift Bridge, MP 410.6
SECTION M110 - MOTOR BRAKE a. Description
1. Description of Work
A. This work shall consist of replacing the existing motor brake and motor brake wheel. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. The motor brake shall be electro-hydraulic thruster type, Pintsch Bubenzer Ø200mm drum brake, catalog no. EBN 200-23/5, or approved equal. The brake shall have a low force hand release lever that will permit release of the brake without energizing the thruster motor. The brake shall be adjustable to regulate the time for setting of the brake. The brake shall be factory set for 150 foot pounds of braking torque. The brakes shall be supplied with stainless steel pivot pins, bearings at all main pivots, lube fittings, and any other optional features necessary for corrosion protection. The brakes shall be painted with a finish coat of Federal Safety Orange prior to final assembly.
B. The motor brake shall operate at 460 volts, 3 phase, 60 Hz. Each motor brake shall be equipped with three separate limit switches for interlocking span control supervision and indications. Two brake limit switches shall provide for sequence interlocking on span control operation and for indication of the set and release status of the brakes. The other brake limit switch shall provide for lock-out of the span control circuitry when any brake is hand released and for indication. Brake limit switches shall be NEMA 4 rated, oil-tight and furnished and mounted on each brake frame by the manufacturer.
C. The motor brake shall operate on a Pintsch Bubenzer, or an approved equal, Ø200mm, 75mm wide symmetric brake wheel. The brake wheel shall be bored for an FN2 fit with the main motor rear shaft extension. A custom keyway shall be machined in the bore with fits, as described elsewhere, with the main motor rear shaft extension key (1/2” parallel square key). All exposed surfaces shall be painted as specified elsewhere herein.
D. The motor brake shall be supplied with a set delay valve. Brake set delay shall be initially set at 1 second. This delay may be adjusted in the field at the discretion of the Engineer.
E. The motor brake shall have the manual low force brake release lever mounted on the side of the brake that provides the most access for operation.
F. Provide the motor brake with a Type 3R stainless steel brake cover, with slots for drive shafts, and access to brake release lever without removal of cover. Cover shall have a hinged lid for inspection purposes. Motor brake covers provided shall not interfere with new or existing machinery components including brake limit switches and wiring.
105 Arkansas River Lift Bridge, MP 410.6
3. Erection
A. The Contractor shall verify all required details in field prior to fabrication.
B. Press the motor brake wheel onto the main motor rear shaft extension so that the end of the shaft is flush with the brake wheel hub.
C. Subdrill the motor and motor brake support for machinery mounting bolt holes. At the shop assembly, align the motor and motor brake on the support with undersized bolts. In the field, clamp and/or bolt the machinery support in place and install the motor coupling. Confirm coupling alignment is within manufacturer recommended tolerances. One at a time, remove the temporary undersized bolts, drill and ream for final turned bolts, then install and torque the turned bolts. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Motor Brake shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M110 Motor Brake will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M110 Motor Brake Lump Sum
END OF SECTION M110
106 Arkansas River Lift Bridge, MP 410.6
SECTION M111 - BEVEL GEAR PLATE a. Description
1. Description of Work
A. This work shall consist of removing miscellaneous plate and hardware from the span drive bevel gear. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Execution
A. Remove the miscellaneous plate and mounting hardware from the bevel gear.
B. Completely protect all machinery, including but not limited to gears, couplings, and bearings, from any dirt/dust/debris, contaminants, or foreign objects. Use special care if cutting or grinding in the machinery room as byproducts can significantly degrade machinery.
C. Submit work procedure and protection plan to the engineer for approval prior to starting any work.
D. Test operate the machinery at full speed following this work. If the bevel gear seems to be out of balance, or if there is unusual vibration at any speed up to and including full speed, use new high strength bolts and nuts to remount the plate to the bevel gear web and properly torque hardware. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Bevel Gear Plate shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M111 Bevel Gear Plate will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M111 Bevel Gear Plate Lump Sum
END OF SECTION M111
107 Arkansas River Lift Bridge, MP 410.6
SECTION M112 - GEARBOX SEAL a. Description
1. Description of Work
A. This work shall consist of replacing the auxiliary drive reversing gearbox input and output shaft seals and inspecting the internal gearing. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. The existing shaft seals must be replaced with new solid lip-type seals as recommended by the OEM, Steward Machine Company, for Earl Power Unit No. A1327, Size 4, Type B, Engine H.P. Rating: 40, RPM: 900, Output RPM: 300.
3. Execution
A. The Contractor shall verify all required details in field prior to fabrication.
B. Remove the auxiliary drive reversing gearbox from its mounted location in the machinery room, pull the coupling hubs from the input and output shafts, and replace the shaft seals with new solid seals.
C. With the gearbox removed, thoroughly inspect the internals for any deficiency. Particular attention should be paid to the gear teeth, the shifting mechanism, and the bearings. If any deficiency is identified, notify AMRR immediately and perform the corrective action, as agreed upon with the railroad.
D. Once the seal and internal inspection work has been completed, clean the inside of the gearbox of all foreign objects and debris, add the recommended oil as required, reinstall the coupling hubs on the gearbox shafts, and reinstall the gearbox on the machinery room support.
E. After replacing the seals, test operate the auxiliary drive through three full bridge operating cycles and check the seals for any leakage or excessive heat buildup. If an issue occurs, repair seals and test again until no issues are detected for three full bridge operating cycles.
F. Maintain proper oil level prior to any test operation and at completion of work.
G. Perform this work prior to the electrical system replacement. Once the work has begun on removing the existing electrical system, the bridge will run exclusively on the auxiliary drive until the electrical work is complete. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Gearbox Seal shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
108 Arkansas River Lift Bridge, MP 410.6
2. BASIS OF PAYMENT - Payment for work in Section M112 Gearbox Seal will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M112 Gearbox Seal Lump Sum
END OF SECTION M112
109 Arkansas River Lift Bridge, MP 410.6
SECTION M113 - UPHAUL ROPE DEFLECTOR SHEAVE BOLTS a. Description
1. Description of Work
A. This work shall consist of replacing the uphaul deflector sheave shaft bolts at all four locations. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. New bolts shall be Ø3/4”–10 UNC x 6” high strength bolts with matching washers and locknuts.
3. Execution
A. The Contractor shall verify all required details in field prior to fabrication.
B. With the lift span seated, release tension on the uphaul ropes. Remove the broken bolt (NW & SE corners), or existing intact bolt (NE & SW corners), from the deflector sheave shaft. Rotate the deflector sheave shaft so that the bolt hole in the shaft and housing are aligned. If necessary, only use a 3/4" bar inserted in the bolt hole to rotate the shaft. Verify that the sheave and shaft rotate independently without excess force. Contact AMRR immediately if the sheave∅ and shaft are seized. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Uphaul Rope Deflector Sheave Bolts shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M113 Uphaul Rope Deflector Sheave Bolts will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M113 Uphaul Rope Deflector Sheave Bolts Lump Sum
END OF SECTION M113
110 Arkansas River Lift Bridge, MP 410.6
SECTION M114 - ACCEPTANCE TESTING a. Description
1. Description of Work
A. This work shall consist of acceptance testing for all new machinery. All other materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Execution
A. All field testing and alignment verification shall be performed in the presence of the Engineer. The Engineer shall be given at least two weeks notification prior to all testing.
B. Prior to performing testing, the Contractor shall submit the proposed procedure. This documentation shall be submitted to the Engineer for review and approval.
C. During final installation, all mechanical bridge components shall be completely assembled and aligned to within manufacturers’ recommended installation tolerances and the tolerances specified in these contract documents. Adjustments shall be made with stainless steel shims. All components requiring lubrication shall be lubricated in accordance with previously approved lubrication schedule prior to bridge operation. The movable span shall then be fully raised and fully lowered five (5) times using the standard operating procedure. During test operations all mechanical components will be monitored for unusual noise, vibration, movement, lubrication leaks, excessive heat, proper alignment, and general proper operating characteristics.
D. Main Operating Machinery
(1) During final installation, the machinery support weldments shall be connected to the machinery house structural steel and adjusted to be level. All span drive machinery shall be assembled complete as to all shafts, couplings, bearings, brakes, motors, and reducers and shall be aligned to within the manufacturer’s recommended installation tolerances. Adjustments shall be made with stainless steel shims. During test operations, parts shall have the minimum amount of play consistent with their free operation where not otherwise specified. The reducer housing shall be checked for leaks at bearing covers, seals, inspection covers, oil drains, bolts, and welds. Noise level of each reducer shall not exceed 90 dB while operating at maximum speed when the microphone is located 3 feet from the reducer housing. Temperature rise of any component shall not exceed 100°F over ambient. Monitor all bearings for excessive noise, temperature, and lubrication leaks. Record and submit, to the Engineer, all test activities and results.
E. Span Locks
(1) After mounting and adjusting each lock assembly, they shall each be field tested by operating through not less than three (3) cycles while the span is in the closed
111 Arkansas River Lift Bridge, MP 410.6
position. Perform one (1) cycle of span lock field testing using the hand crank with the span lock electrically disconnected.
(2) Span lock assemblies shall also be operated during the electrical sequence testing performed under the electrical special provisions.
F. Alignment of all machinery shall be rechecked after all connections and drives have been installed and in operation for a minimum of 10 lift span openings/closings. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Acceptance Testing shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M114 Acceptance Testing will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M114 Acceptance Testing Lump Sum
END OF SECTION M114
112 Arkansas River Lift Bridge, MP 410.6
SECTION M115 - TRAINING AND SUPERVISED OPERATION a. Description
1. Description of Work
A. This work shall consist of training AMRR personnel to operate the span using the new span drive machinery and supervising operations performed by AMRR personnel until AMRR is satisfied with their competence. All materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Execution
A. Provide a minimum of two men to supervise the operation of the bridge for a period of 14 calendar days (24 hours a day) after the bridge is fully operational on the new main motor control system; and for an additional 14-day period (24 hours a day), provide one man. These men shall be able to operate the bridge, to supervise its operation, and to make any adjustments or corrections that may be required in the mechanical equipment of the bridge. They shall instruct and qualify the employees of AMRR in the operation of the bridge. Any adjustments or corrections required during the two 14-day periods shall be at no additional cost. b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Training and Supervised Operation shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M115 Training and Supervised Operation will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M115 Training and Supervised Operation Lump Sum
END OF SECTION M115
113 Arkansas River Lift Bridge, MP 410.6
SECTION M116 - OPERATION AND MAINTENANCE MANUAL a. Description
1. Description of Work
A. This work shall consist of creating an operation and maintenance manual for all new and rehabilitated AMRR Vertical Lift machinery. All materials and equipment necessary to perform the work shall be provided by the Contractor.
B. This work shall consist of providing classroom and on-site operating and maintenance training.
2. Execution
A. The Contractor shall provide three copies of the preliminary version and six copies of the final version of operation and maintenance manuals for the bridge operating machinery. The Contractor shall also submit each version in .pdf format.
B. If standard drawings are used, they will be modified to be suitable, and irrelevant material will be blocked out. All general information used as text will be modified where necessary to show pertinence to the equipment furnished under this Contract, and irrelevant material will be removed.
C. The arrangement of the manual, method of binding, included material and text will be submitted to the Engineer for approval.
D. The manual shall be developed from recommended practice of the machinery manufacturers. The manual shall include forms for recommended maintenance with suggested time intervals indicated for use in scheduling predicative and preventative maintenance, including lubrication.
E. As a minimum, the Contractor shall provide the information, itemized below, for all new and rehabilitated mechanical equipment. Documentation provided shall be current to include all changes made as a result of approval of submittal drawings, field installation changes, changes directed by the railroad after approval of submittals, and changes made during check-out and testing.
(1) certified dimensional drawing(s) (2) installation instructions (3) operating instructions (4) maintenance instructions (5) performance curves and ratings (6) all mill test reports, NDT reports and certificates of compliance and/or certifications required (7) lubrication instructions (8) recommended spare parts list with vendor price list (9) any special handling, rigging, installation, operating or maintenance instructions necessary for AMRR to install, operate or maintain this equipment.
114 Arkansas River Lift Bridge, MP 410.6
3. Construction
A. Binders shall be hardback vinyl, three-ring, loose-leaf type for binding 8-1/2 x 11 inch sheets. Binders shall preferably be 10 x 12 inches and not over three inches thick.
B. The binder spine and front cover shall display labels containing the name of the bridge, the bridge location, the names of the Mechanical Prime and Sub Contractors, and the dates of the work.
(1) The binder holes shall be reinforced for all contents. (2) The paper and ink shall resist smearing, fading and deterioration from age. (3) All lettering shall be clear and legible. (4) All material shall be new; copies from prior submittals shall not be used. This manual shall have index tabs for each major piece of equipment and system. (5) A table of contents shall indicate each chapter, section, specific equipment, and page numbering.
C. Chapters
The volume shall have a format and be divided into chapters as follows.
(1) Chapter 1 will be designated for general information and safety precautions. Applicable information from AREMA shall be included. (2) Chapter 2 shall contain the operational description of major systems, subsystems, and major components. Manufacturer’s data brochures (color originals where available), catalog cuts, and specification sheets shall be included. (3) Chapter 3 shall cover the functional description, including: block diagrams; schematic layout of the entire system; description of subsystem; functional relationship between systems and subsystems. (4) Chapter 4 shall cover scheduled maintenance, where applicable. This chapter shall provide all preventive maintenance procedures to the lowest repairable unit level and any checks, tests and measurements required on a periodic routine basis. Preventive maintenance indexes (PMI's) shall be provided in this section and shall be organized in tabular format to provide quick, easy reference to each preventive maintenance action performed according to the prescribed maintenance interval, as well as applicable preventive maintenance procedures contained within the manual. (5) Chapter 5 shall consist of troubleshooting diagrams (fault isolation trees) to be used by maintenance personnel for isolating fault to the lowest reparable limit level. (6) Chapter 6 shall cover all corrective maintenance procedures that are required to repair a particular system, piece of equipment or material back into satisfactory operating condition. This chapter shall provide step-by-step procedures for the replacement of defective parts. Reference shall be made according to the applicable test procedures established in Chapter 4. Warnings or precautions to be observed during maintenance shall be listed. (7) Chapter 7 shall provide step-by-step installation procedures to the lowest repairable limit level for a particular system, piece of equipment, or material.
115 Arkansas River Lift Bridge, MP 410.6
(8) Chapter 8 shall consist of complete parts lists to the lowest repairable limit level for each system, piece of equipment, or material. Parts lists shall include exploded views of assemblies as required. The local representative of the parts supplier shall be listed. (9) Chapter 9 shall include the duration and contents of all guarantees and warranties. (10) Chapter 10 shall include half-size prints of approved shop drawings (as-built). The prints shall be folded to fit into the manual. (11) Chapter 11 shall consist of a spare parts inventory list, which AMRR shall store on or off site. Spare parts inventory list shall include the minimum quantity recommended to be stocked by AMRR at any time. These shall be items that are frequently replaced and/or have long delivery times when ordered and/or are critical to bridge operations if not stocked by AMRR.
D. The Contractor shall include recommendations, in writing from the vendor, for the Engineer's approval, all lowest repairable units for each system, piece of equipment, or material. A lowest repairable unit shall be defined as that equipment which cannot be economically repaired, or which requires skills and equipment beyond those available by the owner’s maintenance personnel. The lowest repairable unit concept shall be used to prepare all written maintenance, repair, inspection, testing, replacement, and installation procedures for the operation and maintenance manual covered herein.
E. Parts lists shall be in tabular form and shall include each part name, description, name of manufacturer's order/part number and shop drawing reference. Parts lists shall be supported by adequately labeled exploded views or pictorial views where applicable. All special tools, jigs, fixtures, test, and calibration equipment used in any maintenance, inspection repair or adjustments shall be included.
F. Copies of nameplates and/or equipment tags shall be furnished as part of the shop drawing and included in the Operation and Maintenance Manual for future reference on all machinery.
G. All written text and descriptive material shall be plainly written.
H. Paragraph numbering will be sequential and indicate chapter location. Roman numerals shall not be used.
I. Front matter shall include a cover page with descriptive title, project, Contractor, and Engineer.
J. Safety warnings or cautions shall be visibly highlighted within each maintenance procedure. Use of such highlights shall be limited only to critical items and shall not be used in excessive manner which would reduce their effectiveness.
K. Content Requirements
(1) Vendors’ and suppliers’ listings shall include names, addresses and telephone numbers.
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(2) Neatly typewritten index near the front of the manual shall furnish immediate information as to location in the manual of all emergency data regarding the installation. (3) Complete instructions regarding operating, lubricating, adjusting and maintenance of all equipment involved shall be included. (4) Where the contents of the manuals include manufacturer's catalog pages, clearly indicate the precise items included in this installation and delete all manufacturer's data with which this installation is not concerned. (5) All results of testing required by these specifications shall be included.
L. Preliminary manual editions shall present all technical material for the mechanical volume to the greatest extent possible with respect to text, tabular matter, and illustrations. Preliminary manual editions shall be single column, double-spaced, and typewritten. Illustrations shall preferably consist of line drawings. (Sketches or photographs may be used if final line drawings are unavailable at the time of submittal.) All applicable shop drawings shall be included.
M. Preliminary manual editions shall be as technically complete as the final manual edition. All illustrations shall be in final form. Reduced size shop drawings shall be included.
N. Final manual editions shall be technically accurate and complete and shall represent the "as-built" system, piece of equipment, or material given final acceptance by the Engineer. All illustrations, text, and tabular material shall be in final form; all shop drawings (as-built) shall be included.
O. Included Items: Information shall be furnished for the following items of mechanical machinery.
(1) Open gears (2) Bevel gear/pinion (3) Motor and machinery brakes (4) Gearmotor (5) Flexible couplings (6) Bearings and bushings (7) Shafts and keys (8) Tower sheave assemblies and trunnion bearings (9) Wire rope assemblies (10) Deflector sheaves and rope tensioning assemblies (11) Span locks, including operators, guides, and receivers (12) Span guides (13) Counterweight guides (14) Emergency drive system (engine thru shifter clutch) (15) Height indicator assembly (16) Span control equipment (17) Lubrication schedule and diagram (18) Standard operating instructions and emergency operation instructions (Two separate sets of directions.)
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4. Training
A. The training shall be scheduled to commence thirty (30) days (minimum) after the FINAL As-Built O&M Manuals are distributed to AMRR. The Operating and Maintenance Training shall not begin until the FINAL As-Built O&M Manuals are approved by the Engineer.
B. Training of the designated bridge operational personnel shall commence prior to final acceptance of the bridge, in accordance with the approved schedule. The training schedule shall allow training of personnel without interruption of normal traffic flow. The classroom training and field training shall be scheduled for normal daytime working hours.
C. All training for operation and maintenance shall be offered on two separate occasions to allow AMRR personnel to coordinate the instruction with their normal activities.
D. Soft-bound training manuals shall be provided to facilitate the training. Training manuals shall include all relevant shop drawings and bills of materials. Electronic PDF versions of manuals shall also be provided. Submit preliminary electronic versions to the Engineer for review and approval prior to beginning training.
E. The Contractor shall coordinate with AMRR the location where training sessions will be held. The Contractor shall supply all visual aid equipment and other miscellaneous items required for training.
F. The Contractor shall provide a one-day (eight-hour day) training/instruction program, presenting maintenance instructions to the railroad maintenance personnel. The Contractor shall provide instructors who are thoroughly familiar with the O&M manual and the physical components requiring lubrication.
G. Classroom instruction sessions shall be devoted to reviewing the manuals. Field instruction sessions shall require hands-on application of the manual to lubricate and maintain all the movable span machinery, including any moving or sliding components.
Mechanical Maintenance Training Manual Content (at a minimum) shall include: (1) General safety precautions. (2) Description of the bridge drive system and functionality of components. (3) Overview of the lubrication charts and instructions on lubricating all components. (4) Routine maintenance instructions. (5) A minimum of five hardcopies of mechanical maintenance training manuals shall be provided. b. MEASUREMENT AND PAYMENT
A. MEASUREMENT –The Operation and Maintenance Manual shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
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B. BASIS OF PAYMENT - Payment for work in Section M116 Operation and Maintenance Manual will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M116 Operation and Maintenance Manual Lump Sum
END OF SECTION M116
119 Arkansas River Lift Bridge, MP 410.6
SECTION M117 - SPAN LOCKS a. Description
1. Description of Work
A. This work shall consist of replacing the north and south span locks, including span lock actuators with integral lockbar, mounting bolts, washers, nuts, shims, and cover. All materials and equipment necessary to perform the work shall be provided by the Contractor.
2. Products
A. Span lock actuator shall be Earl Gear EG-2B lockbar actuator with 14” stroke and LBO-101P foot mount. Span lock actuators are to be adjusted to fully retract and to extend 13½” minimum. Span locks shall be manufactured with custom hole patterns to match existing hole patterns. Field verify bolt patterns.
B. The lockbar shall be made from ASTM A668, Class M forged alloy steel. It shall be 5” diameter in cross section with a ¼” by 45-degree chamfer at the tip. The lockbar shall be finished all over to 63 micro-inches. Lockbars are to extend 47” from CL of actuator mount to tip of lockbar when extended 13½”.
C. Span lock actuators shall be covered by a 6' X 3' stainless steel cover made of qty (2) C3X4.1 channels and 6'X3' 16-gauge stainless steel sheet centered over span lock actuator.
D. Span lock mounting base, guides and receiver are existing and are to be reused.
E. 3/8” stainless steel shim pack shall be supplied as required for alignment.
3. Erection
A. The Contractor shall verify all required details in field prior to fabrication.
B. Full-size stainless steel shims shall be used to adjust to correct position, alignment and elevation.
C. Final adjustment shall be made at a time when the temperature of the structure is uniform and the wind is calm. Adjust actuator positioning so that no binding occurs when span locks are operated under these conditions.
D. After mounting and adjusting each lock assembly, they shall each be field tested by operating through not less than 3 cycles while the span is in the closed position.
120 Arkansas River Lift Bridge, MP 410.6
b. MEASUREMENT AND PAYMENT
1. MEASUREMENT –The Span Locks shall be measured as a unit acceptably completed as shown on the contract drawings and as specified.
2. BASIS OF PAYMENT - Payment for work in Section M117 Span Locks will be made at the contract lump sum price bid. Price and payment shall be full compensation for furnishing all labor, materials, equipment, and incidentals necessary to complete the work under the item in accordance with the contract drawings and these special provisions, including painting, lubricating, erecting, and all other features necessary to insure the satisfactory operation of the bridge.
DESCRIPTION UNIT
M117 Span Locks Lump Sum
END OF SECTION M117
121 Arkansas River Lift Bridge, MP 410.6
STRUCTURAL SPECIAL PROVISIONS
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COUNTERWEIGHT JACKING AND SUPPORT
a. Description. This work shall consist of providing all labor, materials and equipment required to jack and temporarily support the existing counterweights during construction for replacement of the counterweight wire ropes as described herein and shown on the plans, including all incidental work as shown and required by the Contract. This work includes design of the cribbing and jacks as described below.
b. Applicable Standards. Where not otherwise specified herein, workmanship, materials, fabrication, and erection of the bridge components shall be in accordance with the requirements of the latest revision of The American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Chapter 15.
The work shall also comply with the following standards and specifications as applicable.
• AASHTO LRFD Movable Highway Bridge Design Specifications • AHTD - Arkansas State Highway and Transportation Department, Standard Specifications for Highway Construction • ASTM - American Society for Testing and Materials • ANSI - American National Standards Institute • AWS – American Welding Society
c. General Requirements.
1. Existing Counterweight Beams and Diaphragms. The existing counterweight beams (24WF94) and corresponding diaphragms (12WF27) are to be moved from their respective storage positions on the towers to the proper jacking locations. All existing fasteners required to be removed shall be discarded and replaced with new high strength bolts. The new bolts are to be fully tensioned (friction type connection).
After the replacement of the wire ropes and the removal of the jacking and cribbing, the counterweight beams and diaphragms are to be returned to their original storage positions on the towers. New high strength bolts are to be used to re-attach the beams and diaphragms in the storage position.
2. Jacking and Support. The vertical space between the counterweight beams and the counterweight is to be filled with cribbing and hydraulic jacks. The cribbing and jacks are to be designed by the Contractor.
A. Submittals
(1) The design and associated details shall be prepared and sealed by a Professional Engineer licensed in the State of Arkansas. The Contractor shall submit the design to the Engineer for review and approval a minimum of three months in advance of the scheduled bridge closure to river traffic.
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B. Construction Requirements
(1) The approximate weight of each counterweight is 950,000 pounds.
(2) The counterweight is required to be lifted a minimum of 4” from its original position to facilitate the removal of the existing wire ropes. The counterweight is then required to be raised an additional 10” minimum to install the new wire ropes. The total required lift of the counterweight is approximately 1’-2”. See the suggested wire rope replacement procedure provided in the plans on Sheet No. M6. The procured jacks may accommodate this in a single lift, or the design and construction of the cribbing can be developed to allow for progressive jacking and cribbing installation performed in multiple lifts until the overall lift height is achieved.
(3) The jacking and cribbing should be designed to distribute the weight of the counterweight evenly between the four counterweight beams. Furthermore, the jacking and cribbing should be designed to transmit the load to the counterweight beams in one of two ways:
(a) Uniformly distributed load (along the length of the counterweight beam) of a length equal to or longer than the counterweight itself.
(b) Two concentrated or point loads, symmetrically positioned about the centerline of the counterweight beam and no further than 4 feet from the centerline of each support girder.
(4) Cribbing shall be secured to the counterweight support beams to prevent instability.
(5) The jacks and cribbing will remain the property of the Contractor and shall be removed from the site at the completion of the contract.
d. Materials.
1. Fasteners. Bolts shall conform to ASTM F3125, Grade A325, Type 1, and shall be the size indicated on the plans. High strength bolts shall be heavy hexagonal structural bolts with heavy semi-finished hexagon nuts. A hardened washer shall be placed under the turned element. Heavy hex nuts shall conform to ASTM A 563, Grade DH. The washer material shall conform to ASTM F436.
e. Measurement and Payment. Counterweight jacking and support will not be measured for payment.
All work required to jack and temporarily support the counterweights will not be paid for separately but shall be included in the contract unit price per lump sum for the Counterweight Wire Ropes. This shall include the cost for all labor, materials, and equipment necessary to design the jacking and cribbing, jack and support the counterweights during the wire rope removal and replacement, and reinstall the counterweight support beams and diaphragms on the towers in the proper storage locations in accordance with the plans and specifications. See the Counterweight Wire Ropes special provision for additional information.
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BEARING REPLACEMENT
a. Description. The work consists of providing all labor, materials and equipment required for the following: removal of the existing bearing assembly and select obsolete mechanical components; cleaning and painting existing steel surfaces disturbed or modified during removal activities; cleaning and painting existing steel to be in contact with new steel; installation of new bearings, bolsters, and anchor bolts; installation of concrete encasement around new bolster assembly; and jacking and supporting the existing structure during removal of old bearings and installation of new bearings.
b. Applicable Standards.
1. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only. The latest revisions only shall be used for all references.
2. Where not otherwise specified herein, workmanship, materials, fabrication, and erection of the bridge components shall be in accordance with the requirements of the latest revision of The American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Chapters 8 and 15.
3. Other applicable standards:
• AASHTO LRFD Movable Highway Bridge Design Specifications • AHTD - Arkansas State Highway and Transportation Department, Standard Specifications for Highway Construction • ASTM - American Society for Testing and Materials • ANSI - American National Standards Institute • AWS - American Welding Society
c. General Requirements.
3. Field Measurements and Verification.
A. Before commencing any work, ordering any materials, or fabricating any items, verify all relevant dimensions and other relevant characteristics at the job site and ensure their accuracy.
B. The Railroad and the Engineer will not, as a part of shop drawings review, bear responsibility for verification of any field measurements made by the Contractor. Review of shop drawings by the Railroad and the Engineer does not in any way relieve the Contractor from responsibility for the accuracy of field measurements. Full responsibility for any errors that may result from inaccuracy of field measurements and verifications will be borne by the Contractor.
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4. Jacking and Support.
A. Submittals
(1) The Contractor shall submit details and calculations of their proposed jacking systems, cribbing and procedures for approval of the Engineer before commencing work. The system shall be designed and sealed by a Professional Engineer licensed in the State of Arkansas. Approval will not relieve the Contractor of responsibility for the safety of the structure.
B. Construction Requirements
(1) Jacking and cribbing shall be done only at the locations noted on the contract plans.
(2) If unforeseen field conditions preclude the execution of the approved jacking plan, the Engineer may require the Contractor to provide additional supports or measures. All changes to the revised jacking plan shall be approved by the Professional Engineer licensed in the State of Arkansas that sealed the original jacking plan. Neither the added precautions, nor the failure of the Engineer to order additional protection, will in any way relieve the Contractor of sole responsibility for the safety of lives, equipment, and structure.
(3) The Contractor designed jacking system shall include a sole plate to be temporarily connected to the bottom flange of the end floorbeams at the jacking locations. The width of the sole plate shall be approximately equal to the width of the end floorbeam bottom flange.
(4) Jacks shall be provided with a ram head plate approximately equal in contact area as the sole plate at the beam. The ram head shall be centered on the sole plate. A needle beam or fabricated jacking yoke with two jacks will be allowed provided the design meets with the approval of the Engineer.
(5) All jacking at a given pier shall be done simultaneously and all work completed during the same track outage.
(6) The maximum lift is 1/4 in (7mm) and the maximum differential displacement between adjacent jacks is 1/8 in (4mm). Suitable gauges for the measurement of superstructure movement shall be furnished and installed by the Contractor.
(7) Temporarily disconnect the rail from the structure, as needed, to accommodate jacking of the end floorbeam.
(8) The jacking and cribbing may be removed and train traffic may resume after the bolster assembly and bearing have been installed and the anchor rod adhesive has set per the manufacturer’s direction. The concrete encasement does not have to be installed and/or cured for normal train operations to resume.
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5. Removal of Existing Bearings.
A. Construction Requirements
(1) Only after the jacking and cribbing has been installed and approved by the Engineer, may the existing bearings and the indicated mechanical components be removed.
(2) Extreme care shall be taken while removing the existing bearings to prevent damage to the existing structural steel which is to remain. All damage to existing members which are to remain shall be repaired or the member replaced to the satisfaction of the Engineer. Repair or replacement of damaged members shall be at the Contractor’s expense.
(3) Burning of existing fasteners between the existing lower chord and the bearing is not permitted.
(4) Existing steel to be in contact with new steel and existing steel surfaces at areas of steel removal and/or modification shall be cleaned and painted in accordance with the General Notes shown on Sheet S2 of the contract plans.
6. Installation of New Bearings.
A. Product Description
(1) Guided expansion polyether urethane disc bearings are to be installed per the contract plans. Note that the bearings at Pier 3 require uplift resistance.
(2) The Contractor shall select suitable disc bearings that adhere to the load and movement requirements on the plans, as well as all applicable design requirements in AREMA Chapter 15, Section 5.7.
B. Submittals
(1) Prior to the ordering of any materials, the proposed bearings and related shop drawings shall be submitted to the Engineer for review and approval per AREMA Chapter 15, Section 5.8.
(2) The Contractor shall furnish certified copies of the bearing manufacturer’s test reports on the physical properties of the component materials for the bearings to be furnished and a certification by the bearing manufacturer stating the bearing assemblies furnished conform to all requirements shown on the plans and as herein specified. Submittals with insufficient test data and supporting certifications will be rejected.
C. Construction Requirements
(1) Construction materials, fabrication, and installation of the disc bearing shall adhere to the manufacturer’s requirements as well as AREMA Chapter 15, Sections 5.2.6, 5.8, and 5.13 and all other applicable referenced sections.
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(2) Steel Bolster assembly materials, fabrication, and installation shall be according to AREMA Chapter 15, Sections 5.9.2 and 5.9.4.
(3) Anchor rods shall be set in drilled holes and held in place by an approved epoxy or non-shrink grout according to AHTD Section 807.66.
Holes shall be drilled in the concrete to ¼” larger in diameter than the diameter of the anchor rods and to the depth shown on the plans. A template or other approved method shall be used to assure accurate location of the drilled holes. All holes shall be blown free of concrete dust and chips and shall be dry prior to placing epoxy or non-shrink grout. The anchor rod shall be aligned to maintain a perpendicular plane. No load shall be applied to the anchors until the epoxy or non-shrink grout has cured for at least 24 hours.
d. Materials.
2. Fasteners.
A. Fasteners for Guided Expansion Disc Bearing. Bolts and threaded studs shall conform to ASTM F3125, Grade A325, Type 1, hot-dip galvanized, and shall be the size indicated on the plans. High strength bolts shall be heavy hexagonal structural bolts with galvanized heavy semi-finished hexagon nuts. A hardened washer shall be placed under the turned element. Heavy hex nuts shall conform to ASTM A 563, Grade DH, hot-dip galvanized. The washer material shall conform to ASTM F436, hot-dip galvanized.
B. Fasteners for Steel Bolster Assembly. Bolts shall conform to ASTM F3125, Grade A325, Type 1, mechanically galvanized, and shall be the size indicated on the plans. High strength bolts shall be heavy hexagonal structural bolts with galvanized heavy semi- finished hexagon nuts. A hardened washer shall be placed under the turned element. Heavy hex nuts shall conform to ASTM A 563, Grade DH, mechanically galvanized. The washer material shall conform to ASTM F436, mechanically galvanized.
3. Steel. Structural steel shall conform to ASTM A709, Grade 50.
4. Anchor Rod Adhesive. Anchor rods are to be set in drilled holes and held in place by an approved epoxy or non-shrink grout according to the AHTD Standard Specifications for Highway Construction, Section 807.66.
5. Anchor Rods. Anchor rods shall conform to ASTM F1554 and shall be all thread rods of the grade and size indicated on the plans and hot-dip galvanized in accordance with ASTM B695, Class 50. Anchor rods shall also meet the requirements of AREMA Chapter 15, Section 5.3.2.2.
6. Polyether Urethane Disc. Polyether Urethane Discs shall be according to AREMA Chapter 15, Section 5.7.2.d.
7. Sliding Surface. The sliding surfaces shall be according to AREMA Chapter 15, Section 5.7.2.c and 5.4.2.
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8. Concrete. The concrete encasement shall be according to the AHTD Standard Specifications for Highway Construction, Section 802, Class S concrete and conform to the construction requirements of AREMA Chapter 8, Part 1.
9. Welded Wire Reinforcement. Welded Wire Reinforcement shall be according to ASTM A1064, Grade 65.
10. Grout Pad. The concrete grout pad shall consist of a non-shrink grout conforming to ASTM C 1107. The prepackaged product shall be mixed and placed according to the manufacturer’s instructions. Water shall not exceed the minimum needed for placement and finishing.
e. Measurement and Payment. Bearing replacement will not be measured for payment.
The completed bearing replacement at each specified pier will be paid for at the contract unit price per lump sum for the following pay items, which shall include all labor, materials, and equipment necessary to complete the work.
Pay Item Pay Unit
Bearing Replacement, Span 5, Pier 3 ...... Lump Sum
Bearing Replacement, Span 6, Pier 6 ...... Lump Sum
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FOUNDATION PROTECTION RIPRAP
Section 816.02(a)(3) Materials. Stone. Foundation Protection Riprap. Replace the entire paragraph of this section with the following.
Pieces of stone or steel slag for Foundation Protection Riprap shall meet the gradation limits listed in the following table. Gradations produced shall be well graded from coarse to fine in such manner as to produce a minimum of voids.
FOUNDATION PROTECTION RIPRAP GRADATION Percent Passing Rock Size (lb) 1000 600 400 300 170 150 90 50 40 12 10 6 3 1 Riprap 100 50±20 8±8 Gradation
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DUMPED RIPRAP
Section 816.02(a)(2) Materials. Stone. Dumped Riprap. Replace the first paragraph of this section with the following.
“Dumped riprap shall be reasonably free of fines and reasonably well graded between the maximum and minimum rock sizes so as to produce a minimum of voids. In general, the maximum piece size shall be not greater than 12” (0.3 m) in any dimension and approximately 50% of the material shall consist of pieces weighing 35 pounds (15 kg) or more.”
Section 816.04 Method of Measurement. Replace the entire paragraph of this section with the following.
“Filter Blanket and riprap will be measured according to the units of measure herein specified. Quantities shown on the plans for Filter Blanket, Concrete Riprap, Sacked Sand- Cement Riprap, and Dumped Riprap (Grouted) will be considered as the final quantities and no further measurement will be made unless, in the opinion of the Engineer or upon evidence furnished by the Contractor, substantial variations exist between quantities shown on the plans and actual quantities due to changes in alignment or dimensions or to apparent errors, in which case the entire in-place quantity at the affected location(s) will be measured, with measurement being made parallel to the surface. Concrete Riprap, Sacked Sand-Cement Riprap, and Dumped Riprap (Grouted) will be measured by the cubic yard (cubic meter). Filter Blanket will be measured by the square yard (square meter). Dumped Riprap and Foundation Protection Riprap will be measured by the ton (metric ton).”
Section 816.05 Basis of Payment. Replace the first paragraph of this section with the following.
“Work completed and accepted and measured as provided above will be paid for at the contract unit price bid per square yard (square meter) for Filter Blanket; per cubic yard (cubic meter) for the items Concrete Riprap, Sacked Sand-Cement Riprap, and Dumped Riprap (Grouted); or per ton (metric ton) for Dumped Riprap and Foundation Protection Riprap, which prices shall be full compensation for furnishing materials, including reinforcing steel when specified on the plans; for preparation of the slope; for excavation including toe trench and backfill; for performing mix designs, and quality control and acceptance sampling and testing for concrete riprap; for placing; and for all labor, equipment, tools, and incidentals necessary to complete the work.”
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Section 816.05 Basis of Payment. Replace the last paragraph of this section with the following.
Payment will be made under:
Pay Item Pay Unit
Filter Blanket Square Yard (Square Meter)
Dumped Riprap Ton (Metric Ton)
Concrete Riprap Cubic Yard (Cubic Meter)
Foundation Protection Riprap Ton (Metric Ton)
Sacked Sand-Cement Riprap Cubic Yard (Cubic Meter)
Dumped Riprap (Grouted) Cubic Yard (Cubic Meter)
132
BRIDGE INTERLOCKING AND SIGNALS SPECIFICATIONS
PART TITLE
34 42 23 RAILWAY SIGNAL CONTROL EQUIPMENT
34 42 44 SIGNAL ENGINEERING REQUIREMENTS
34 42 45 SIGNAL INSTALLATION REQUIREMENTS
SEALED: 07/23/2021
Rehabilitation and Improvement of the Arkansas River Lift Bridge 133 Arkansas River Lift Bridge, MP 410.6
34 42 23 RAILWAY SIGNAL CONTROL EQUIPMENT
PART 1 - GENERAL
1.1 WORK INCLUDED
A. Contractor shall be responsible for all transportation and storage of materials, all required tools, labor and supervision, and all required safety equipment; and shall maintain good housekeeping about the workplace, observing all laws, rules and regulations concerning storage of equipment onsite, protection of open trenches, work about roadways, work about railways and safety of personnel. The Contractor shall maintain a safe system of work and shall promptly report any accidents, either to staff or to the public, to the Railroad, or its designated representative.
B. Contractor shall be responsible for obtaining all necessary licenses and permits.
C. Contractor shall provide connection from service or service panels to electrical panels located inside the equipment housings.
D. Contractor shall provide complete detailed as-built wiring diagrams, track plan drawings and instrument housing layout drawings, as needed. As-built red-lines will be provided to the Railroad following the approval of the installed systems.
1. Circuit nomenclature and symbols shall conform to the recommendation of the AREMA Communications and Signals Manual. All design shall be to the best current practice and using failsafe principles.
2. During the field installation of the project a working set of the plans shall be maintained with changes and additions to the plans captured, and initialed, as they occur. In addition, a set of testing plans shall be maintained. All changes made to the working set shall be transferred to the testing set. All testing shall be captured, and initialed, on the testing set. At the completion of testing of the installed systems, both the working set and the testing set of plans shall be used to up-date the drawings to as-built condition. As-built plans shall be legible and provided to the Railroad electronically in PDF format and 3 sets 11” x 17” paper. 11” x 17” paper copies of the as-built prints shall be left in left in the signal bungalows.
3. A system of configuration management shall be used to maintain the plans during the course of the project. Revised plans shall be issued as complete sets including all drawings, whether revisions are made to all sheets or not. Drawings that are revised will bear a new revision number and note, and changes to the plan will be highlighted as X=OUT and O=IN.
4. The Contract Drawings are a 100 percent detailed set of drawings that may be utilized as the working construction drawings for the project. Any changes required to the Contract Drawings due to substitutions or to change in the plan of work are solely the responsibility of the Contractor.
E. New construction and modifications to the existing systems shall be compatible with
134 Arkansas River Lift Bridge, MP 410.6
any existing system(s) in all respects, and shall be designed to provide the highest levels of reliability, maintainability, and safety performance within the operational parameters of the existing system.
F. Should interfaces to any existing systems be required, such interfaces shall be made so that the existing and new systems form a complete, functional and seamless signaling system. Existing systems include Electrocode track circuits. Where required, interface shall be compatible with these systems. If deviating from the Contract Drawings, the Contractor shall be responsible for the provision of any required tie-in plans. Such plans shall be prepared under the supervision of an engineer with adequate experience in signal engineering to be competent in the preparation of such plans. Engineer’s resume and tie-in plans shall be submitted for approval.
G. If interface to existing systems is required, the Contractor shall submit a plan identifying specific measures and tests intended to assure compatibility with the existing wayside signaling system. Testing of the Electrocode track circuit interface with Union Pacific Railroad Van Buren Interlocking shall be coordinated by AMRR or their representative.
H. Where required by the Contract Drawings, the Contractor shall determine the suitability of existing infrastructure for reuse in the revised system. This shall include, but not necessarily be limited to, bridge signal mounts, rail seated proximity switches, proximity switch amplifiers, DTMF radio, radio peripherals, cable, conduit and conduit accessories, insulated rail joints, web and head bonds, track connections, insulated rail joints, and insulated gauge plates.
I. Contractor, before beginning the work, shall provide the Railroad a statement confirming that infrastructure that is indicated by the Contract Drawings to be reused is suitable for purpose. Subsequent discovery that existing infrastructure is not suitable for reuse shall not necessarily be grounds for a change to the Contract. Such a change shall only be allowed if in the judgment of the Railroad it was not reasonable for the Contractor to anticipate the situation. The extent to which such a discovery shall be grounds for a change is the sole judgment of the Railroad.
J. Contractor shall work with the Railroad to identify retired equipment and material that is suitable for recovery or otherwise identified as to be salvaged. Equipment and material so deemed shall be protected in place and then transported to the Railroad’s depot at 306 E. Emma Street in Springdale, AR. The Contractor shall be responsible for the safe transfer of such equipment and material. Batteries shall be removed from bungalows and cases prior to their removal and transported separately. Secure any loose items in bungalows and cases prior to their removal or otherwise remove and transport separately.
K. The Contractor shall work with the Railroad to determine the proper phasing of the work and shall be responsible for the provision of temporary tie-in plans. Phasing and tie-in plans shall be approved by the Engineer.
L. All test equipment, ie, meggers and meters, shall bear current calibration stickers from a recognized calibration firm.
135 Arkansas River Lift Bridge, MP 410.6
M. The Contractor shall cooperate with the Railroad to assure that his work with microprocessor-based signal controllers conforms to the instruction of the Railroad’s Software Management Control Plan. The Contractor shall, at his expense, provide his personnel responsible for the execution of the plan any necessary training.
N. The Contractor shall remove all retired signal equipment. Equipment identified for salvage shall be removed in an undamaged condition and delivered to the Railroad’s designated facility.
O. All system testing shall be recorded on test forms. Test procedures and forms for approval shall be submitted at least 30 days before their use.
P. Depending upon the manner in which the project is commissioned, it may be necessary for phasing plans to be provided. The Contractor shall provide the Railroad with a narrative describing the phasing, and its impact on the total project. Additionally, the Contractor shall be responsible for the provision of phasing plans. Phasing narrative and phasing plans shall be submitted at least 30 days before the work is planned to be executed.
1.2 PAYMENT ITEMS
A. Mobilization – Costs of mobilization for signal procurement and construction.
B. Delivery of 8’X10’ Main Bungalow – Includes the procurement, wiring, acceptance testing and delivery of the Main Bungalow and associated equipment per the Contract Drawings to the project staging area as accepted by the Railroad or its Representative.
C. Delivery of 4’X6’ Remote Bungalow – Includes the procurement, wiring, acceptance testing and delivery of the Remote Bungalow and associated equipment per the Contract Drawings to the project staging area as accepted by the Railroad or its Representative.
D. Delivery of Field Material Package – Includes the procurement and delivery of signals, limit switches, junction boxes, cable, and conduit per the Contract Drawings to the project staging area as accepted by the Railroad or its Representative.
E. Test and Commission Interlocking – Includes all signal demolition and removals, installation, inspection, testing and commissioning of the Bridge Interlocking and Signals as accepted by the Railroad or its Representative.
F. Install and Test Track Circuit Connectors – Includes procurement, installation, and testing of the Track Circuit Connectors as well as subsequent removal of existing ariel track circuit jumper cables as accepted by the Railroad or its Representative.
G. Salvage, Cleanup and Disposal – Delivery of salvaged materials to designated location and final staging area and job-site conditions as accepted by the Railroad or its Representative.
136 Arkansas River Lift Bridge, MP 410.6
1.3 ABBREVIATIONS AND DEFINITIONS
A. AC. Alternating Current.
B. AC/DC. Alternating Current/Direct Current.
C. AREMA. American Railway Engineering and Maintenance of Way Association.
D. ASTM. American Society of Testing and Materials.
E. CP. Control Point.
F. PUC. Public Utility Commission.
G. CTC. Centralized Train Control.
H. DC. Direct Current.
I. DTMF. Dual Tone Modulated Frequency.
J. FPM. Flashes per minute.
K. FRA. Federal Railroad Administration
L. G.O. General Order.
M. IEEE. Institute of Electrical and Electronic Engineers
N. I/O. Input/Output.
O. LED. Light Emitting Diodes.
P. ML. Mainline
Q. USCG. United States Coast Guard
1.4 SUBMITTALS
A. Before progressing with the Work, the Contractor shall submit the drawings and catalog cut sheets for equipment to the Railroad for approval. Work performed without the approval of the Railroad shall, at the request of the Railroad, be completely removed, and then performed in an approved manner by the Contractor at no additional cost to the project. All equipment shall be designed for use on the railroad in an environment similar to that of the site and shall have a minimum five year history of use in similar projects.
B. Before progressing with the Work, the Contractor shall submit a phasing narrative describing how the work will be performed and detailing coordination with the bridge contractor. The narrative shall address all construction and demolition required for the project and shall identify a critical path for all the work. Coordination with Railroad
137 Arkansas River Lift Bridge, MP 410.6
operations shall be addressed in the narrative and that measures are taken to assure that Railroad operations suffers a minimum of disruption.
C. The systems shall be fully tested following installation. Testing shall shall follow the requirements of FRA CFR49 Part 234, the requirements of the United States Coast Guard and recommended practices of AREMA. All testing shall be documented using the proper test forms. Factory and Field Test procedures and test forms shall be submitted to the Railroad for their approval at least 30 days prior to the start of testing. No more than thirty days following the completion of installation testing, all documentation, including the as-built red-lines, shall be submitted to the Railroad for approval. The Work shall not be considered as completed until approval of the installation, as-built red-lines, and of the final installation testing is received from the Railroad.
D. If other than ALSTOM Electrocode, the Electronic Coded Track Circuits proposed shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
E. Cable and wire proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
F. If other than ALSTOM ElectrologIXS, the solid-state interlocking, all I/O modules, interface modules, plug-couplers, and other devices required for the system shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
G. If other than ALSTOM ElectrologIXS, the applications logic programming and compiler tools, including those tools required to maintain the configuration of applications software when it is changed, shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
H. Supplier cut sheets for bungalows and cases proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
I. Battery chargers, batteries and battery trays shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
J. If deviating from battery capacities in the contract drawings, all calculations of backup capacity shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
K. Equalizers and lightning arresters shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
L. Binding posts, and required accessories proposed for use, shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
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M. Rail bonds and connections proposed for use shall be submitted to the Engineer for approval. Submittals shall include the means of preparing the rail for welding and the welding materials to be used. Submittals shall be made as described in the appropriate section of this specification.
N. Sealing compounds proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
O. If other than ALSTOM EPC-2TC, the DC Track Circuit Driver proposed shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
P. Pushbuttons shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
Q. Pushbutton boxes shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
R. Color light Signal Head assemblies proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
S. Grounding plan for bungalows, exothermic welds, and ground wire proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification.
T. Conduit, conduit fittings, cleaner solution and solvent cement, pull line, and marker tape proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification.
U. Junction boxes proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
V. Wire and cable tags proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
W. Locks proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of this specification.
X. Tape (Vinyl and Rubber) proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification.
Y. Wayside signs and hardware shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification. This includes any temporary signage identified in the contractor’s work plan.
Z. Terminals, crimping and strip tools, and wire connectors proposed for use shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification.
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AA. Paints, including spray paints used for touch-up, shall be submitted to the Engineer for approval. Submittals shall be made as described in the appropriate section of the specification.
BB. Signals Contract Deliverables Requirement Listing (CDRL)
Specification Section Description 34.42.23 Part 1, 1.1.G Compatibility w/Existing Systems 34.42.23 Part 1, 1.1.I Statement Concerning Suitability of Existing Infrastructure 34.42.23 Part 2, 2.1 Electronic Coded Track Circuits, Electrocode 34.42.23 Part 2, 2.2 Wire and Cable 34.42.23 Part 2, 2.3 Solid-State Interlockings 34.42.23 Part 2, 2.3.A.20 Applications logic programming and compiler tools 34.42.23 Part 2, 2.4 Equipment Houses and Cases 34.42.23 Part 2, 2.5 Batteries, Battery Chargers and Battery Trays 34.42.23 Part 2, 2.5.B Battery Capacity Calculations 34.42.23 Part 2, 2.6 Lightning Arresters and Equalizers 34.42.23 Part 2, 2.7 Binding Posts 34.42.23 Part 2, 2.8 Rail Bonds and Connections 34.42.23 Part 2, 2.9 Sealing Compound 34.42.23 Part 2, 2.10 N/A 34.42.23 Part 2, 2.11 N/A 34.42.23 Part 2, 2.12 N/A 34.42.23 Part 2, 2.13 N/A 34.42.23 Part 2, 2.14 N/A 34.42.23 Part 2, 2.15 N/A 34.42.23 Part 2, 2.16 N/A 34.42.23 Part 2, 2.17 N/A 34.42.23 Part 2, 2.17.A.8 N/A 34.42.23 Part 2, 2.18 N/A 34.42.23 Part 2, 2.18 N/A 34.42.23 Part 2, 2.19 N/A 34.42.23 Part 2, 2.19 Galvanized Foundations 34.42.23 Part 2, 2.20 N/A 34.42.23 Part 2, 2.21 N/A 34.42.23 Part 2, 2.22 N/A 34.42.23 Part 2, 2.23 Track Circuit, Style C 34.42.23 Part 2, 2.24 DC Track Circuit 32.42.23 Part 2, 2.25 N/A 34.42.23 Part 2, 2.25 N/A
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34.42.23 Part 2, 2.26 N/A 34.42.23 Part 2, 2.27 Color light Signal Heads 34.42.23 Part 2, 2.28 N/A 34.42.23 Part 2, 2.29 N/A 34.42.23 Part 2, 2.30 Grounding 34.42.23 Part 2, 2.31 Conduit 34.42.23 Part 2, 2.32 N/A 34.42.23 Part 2, 2.33 Wire and Cable Tags 34.42.23 Part 2, 2.34 Locks 34.42.23 Part 2, 2.35 Tape 34.42.23 Part 2, 2.36 Wayside Signs 34.42.23 Part 2, 2.41 N/A 34.42.23 Part 2, 2.42 N/A 34.42.23 Part 2, 2.43 N/A 34.42.23 Part 2, 2.44 N/A 34.42.23 Part 2, 2.45 Data Radios 34.42.23 Part 2, 2.45 DC-DC Converters for use with Data Radios 34.42.23 Part 2, 2.45 Antennae, Cable and Hardware for Data Radios 34.42.23 Part 2. 2.46 Limit Switch
34.42.44 Part 1.1.4 Project Engineer Resume 34.42.44 Part 1.1.4 Signal Foremen Resumes 34.42.44 Part 1.1.4 As-Wired Plans 34.42.44 Part 1.1.4 As-Built Plans 34.42.44 Part 1.1.4 Test Forms 34.42.44 Part 1.1.4 Tie-In Plans 34.42.44 Part 1.1.4 Phasing Narrative and Phasing Plans 34.42.44 Part 1.1.4 Applications Logic 34.42.44 Part 1.1.4 Software Management Control Plan
PART 2 - PRODUCTS
2.1 ELECTRONIC CODED TRACK CIRCUITS, ELECTROCODE
A. Description: Electronic coded track circuits shall be provided as described in the Contract Drawings. Electronic coded track circuits shall be controlled by a solid- state interlocking and shall either consist of an electronic coded track circuit module to be installed in the solid-state interlocking chassis, or an interface module installed in the solid-state interlocking chassis coupled to track interface panel. The electronic coded track circuit shall be ElectrologIXS VTI-2S, or approved equivalent.
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B. General performance requirements:
1. The electronic coded track circuit provided shall be capable of interface with products of the EC4 and EC5 generations of products.
2. Track circuits shall be separated by an insulated joint installed in each rail.
3. Track codes generated by the electronic coded track circuit transmitter shall consist of DC pulses. Both vital and non-vital track codes, including a tumbledown code, shall be available. A minimum of ten track codes shall be provided.
4. Track circuits shall provide broken rail detection for both rails.
5. Track circuit equipment shall detect the failure of an insulated joint and protect against it causing any unsafe condition.
6. Track codes shall be adjusted such that occupation of the track circuit by a train, a false shunt, a broken rail, a broken track connection, or other fault to the track circuit shall cause the electronic coded track circuit receiver to vitally indicate the track circuit as occupied. The electronic coded track circuit shall be powered from a backed DC source such that a failure of the public utility power shall not cause a failure of the track circuits.
7. Track circuit resistors shall comply with the requirements of AREMA Communications and Signal Manual Part 14.2.15.
8. Track circuit connections shall be protected from a line-to-ground fault by heavy-duty line arresters and from line-to-line faults by a surge equalizer.
C. Detection Requirements:
1. Track circuits shall detect a shunt anywhere within the track circuit boundaries. Shunting sensitivity shall be 0.06 Ohm with a rail-to-rail leakage impedance of 3 Ohms minimum per 1,000 feet of track at the operating frequency, under the following conditions:
a. Train moving or stopped.
b. Rail condition for prevalent operation; that is, a secondary, lightly used line where the rail is subject to accumulations of rust and scale.
2. Failure of track circuit components shall not permit the shunting sensitivity to fall below that specified after the track circuit has been properly adjusted. Failures of track circuit components shall result in failsafe operation.
D. Track Devices: Insulated rail joints, insulated switch rods, and insulated gauge plates shall be furnished and installed by the Contractor; however, this specification does not intend to describe the insulation to be provided, nor the method of installation. The Contractor shall be responsible for inspection of the track and
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provision and installation of the required devices. Failure of the Contractor to anticipate the required devices shall not result in additional cost to the Department.
E. Track Leads: The Contractor shall provide and install connections to the rails, and all other material and apparatus including track and jumper bonds, as required for a complete track circuit installation.
F. Design Requirements:
1. The equipment shall meet FRA requirements. The equipment shall meet or exceed the standards and requirements of the AREMA Communications and Signals Manual of Recommended Practice. The equipment shall be applied per the recommendation of the manufacturer. Track circuits shall be configured as described in the Contract Drawings.
2. All terminations, cable materials, and methods shall be of commercially available types. Any terminals for the direct connection of underground single or multiple conductor cables shall be AREMA approved binding posts. An insulating test device enabling the wire to be opened for meggering or testing without removing the wire from the terminal shall be installed where underground single or multiple conductor cables enter the Equipment House.
3. Parts shall be available for a minimum of ten (10) years after Final Acceptance.
4. Environment: Equipment shall meet the basic temperature requirements, without heating or cooling enhancements such as heating strips and fans.
5. Inputs for the equipment shall be electrically and physically isolated from one another.
6. Outputs for the equipment shall be electrically and physically isolated from one another.
7. Mounting: The track driver equipment shall be capable of being mounted in a standard relay rack
Lightning Protection: Lightning protection devices shall be provided according to the manufacturer's standard. Protection against lightning, surges, spikes, and over-voltage shall be provided. The Contractor shall protect all input and output lines and any auxiliary equipment as necessary.
Because of the low input impedance of the electronic coded track circuit, where audio frequency track circuits are superimposed on electronic coded track circuits a choke shall be installed in one of the track leads.
2.2 WIRE AND CABLE
A. Requirements: The Contractor shall furnish and install the wire and cable required for the work.
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B. Cables shall be suitable for installation in direct contact with earth, in trenches, cable ducts, troughs, on messengers, or in any combination of these methods.
A. Control Cable shall conform to or exceed the following requirements:
1. All cable shall be suitable for direct burial, hanging on messenger and installing in conduit. The cable furnished shall be compact and shall be of the highest standards of the industry. There will be no relaxation on the quality of the materials or thickness specified. Cable used for aerial installation and/ or exposed installation shall be specifically qualified as Aerial type cable.
2. The conductor shall be soft annealed solid copper.
3. Each shipped length of cable shall bear a marking (full length) showing the name of the manufacturer. Multiconductor cable shall also be marked with the year of manufacture. Single conductor cable shall also be marked with the wire gauge number.
4. The Contractor shall furnish Manufacturer’s catalog sheets stating compliance of the tests called for in the respective IEEE, ASTM and ICEA-NEMA Specifications.
5. The Contractor shall procure the cable from a manufacturer who has had adequate successful commercial experience in the manufacture of the basic type of cable the Contractor proposes to furnish.
D. Control cable shall conform to, or exceed, the following minimum requirements:
CABLE DESIGN AWG CONSTRUCTION Colorlight Signal 5C # 6 Solid Limit Switch 7C # 14 Solid Track Circuit 2C # 6 TW Solid Track Circuit Connection 1C 3/16” Stranded
Battery Buss and Supply # 6 Stranded Type B1 & B2 Relay Wiring # 16, # 10 Stranded
1. These Specifications provide for single and multi-conductor insulated and jacketed cable for installation in direct contact with the earth, in conduit or pipe, or any combination of these types of installations, on circuits rated at up to six hundred (600) volts.
2. The signaling cable required for this project shall consist of the following types:
a. Sizes of wire stated above shall be considered minimum. The Contractor shall be responsible for sizing the cable to accommodate the calculated load.
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b. Coordinate with Electrical Contractor for cable/ conductor requirements for 120/ 240VAC power.
c. In addition to the number of active conductors that are required in these types of cable in order to provide a complete working Train Control System, the following spare conductors shall also be provided:
1) Fifteen 15 percent spare conductors with a minimum of one 1 spare conductor in each main line cable. If multiple cables run to the same destination, the spares for all cables may be consolidated in one construction, provided that the requirement for total spares is still met.
2) Spare conductors are not required in track circuit feeds.
E. Qualifications:
1. The manufacture of cables in accordance with the requirements of these Specifications shall be accomplished in compliance with a Quality Assurance Program that meets the intent of ASQC Standard C1, General Requirements for a Quality Program. Such compliance shall assure the production of properly designed, well made, and thoroughly tested cable, which will render long service life to the user. Efficient methods of production test and production evaluation shall be used, but prime concern shall be focused on the necessary formal quality requirements to ensure that cable failure cannot be attributed to actions or lack of actions by the manufacturer.
2. To assure accountability and traceability in applicability of the quality assurance plan, the manufacturer shall prepare, and apply conductor insulating materials and cable outer coverings and shall perform conductor insulating and cable assembly and testing in its own plant.
3. If the vendor does not normally prepare insulating materials in its own plant, it is acceptable for the vendor to have its proprietary formulations prepared at another non-owned facility. This facility shall be subject to the same Quality Assurance procedures and systems the vendor uses in its own facilities.
4. Cable design and insulation materials offered for this service shall have a minimum of 15 years reliable experience on vital circuit signaling cables with a minimum of at least 2 million cable feet installed.
F. Conductor: The conductor shall be solid and shall conform to ASTM B33 or ASTM B3.
G. Insulation (Signal Cable):
1. The insulation shall be a synthetic rubber compound consisting substantially of ethylene propylene rubber and shall meet the experience requirements, and pass the qualification requirements of these Contract Documents.
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2. The insulation shall be applied by the continuous tube method without joints; it shall be properly vulcanized homogeneous in character, tough, elastic, concentrically applied about the conductor, and shall fit tightly thereto. Where an insulating jacket is applied over the insulation, it also shall be homogeneous in character, tough, elastic, concentrically applied about the conductor, and shall fit tightly thereto.
3. The insulating compound shall be clean and free stripped, leaving the coated conductor unimpaired and ready for soldering.
4. Insulation on Aerial cables shall meet the requirements of AREMA Class B insulation.
H. Identification:
1. Multi-conductor Cable: Each length of cable shall be permanently identified as to the manufacturer and year of manufacture, at intervals not more than one foot, with a moisture resistant marker tape under the jacket and parallel to the longitudinal axis of the cable.
2. Single Conductor Cable. It shall be identified by a printing, contrasting painted, printed or manufacturer’s color threads. The printing shall be on the outer jacket and parallel to the longitudinal axis of the cable. The color threads shall be placed under the outer jacket and parallel to the longitudinal axis of the cable.
I. Inspections and Tests:
1. Types of Tests. The manufacturer shall, at the point of production, carry out all of the following tests:
a. Conductor size and physical characteristics
b. Insulation high-voltage and insulation resistance tests c. Physical dimension tests
d. Final, high-voltage, insulation resistance and conductor resistance tests on shipping reels.
2. Certified Test Reports: The Contractor shall furnish certified electrical and physical test reports for the finished single conductor and multiple conductor cables on request.
3. Rejected Cable: Cable, which does not meet the minimum requirements of these Specifications, will be rejected. Wire or cable, which shows defects or non-compliance with these Specifications, after arrival at the Project destination, will be rejected and returned to the manufacturer at no additional cost to the Contract.
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2.3 SOLID-STATE INTERLOCKINGS
A. General: Solid-state interlockings shall be provided as described in the contract drawings. They shall be capable of interface with typical signal apparatus such as relay coils, switch machines, LED signals, and electronic coded track circuit transceivers. Software for solid-state interlockings shall consist of an executive and an application. Both the executive and the application may consist of a vital and a non-vital software. The vital executive software shall provide for the fail-safe operation of inputs and outputs. The vital application software shall provide for site specific operation. Non-vital executive software, if required, shall provide for control of communications ports associated with the solid-state interlocking, diagnostics, recorders, and interface with local control panels. Non-vital applications software shall provide the site specific information required for the non-vital interfaces, such as the local control panel. In the event that the solid-state interlocking proposed for use does not require non-vital executive and applications software, it shall still be capable of the interfaces described in this part. The solid-state interlocking shall be the ALSTOM ElectrologIXS VLC.
1. The solid-state interlocking shall be capable of fail-safe operation when performing vital functions. All I/O modules used for vital functions shall be designed to be fail-safe. No non-vital I/O modules shall be used to perform vital functions. Where separate software is provided for vital and non-vital functions, care will be taken to assure that vital functionality is not performed by the non- vital software and that non-vital variables are not used to perform vital functions in the vital software. Where non-vital variables are shared between the non- vital and vital software, methods will be used to ‘vitalize’ the non-vital variables used in the vital software much as non-vital contacts are ‘vitalized’ when used in relay circuits.
2. The solid-state interlocking shall be protected against surge as recommended in AREMA Communications and Signal Manual, Part 11.3, and as recommended by the manufacturer.
3. The solid-state interlocking shall conform to the requirements of FCC Rules Part 15, Subpart B for unintentional radiators.
4. The solid-state interlocking shall be suitable for mounting in standard 19 inch EIA racks.
5. All electrical components associated with the solid-state interlocking, with the exception of primary surge protection, shall be mounted on plug-in circuit boards or plug coupled subassemblies.
6. All circuit boards or subassemblies of the same type shall be interchangeable. Switches, jumpers and non-volatile memory shall be mounted I the main frame of the system or confined to site-specific plug-in circuit boards that can be easily transferred to a new solid-state interlocking chassis.
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7. The solid-state interlocking shall provide communications ports capable of both vital and non-vital interface. Serial ports shall be compatible with RS-232, RS- 422 and/or RS-485.
8. The solid-state interlocking shall be capable of driving standard railroad signal LED units or incandescent lamps. Lamp driver circuitry shall provide both hot and cold filament checks for light-out protection. Lamp driver circuitry shall be capable of flashing outputs. Lamp drivers shall permit the use of common-wire lighting circuits.
9. Relay driver outputs shall be capable of driving a load of a minimum of 100 ohms. Vital relay driver outputs shall be two-wire.
10. Relay inputs shall be capable of detecting neutral and polar circuits. Vital inputs shall be two-wire.
11. The solid-state interlocking shall provide for non-vital communication with office code systems, local control panels, recorders, and, through a diagnostic port, with PCs. Vital communications shall be provided using a secure vital protocol.
12. The vital application software shall provide for slow release of inputs, and through timers, for various timing functions such as slow pick, etc. Vital timers shall be provided as part of the vital application software.
13. The solid-state interlocking shall attempt to reboot following any fault that causes the system to reset. It shall not be required for an outside input to be applied to start the reboot process.
14. The solid-state interlocking should provide a means of identifying the checksums and CRCs of all executive and applications logic via the diagnostics.
15. A means shall be provided to ‘key’ the solid-state interlocking such that only the applications logic intended for a particular site can be run at that site. Applications logic will be similarly keyed.
16. Plug-in modules shall be keyed such that they cannot be inserted in the wrong slot in the solid-state interlocking chassis, or, in the case that they are installed in the wrong slot, the applications logic will not execute and the modules will not be damaged.
17. The executive logic for the solid-state interlocking shall be written by the manufacturer and shall not be able to be modified by the user. Executive logic must be version controlled such that the configuration of the software can be verified as required by FRA 236.18.
18. The applications logic for the ElectrologIXS shall be provided by the Engineer. The compiler for the software shall provide a configuration for the software that consists of a checksum and CRC. Configuration for the software must be controlled as required by FRA 236.18.
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19. A means must be provided by the manufacturer, and used by the Contractor, to assure that configuration of the applications logic is maintained in the event that changes to the logic are required. This means must provide a difference listing to assist in the formation of a minimum retest plan.
20. Applications logic compiler and tools for validating logic and changes to application logic shall be such that applications logic can be presented in a ladder logic, or relay logic format. Boolean format, or other formats, shall not be acceptable. Validation tools shall provide both a certificate confirming the validity and configuration of the applications logic and difference reports for changes to applications logic. Difference reports shall clearly indicate changes to the applications logic providing before and after constructs in a ladder logic, or relay logic, format.
2.4 SIGNAL SHELTERS AND SIGNAL CASES
A. General:
1. All equipment shall operate correctly and without damage over a temperature range of minus forty degrees to one hundred sixty degrees Fahrenheit (-40°F to 160°F). Where AREMA requirements for specific equipment exceed the limits of this temperature range, such equipment shall conform to requirements set forth by the AREMA.
2. The Equipment House shall be identified by a name/address sign. The name/address signs shall be installed adjacent to the main access door. Make the sign of A-2 aluminum, 0.080-inch thick minimum, secured by stainless steel vandal proof screws, white reflective enamel background with silk-screened, black enamel lettering. The Railroad shall provide a name and address for the sign. The Contractor shall submit the name/address sign to the Railroad for review. Signs shall include lettering as follows:
First line - [Street Name or Location]
Second line - [Street address or Milepost]
DOT number – [Highway crossings]
3. The Equipment House shall be furnished complete with an electrical panel including main breaker and required branch breakers as described in the Contract Drawings.
4. The Equipment House shall be constructed to comply with BOCA (Building Officials & Code Administrators International, Inc.) Section 1610.6.4 – Mechanical, Electrical Component and Systems Coefficient (C ) and C Performance Factor (P).
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B. Description:
1. Size and Equipment Mounting.
a. Equipment Houses and Cases shall be sized as described by the Contract Drawings.
b. Clearances as described in the Contract Drawings shall be observed for the installation of equipment, racks, terminal boards and shelves.
c. Relays and electronic components which require periodic test and adjustment shall be mounted a minimum of 18 inches above floor level and not higher than 6 feet, 6 inches (6’ - 6”) above floor level, as described by the Contract Drawings and Specification..
2. Equipment House:
a. Minimum interior headroom is 7 feet. Width and length shall be as described in the Contract Drawings.
b. The Equipment House shall be located as described in the Contract Drawings, but in no case shall the Equipment House or Case be allowed to intrude into the dynamic envelope of operating trains.
C. Construction:
1. Equipment House shall be of a walk-in modular construction fabricated of 0.100 inch 3003 aluminum with PVC peel coat to the protect exterior surfaces of walls, doors and the roof during manufacturing. The peel coat shall be removed before shipping. House walls shall be insulated with 1” fiberglass faced polyisocyanurate panels and the doors shall be insulated with 2 inch panels of a similar material. The walls shall then be covered with 31/32 inch plywood laminated with .045 inch plastic. The House ceiling shall be insulated with 2 inch panels covered by .045 inch plastic panels.
1. All exterior seams shall be caulked with gray RTV silicone. A manufacturer’s nameplate with the Equipment House serial number shall be riveted above the door on the (D) side of the house.
2. A threaded grounding stud shall be provided 6 inches above the floor on wall (B) of the Equipment House. The stud shall extend through the wall and shall provide for continuous electrical contact with the exterior shell of the Equipment House. Two securing nuts, two flat washers, a star washer and a locking washer shall be provided on the outside threads of the stud. A rubber hose shall be placed over the stud and taped in place to protect the threads during shipment. Two securing nuts, two flat washers, a star washer and a locking washer shall be provided on the inside threads of the stud. The stud shall provide a central ground point for all systems within the Equipment House.
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4. The Equipment House floor shall be constructed of .125” 3003 aluminum, and shall be finished with 1/2 inch insulating material. The insulation shall be covered by a 1/4 inch non-skid, non-grooved rubber mat.
5. A lockable door shall be provided at each end of the Equipment House, designated (B) and (D) as shown in the Contract Drawings. The (D) door shall provide access to the house. The main terminal board shall be in-stalled at the (B) end and the (B) door shall provide access to the rear of the terminal board. Both (D) and (B) doors shall be equipped with gutters and/or rain shields.
6. All doors shall be equipped with three-point latching devices, which ensure that the door cannot be locked until it is completely closed. Hasps and handles shall be reinforced and partly shielded to prevent breakage. The door locking mechanism shall be configured so the door can be opened from the inside even if a padlock has been inserted in the exterior locking hasp. Each door shall contain ventilating openings in accordance with manufacturer’s standards. Louvers shall be closable, covered with fine stainless steel mesh screens and protected by weather caps, which shall prevent the entrance of moisture.
7. All doors shall be equipped with lubricated hinge fittings and with hooks to hold the doors open at either ninety or one hundred eighty degree (90 degrees or 160 degrees) positions.
8. All doors shall have gaskets to prevent dust and water incursions.
9. Lifting hooks shall be provided at all four corners of the Equipment House which shall allow completely wired and equipped houses to be lifted into place. The lifting hooks shall be integral to the house and shall be designed to prevent damage during handling and lifting into place. The Equipment House shall have sufficient structural strength that no additional bracing is required to permit lifting by an overhead crane for loading, unloading and placement on the house foundations.
10. Houses shall be constructed and installed without contact between dissimilar metals, to prevent electrolysis.
11. The interior of the Equipment House shall be insulated with a minimum of 1 inch thick fiberglass insulation on the walls and 2 inch thick fiberglass insulation in the ceiling and doors. The Equipment House shall be equipped with a 120 volt AC thermostatically controlled exhaust fan.
12. The Equipment House shall be equipped with one ceiling mounted exhaust fan with closable weatherproof aluminum louvers. The Equipment House doors shall also be provided with a closable weatherproof louver covered by a fine screen mesh and provided with filters to allow cross-ventilation of the house when the exhaust fan operates. The exhaust fan thermostat shall allow the fan to turn on automatically when the temperature inside the house reaches ninety degrees (90 degees F). The exhaust fan shall be protected by its own circuit breaker on the power panel.
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13. The Equipment House shall be equipped with shelves as described in the Contract Drawings. Shelves shall be constructed of 1” shelving material and shall be mounted to 3/8 inch by 1 1/2 inch steel bar brackets bolted to the vertical keyways on the wall. Shelves shall be painted white and then covered on their upper surface by 1/4 inch non-grooved rubber mat. Shelf brackets and miscellaneous hardware shall be finished with white polyester powdercoat or with zinc plated clear chromate.
14. Field cables shall enter the house by means of 4-3/4 inch sealed ducts in the floor adjacent to the (C) door. Four three-foot lengths of 4 inch schedule 40 PVC conduit with one end finished with a collar shall be provided to serve as the cable entries. All cable entrance conduits shall be sealed with a pliable duct sealant following the installation of cable.
15. Overhead ladder type cable trays shall be provided to route the cables to the racks, terminal boards and shelves. Cable trays shall provide a continuous means of routing cables along walls (A), (B), (C) and (D) of the Equipment House and shall extend from wall to wall over the centerline of the equipment rack. Cable trays shall be 6 inches wide and 3 inches deep with 9 inch rung spacing. Cable trays and miscellaneous hardware shall be finished with white polyester powdercoat or with zinc plated clear chromate. The finish shall be smooth to the touch with no sharp burrs that might snag the insulation on wire or cable laid in the trays. Where wire and cables make transitions in the trays, rub strips shall be placed over corners of the tray or over the rungs to provide further protection for cable and wire insulation.
16. A terminal board shall be provided in front of the cable entry ducts on wall (B) as described in the Contract Drawings. The terminal board shall provide space for landing and terminating outside cables, mounting surge arresters and equalizers for circuit protection and joining the cable conductors with wires from the inside house crossing logic circuits, as well as providing space for the mounting of relays, track voltage generators, power-off transformers and other equipment as described in the Contract Drawings.
17. The terminal board shall be constricted of 3/4 inch MDO plywood in a width and height as described in the Contract Drawings. The terminal board shall be pre- drilled for the landing of cable conductors as described in the Contract Drawings. Drilled holes shall be deburred, and splintered areas around holes shall be filled with wood filler and sanded smooth. Holes shall be through- painted. The terminal board shall be painted white.
18. The terminal board shall be wrapped with a rigid aluminum frame of a height and width as described in the Contract Drawings. The frame shall be bolted to the floor of the equipment house and shall be equipped with brackets that are bolted to the ladder type cable tray. The seams of the frame shall be welded. All seams and corners of the frame shall be free from burrs and sharp edges. The frame and all miscellaneous hardware shall be finished with white polyester powdercoat or with zinc plated clear chromate.
19. Three relay mounting bars and two relay tie bars shall be provided at the top of
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the terminal board as described in the Contract Drawings to provide mounting space for relays, track voltage generators, power-off transformers and other equipment as described in the Contract Drawings. The relay mounting bars shall be spaced to provide for the mounting of relay bases for B or ST style relays. The relay bars, relay tie bars and miscellaneous hardware shall be finished with white polyester powdercoat or with zinc plated clear chromate.
20. Power for the Equipment House shall be as described in the Contract Drawings. The Contractor shall coordinate with the Electrical Contractor. The feed cable shall be run in conduit and secured to the house structure. All wiring shall be per the best practices of the NEC and shall be sized, at a minimum, as described in the Contract Drawings.
21. AC power shall be brought into the Equipment House via a 100 Ampere, one hundred twenty/two hundred forty (120/240V) volt, 3-wire, UL approved Load Center panel. The panel shall be as furnished by Square D, or approved equivalent. A secondary surge arrester shall be provided on the incoming feed to the panel as described in the Contract Drawings.
22. The circuit breakers shall be thermal-magnetic type, UL rated. Main and branch breakers shall be provided as described in the Contract Drawings. All circuits shall be identified by name on the inside of the panel door.
23. LED ceiling lights and convenience outlets. LED ceiling lights shall be provided. 6’ X 6’ Houses and larger shall have 2 rows of LED ceiling lights. Light housings shall be securely attached to the house structure using appropriate brackets. All wires to the lights shall be run in flexible metal conduit. Housings shall not be used as junction boxes. The lights shall be switched by a switch located on wall (D) near the entrance door of the Equipment House. Two convenience outlets shall be provided on wall (D) near the entrance door and a further two convenience outlets shall be provided on wall (B). The outlets shall be fed by a GFCI (Ground Fault Circuit Interrupter) breaker as described in the Contract Drawings. The fluorescent ceiling lights and the convenience outlets shall be fed from separate branch circuit breakers as described in the Contract Drawings.
24. Provisions shall be made for a portable generator to be installed to supply power in the event of a loss of utility electrical power. A 30A, 240V, 2 pole, 2 wire branch circuit breaker, interlocked with the main breaker, such that only one power source can be fed to the panel at a time, shall be installed. The generator receptacle shall be installed through the wall of the Equipment House with the outside socket covered by a weatherproof, gasketed cover. The receptacle shall be of a locking type. The Railroad shall provide guidance to the Contractor concerning the configuration of the socket for the generator receptacle.
25. A separate branch breaker shall be provided for each battery charger and for the thermostatically controlled exhaust fan as described in the Contract Drawings. The receptacles for the battery chargers shall be 240V, locking type. All wiring to the receptacles and to the exhaust fan shall be run in flexible metal
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conduit.
26. The Equipment House shall be factory wired and tested in accordance with the Contract Drawings of the circuit and wiring diagrams. Wire, cable, wire and cable termination, cable entrances, and tagging shall be provided in accordance with the Contract Drawings. All bundled wire shall be tied approximately every 3 inches with Nylon straps in accordance with AREMA recommendations. No more than 2 wires shall be terminated on any 1 terminal post. Wire, with the exception of wire used within the LCP, shall be ETFE insulated as described in AREMA 10.3.14.
27. All wires terminated on AREMA type binding posts strips shall be fitted with an approved insulated crimp type terminal. Wire eyes shall not be permitted in stranded wires. Solid conductors may be eyed, but insulation shall not be removed by ‘ringing’ the conductor. Insulation shall be carefully removed from the conductors without marring the finish. Eyes will be large enough to slide easily over the binding post, but shall not be so loose as to extend outside the washers placed over and under the conductor. The terminals used on stranded wire shall conform to Section 14.1.1 of the AREMA recommendations.
28. All vital wiring shall be minimum No. 16 AWG, stranded and terminated in accordance with AREMA recommendations. No. 22 AWG wire is permitted when called out specifically for the use of jumpers between cage clamp terminals.
29. All wiring shall be provided with sufficient slack to prevent stress or pulling on any termination point. All relay-connected wires shall be of sufficient length to permit them to be moved to any contact on the same relay or around bends. All bends in cable/wires shall be greater than the minimum bending radius of the cable/wire recommended by the manufacturer.
30. Terminals shall be placed on the wire by means of a standard forming tool of the proper size, which is equipped with a lock to guarantee that the proper pressure is applied before the tool is released. Care shall be taken to assure that the correct size of wire terminal is used, and that the wire is thoroughly cleaned and centered properly in the wire terminal when using the forming tool.
31. Wire terminals shall not be bent, nicked or otherwise damaged. An approved wire-stripping tool shall be carefully used to remove the insulation from No. 9 AWG and smaller wires. Scraping of these conductors with any sharp instruments shall not be permitted. For wires larger than No. 9 AWG, a knife may be used to remove the insulation, with extreme care being taken to prevent nicking the conductors. The Contractor shall submit catalog data and samples of the terminals proposed for use in connecting all wires to binding posts.
32. Connections to bases for plug-in relays and similar connections crimped using an approved connector. Not more than 2 wires shall be attached to a terminal of the relay bases.
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33. The terminal board shall be located in front of the cable entrances to accommodate cable entrances as described in the Contract Documents.
34. The terminal board shall be used for wire and cable termination, including lightning arresters.
35. Wire and cable shall be brought to the rear of the terminal board and terminated to the binding posts through holes drilled next to the termination point. The holes shall be capable of accepting the largest diameter wire lug to be terminated on the terminal board. All wires and cables shall be run, trained, tagged and terminated in a neat and workmanlike manner.
36. Insulated nuts shall be provided on all AREMA terminals energized with 50 volts or more.
37. Cables entering from the outside of the Equipment House shall be run and terminated such that any wire in a cable can be relocated to any place on the terminal board.
38. The Equipment House shall be securely mounted per Manufacturer’s recommendations and requirements of the Contract Drawings.
2.5 POWER SUPPLIES, BATTERY CHARGERS AND BATTERIES
A. General: All DC power supplies furnished under this Contract shall meet the following minimum basic requirements:
1. Batteries and chargers shall be provided.
2. Cooling.
a. The power supplies shall be natural convection cooled. No supplementary fans or other cooling devices will be allowed.
3. Duty Cycle: The power supplies shall be rated for a continuous duty cycle.
4. Input Voltage: The power supplies shall not be damaged by a sustained input voltage varying from 0-150 percent of the rated input voltage.
5. Current Rating: The power supplies shall be sized in such a manner that no individual power supply operates at less than 20 percent of its rated current output during normal operation.
6. Output Current: The power supplies shall self-limit their output current to no more than 200 percent of their rated load unless otherwise specified herein. Reverse output current protection shall be provided to prevent shorting or sagging of tandem supplies in the event of a filter capacitor failure.
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7. Identification: Each power supply shall be clearly and permanently labeled with the following:
a. Manufacturer's name.
b. Part or model number.
c. Serial number.
d. Input rating. e. Continuous output rating.
8. Chargers shall be fully programmable.
B. Batteries and Chargers: Maintenance-free storage batteries and chargers shall be supplied. Each battery bank shall consist of maintenance free storage cells, sized per the Contract Drawings. Electronic Equipment battery banks shall be sized so that the operating voltages and currents are maintained for a minimum of 24 hours under normal operating conditions. Lighting and Gate Control battery banks shall be sized so that the operating voltages and currents are maintained for a minimum of 8 hours of continuous operating conditions. Switch Control battery banks shall be sized so that the operating voltages and currents are maintained for a minimum of 24 hours under normal operating conditions.
1. The charger for this battery shall be regulated and filtered. Output shall be adjustable up to 19 volts. Ripple shall not exceed 1 volt peak-to-peak at 30 Amperes output.
2. The charger/battery shall be able to maintain/charge the batteries in both float and equalizing charge modes.
3. The chargers shall be NRS ERBC models 12/20, 12/40 or 24/30, or approved equivalent.
4. Batteries shall be maintenance-free storage batteries sized as described in this section. The electronic equipment battery banks shall have a nominal voltage of 12VDC. The lighting and gate control battery banks shall have a nominal voltage of 14VDC. The switch control battery banks shall have a nominal voltage of 30VDC. Batteries shall be GNB Absolyte, or approved equivalent.
5. Battery trays shall be provided for all battery sets. Trays shall be sized as required to accommodate the battery sets and shall be as provided by FIBERCO, or approved equivalent.
2.6 LIGHTNING ARRESTERS AND EQUALIZERS
A. Lightning arresters shall be provided to protect signaling equipment.
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B. Arrester Types:
1. Signaling arresters shall be specifically designed for railway signaling use.
2. The primary function of the signaling arresters shall be to provide line-to-ground protection. This requirement shall not exclude the arrester from performing other functions.
3. Arresters, line-to-ground type
a. The arrester shall pass negligible current at rated circuit voltage.
b. The arrester failure mode shall be to open rather than short circuit or partially short circuit.
c. The arrester shall be suitable for use on circuits of 0 to 35 volts DC without circuit impedance restrictions.
d. The arresters shall have an average DC breakdown voltage of 1,000 volts or less.
e. Arresters shall have a maximum impulse spark over voltage not exceeding 2,000 volts peak for an impulse with a 10 –kV/microsecond rise time. The arrester shall be heavy-duty clearview manufactured by Safetran Systems Corp., or acceptable equal.
2.7 BINDING POSTS
A. Signal circuits shall be terminated on terminal binding posts. Terminal binding posts shall be in accordance with AREMA Communications and Signals, Part 14.1.0.
2.8 RAIL BONDS AND CONNECTIONS
A. Signal rail bonds shall be rail head type manufactured bonds prepared for welding. The bonds shall be as described in AREMA Communications and Signals Manual Part 8.1.30. Signal rail bonds shall be as manufactured by Erico Products, Inc., or approved equal. These bonds shall be manufacturer's bonds prepared for welding by the exothermic process. Non-signaled track shall be double-bonded for the length of the track circuit. B. Signal rail connections shall be manufactured connections prepared for welding. The bonds shall be as described in AREMA Communications and Signals Manual, Part 8.1.32. Signal rail connections shallbe as manufactured by Erico Products, Inc., or approved equal.
2.9 SEALING COMPOUND
A. Sealing compound shall meet the requirements of the AREMA Communications and Signals Manual, Part 15.2.15.
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2.10 NOT USED
2.11 NOT USED
2.12 NOT USED
2.13 NOT USED
2.14 NOT USED
2.15 NOT USED
2.16 NOT USED
2.17 NOT USED
2.18 NOT USED
2.19 GALVANIZED FOUNDATIONS
A. Galvanized Steel Foundations shall conform to the requirements of AREMA Communications and Signals Manual Parts 4.4.17 through 4.4.23, as appropriate.
1. Steel used in the foundations shall conform to the requirements of ASTM Standard A35/A36M-96. Steel shall be hot dipped galvanized and shall conform to the requirements of ASTM standard A123/A123M-97A and shall have a minimum galvanized thickness of 0.0034 inches.
2. Bolts, nuts and washers shall be galvanized or zinc plated and shall conform to AREMA Communications ands Signals Manual Part 15.3.1.
3. All joints shall be welded by certified welders using certified welding procedures.
2.20 NOT USED
2.21 NOT USED
2.22 NOT USED
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2.23 TRACK CIRCUITS, STYLE C HALF-WAVE RECTIFIED AC/DC
A. Description: Track circuits shall be style C, half-wave rectified AC/DC. Track circuits shall utilize both running rails, and shall provide reliable train detection on lightly used rail that may be coated with rust or scale. The track circuit driver shall be a GETS TD-4 or approved equivalent.
B. General performance requirements:
1. Track circuit drivers shall consist of a DC to AC inverter and power amplifier. At least four track driver outputs shall be housed in a single unit. Track drivers shall be capable of operation from DC sources ranging from 10 to 16 volts.
2. Track circuits shall be terminated by a diode rectifier. Track circuits shall be separated by an insulated joint installed in each rail. In order to prevent the detection of approaching trains beyond the termination point of the approach track circuits, insulated joints shall be installed in each rail at the extent of the crossing approaches.
3. Diode rectifiers shall be constructed specifically for use in style C track circuits and shall be housed in a weather-proof enclosure that is designed to be fastened directly to ties between the rails. Diode rectifiers shall be GETS Ring 10, or an approved equal.
4. Track circuit drivers shall be capable of driving a standard 4 ohm track relay.
5. Track circuits shall provide broken rail detection for both rails.
6. Track circuit equipment shall detect the failure of an insulated joint and protect against it causing any unsafe condition.
7. Track circuits shall be normally energized such that occupation of the track circuit by a train, a false shunt, a broken rail, a broken track connection, or other fault to the track circuit shall cause the track relay to be de-energized.
8. Track circuit drivers shall be powered from a backed DC source such that a failure of the public utility power shall not cause a failure of the track circuits.
9. Track circuit resistors shall comply with the requirements of AREMA Communications and Signal Manual Part 14.2.15.
10. Track circuit connections shall be protected from a line-to-ground fault by heavy-duty line arresters and from line-to-line faults by a surge equalizer.
C. Detection Requirements:
1. Track circuits shall detect a shunt anywhere within the track circuit boundaries. Shunting sensitivity shall be 0.06 Ohm with a rail-to-rail leakage impedance of 3 Ohms minimum per 1,000 feet of track at the operating frequency, under the following conditions:
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a. Train moving or stopped.
b. Rail condition for prevalent operation; that is, a secondary, lightly used line where the rail is subject to accumulations of rust and scale.
2. Failure of track circuit components shall not permit the shunting sensitivity to fall below that specified after the track circuit has been properly adjusted. Failures of track circuit components shall result in failsafe operation.
D. Track Devices: Insulated rail joints, insulated switch rods, and insulated gauge plates shall be furnished and installed by the Contractor; however, this specification does not intend to describe the insulation to be provided, nor the method of installation. Contractor shall be responsible for inspection of the track and provision and installation of the required devices. Failure of the Contractor to anticipate the required devices shall not result in additional cost to the project.
E. Track Leads: The Contractor shall provide and install connections to the rails, and all other material and apparatus including track and jumper bonds, as required for a complete track circuit installation.
F. Diode rectifiers: The Contractor shall provide and install the necessary diode rectifiers to terminate the required track circuits. Diode rectifiers shall be attached to the ties between the rails and track connections shall be made as described elsewhere in this specification.
G. Design Requirements:
1. The equipment shall meet FRA requirements. The equipment shall meet or exceed the standards and requirements of the AREMA Communications and Signals Manual of Recommended Practice. The equipment shall be applied per the recommendation of the manufacturer. Track circuits shall be configured as described in the Contract Drawings.
2. All terminations, cable materials, and methods shall be of commercially available types. Any terminals for the direct connection of underground single or multiple conductor cables shall be AREMA approved binding posts. An insulating test device enabling the wire to be opened for meggering or testing without removing the wire from the terminal shall be installed where underground single or multiple conductor cables enter the Equipment House.
3. Parts shall be available for a minimum of 10 years after Final Acceptance.
4. Environment. Equipment shall meet the basic temperature requirements, without heating or cooling enhancements such as heating strips and fans.
5. Inputs for the equipment shall be electrically and physically isolated from one another.
6. Outputs for the equipment shall be electrically and physically isolated from one another.
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7. Mounting: The track driver equipment shall be capable of being mounted in a standard relay rack
8. Lightning Protection: Lightning protection devices shall be provided according to the manufacturer's standard. Protection against lightning, surges, spikes, and over-voltage shall be provided. The Contractor shall protect all input and output lines and any auxiliary equipment as necessary.
2.24 DC TRACK CIRCUITS
A. Description. DC track circuits shall be provided inside interlocking limits as described in the Contract Drawings. DC track circuits shall be driven by a track battery replacer. The track battery replacer shall be a DC/DC converter that operates on a 10-VDC nominal input voltage and provides an output voltage ranging from 2.2-VDC to 0.7-VDC, depending upon load. The output drive shall be isolated from the input drive. The track battery replacer must be capable of driving at least one DC track circuit; however, more than one track circuit may be driven from a single unit. The track battery replacer shall be a ALSTOM 2TC, or approved equivalent. Where additional drive is required for longer track circuits, the track battery replacer may be a GETS 3TC. Track relays shall be vital plug-in relays as specified in this Section.
B. General performance requirements:
1. Track circuit drivers shall consist of a DC to DC converter.
2. Track circuits shall be separated by an insulated joint installed in each rail.
3. Track circuit drivers shall be capable of driving a standard 4 ohm track relay.
4. Track circuits shall provide broken rail detection for both rails.
5. Track circuit equipment shall detect the failure of an insulated joint and protect against it causing any unsafe condition.
6. Track circuits shall be normally energized such that occupation of the track circuit by a train, a false shunt, a broken rail, a broken track connection, or other fault to the track circuit shall cause the track relay to be deenergized.
7. Track circuit drivers shall be powered from a backed DC source such that a failure of the public utility power shall not cause a failure of the track circuits.
8. Track circuit resistors shall comply with the requirements of AREMA Communications and Signal Manual Part 14.2.15.
9. Track circuit connections shall be protected from a line-to-ground fault by heavy-duty line arresters and from line-to-line faults by a surge equalizer.
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C. Detection Requirements:
1. Track circuits shall detect a shunt anywhere within the track circuit boundaries. Shunting sensitivity shall be 0.06 Ohm with a rail-to-rail leakage impedance of 3 Ohms minimum per 1,000 feet of track at the operating frequency, under the following conditions:
a. Train moving or stopped.
b. Rail condition for prevalent operation; that is, a secondary, lightly used line where the rail is subject to accumulations of rust and scale.
2. Failure of track circuit components shall not permit the shunting sensitivity to fall below that specified after the track circuit has been properly adjusted. Failures of track circuit components shall result in failsafe operation.
D. Track Devices: Insulated rail joints, insulated switch rods, and insulated gauge plates shall be furnished and installed by the Contractor; however, this specification does not intend to describe the insulation to be provided, nor the method of installation. The Contractor shall be responsible for inspection of the track and provision and installation of the required devices. Failure of the Contractor to anticipate the required devices shall not result in additional cost to the project.
E. Track Leads: Contractor shall provide and install connections to the rails, and all other material and apparatus including track and jumper bonds, as required for a complete track circuit installation.
F. Design Requirements:
1. The equipment shall meet FRA requirements. The equipment shall meet or exceed the standards and requirements of the AREMA Communications and Signals Manual of Recommended Practice. The equipment shall be applied per the recommendation of the manufacturer. Track circuits shall be configured as described in the Contract Drawings.
2. All terminations, cable materials, and methods shall be of commercially available types. Any terminals for the direct connection of underground single or multiple conductor cables shall be AREMA approved binding posts. An insulating test device enabling the wire to be opened for meggering or testing without removing the wire from the terminal shall be installed where underground single or multiple conductor cables enter the Equipment House.
3. Parts shall be available for a minimum of 10 years after Final completion of Project.
4. Environment: Equipment shall meet the basic temperature requirements, without heating or cooling enhancements such as heating strips and fans.
5. Inputs for the equipment shall be electrically and physically isolated from one another.
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6. Outputs for the equipment shall be electrically and physically isolated from one another.
7. Mounting: The track driver equipment shall be capable of being mounted in a standard relay rack
8. Lightning Protection: Lightning protection devices shall be provided according to the manufacturer's standard. Protection against lightning, surges, spikes, and over-voltage shall be provided. The Contractor shall protect all input and output lines and any auxiliary equipment as necessary.
9. Because of the low input impedance of the DC track battery replacer, where Audio Frequency track circuits, such as those associated with CWTD (Constant Warning Time Device), are superimposed on the DC track circuit, a choke shall be installed in one of the track leads as described on the Drawings.
2.25 NOT USED
2.26 NOT USED
2.27 COLORLIGHT SIGNAL HEADS
A. General: Color light signal heads shall be provided as described in the Contract Drawings. One-, two- and three-aspect heads shall be provided. LED insert colors shall be green, yellow, lunar white and red as described on the Contract Drawings.
1. High signals shall utilize 8 3/8 inch diameter LED inserts.
2. Outlets shall be provided for cable or wire entering the signal head. The wire entrance outlet shall have edges rounded and be readily accessible for sealing. Outlets shall be designed to allow conduit to be mechanically connected so as to be weatherproof.
B. Light units shall be designed and constructed such that they avoid the undesirable reflection of external light.
C. Backgrounds and hoods shall be provided on all high signal heads. Hoods shall be provided for dwarfs, with a provision for backgrounds on dwarfs where required to improve visibility if clearance allows. Backgrounds and hoods shall be constructed of aluminum. The outer edge of backgrounds for high signals shall extend 12 inch from the center of any lens unit. Hoods shall be a minimum of 8 inch for high signals and 4 inch for dwarf signals.
D. Mounting for the signal heads shall be either top-of-mast or bracket type as described in the contract drawings. Dwarf signals shall include adjustable base that allows tilt for signal sighting purposes. Terminals shall be provided for the landing of wire and cable in the light units. They shall be located so as to be easily accessible and shall conform to the requirements of AREMA Communications & Signals
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Manual Part 1.4.1, Section C.
E. All signal heads, hoods and backgrounds shall be painted black. Hoods and backgrounds shall be to Class 1 Railroad standards.
F. Provide adapter plates for signal mounts as needed and called out in the Contract Drawings. Adapter plates and hardware shall meet the applicable requirements of Part 2.19 Galvanized Foundations in this Specification.
2.28 NOT USED
2.29 NOT USED
2.30 GROUNDING
A. The Contractor shall furnish all grounding materials. A No.6 AWG bare solid, soft- drawn copper conductor shall then be run from each ground connection on the bungalow to a suitable connection point on the bridge structure. The conductor shall be exothermically welded using a product such as produced by Erico Products, Inc., or an approved equivalent.
2.31 CONDUITS
A. Conduits: Conduits for the routing of signaling cables shall be furnished and installed by the Contractor. Conduits shall be installed where it is necessary to route cables beneath the roadway, pavement, or the track. Pull boxes shall be provided at the equipment house, either side of the roadway, and at points in conduit runs where pulling pressures would exceed recommendations.
1. Conduit shall be Galvanized Rigid Steel (GRS) Conduit. Conduit and fittings shall be made of the best grade standard weight steel pipe protected inside and outside by a coat of hot-dip galvanizing. Minimum size of conduits shall be 4 inches; however, it is the Contractor’s responsibility to assure that the size of the conduit is suitable to assure no more than 40 percent fill and to reduce necessary pulling pressures and the possibility of cable jams. Conduit sizes for AC power and communications shall match bungalow riser sizes.
2. A pull line shall be provided in each conduit. The pull line shall be a minimum of 3/16 inches in diameter with a tensile strength of 720 pounds. The pull line shall be a polypro material, highly visible bright yellow and weather resistant.
3. Conduit openings shall be sealed using an appropriate sealing compound. The sealing compound shall be suitable for burial and shall be impervious to contaminants in the soil and wet conditions. Stuffing the ends of conduits with rags or paper shall not be permitted.
4. A mandrel shall be run through the conduit before the installation of cable. The mandrel shall be appropriately sized for the conduit and shall be tapered on
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both ends to allow it to be pulled in either direction. The mandrel shall be fabricated from a soft material that will not cut the conduit walls.
2.32 NOT USED
2.33 WIRE AND CABLE TAGS
A. Requirements. Tags shall be provided on cables, wires, terminal boards, relays and wayside devices as described in this section. The lettering on the tags shall be easily readable. The minimum acceptable font size shall be 10 points. A point is defined as 1/72 of an inch. The nomenclature used on the tags shall correspond to that shown on Drawings.
B. Cables: Each conductor in each cable shall be tagged on both ends with its nomenclature. Nomenclature shall, with the exception of the “TO” and “FROM”, lines match at both ends of a conductor. Spare conductors shall be tagged with their nomenclature.
C. Wires: All wires shall be tagged at each termination point with a waterproof sleeve- type tag. Each terminal board terminal shall also be tagged with a waterproof flat- type tag securely fastened to the front of the board. The lettering on all tags shall be typed or computer generated and waterproofed; tag lettering shall also be permatized. Hand lettering of tags will not be allowed. The wire tags shall bear the following information in the sequence listed:
1. Wire nomenclature.
2. Near end termination point (rack number, row and contact number, if applicable).
3. Far end termination point (rack number, row, and contact number, if applicable).
D. Terminal Boards. All external wires, cables, and wires from terminal boards to terminal boards shall be tagged at both ends. The individual wires shall be tagged with a white, waterproof, plastic, flat tag suitable for slipping over the wire insulation prior to termination. Tags shall bear the following information in the sequence listed:
1. The nomenclature of the wire.
2. Local terminal designation.
3. Terminal designation for the far end of the wire.
4. This nomenclature shall be in waterproof black printing. Hand lettering of tags will not be allowed. Tags for main terminal boards shall attach to the board with escutcheon pins.
E. Relays. Tags for wires terminating at relays and relay bases shall be of the sleeve
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type and shall be white with black printing. Hand lettering of tags will not be allowed. Tags shall show the following information in the sequence listed:
1. Nomenclature of the wire.
2. Relay contact number. 3. The terminal or contact designation for the far end of the wire.
F. Wayside Devices: Tags at wayside devices shall be of the sleeve type and shall bear the wire nomenclature, terminal number, and cable number.
2.34 LOCKS
A. Scope: Contractor shall provide screw locks for all equipment enclosures that have hinged or removable doors, and for other specific devices defined herein that must be secured. These locks shall be equipped with a bronze chain, which the Contractor shall attach to the housing adjacent to the lock location. The Contractor shall also provide all necessary screws, washers, nuts and other fastenings necessary for this attachment. Locks shall be submitted to PHL for their approval.
B. Locks shall be provided for, at a minimum, all Equipment House doors, the key control box door, all junction box doors and all gate mechanisms, as well as all other devices provided with a hasp. Devices that have built-in screw locks, such as flashing light bodies, shall not require additional security. Locks shall be submitted to PHL for their approval.
2.35 TAPE
A. Rubber Tape: The Contractor shall furnish and apply field-applied rubber tape. Rubber tape shall be “Scotch Super 33+inch, or approved equivalent.
B. Friction Tape: The Contractor shall furnish and apply field-applied friction tape. Friction tape shall be 3/4 inch in wide and shall be overlapped ¼ of its width in application. Applications shall be give an coating of insulating paint such as “P and B” supplied by the Rubberoid Company, or “Victolac” supplied by Western RR Supply Company, or acceptable equivalent.
2.36 WAYSIDE SIGNS
A. Wayside signs shall be provided as described in the Contract Drawings. Signs shall include number boards for non-controlled signals, begin/end CTC signs, begin/end Yard Limits signs, D signs, CP signs and any signs required to describe yard switch operations.
1. Signs shall be constructed of aluminum with high intensity reflective sheeting. Letting shall be round type 5 1/2 inch.
2. Hardware for signs shall be stainless steel, or hot dipped galvanized.
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2.37 COORDINATION OF THE WORK
A. Requirements: Contractor shall submit an installation and cut-over sequence plan. The plan shall be submitted prior to commencing any field installation work, and shall include, at a minimum, the following:
1. Narrative descriptions and schematics to maintain existing train operations and headways.
2. Narrative descriptions and schematics for temporary or interim circuits and materials.
3. Narrative descriptions and schematics for final circuits and materials.
4. Descriptions for the implementation and sequencing of all required tests.
B. Interface Requirements: The Contractor shall be responsible for all design and development of the interface between Contractor-furnished equipment and existing equipment and installations not addressed in the Contract Design.
2.38 ELECTRICAL CONNECTIONS
A. Terminals: These requirements for electrical connections shall apply to factory and field wiring. All wires which are terminated on AREMA binding posts shall be fitted with an acceptable insulated crimped type terminal as described in AREMA Communications and Signal Section, Part 14.1.1. These terminals shall be placed on the wire by means of standard forming tools of the proper size, equipped with locks to assure that the proper pressure is applied before the tool is released. Care shall be taken to assure that the correct size of wire terminal is used and that the wire is thoroughly cleaned and centered properly in the wire terminal when using the forming tool.
B. Stripping of Wires: Wire terminals shall not be bent, nicked or otherwise damaged. An acceptable wirestripping tool shall be carefully used to remove the insulation from No. 9 AWG and smaller wires. Scraping of these conductors with any sharp instruments shall not be permitted. For wires larger than No. 9 AWG, a knife may be used to remove the insulation, extreme care being taken to prevent nicking the conductors.
C. Wire Connections: Connections to bases for plug-in relays and similar connections lamp contacts shall be soldered or crimped using a connector.
2.39 PAINTING
A. Requirement: All painting and other coating shall be furnished and applied as specified in this Article unless otherwise specified.
B. The painting and coating of materials and equipment furnished under these Contract Documents shall comply with the requirements of the AREMA Communications and Signal Manual, Part 2.4.30, insofar as they apply and except as hereinafter
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modified. With the exception of galvanized and plated surfaces, machined surfaces, wires and cable, bolts and nuts for field assembly and other similar surfaces and materials, all materials and equipment to be furnished under this Contract shall be cleaned and painted in the factory with 1 prime coat and 1 finish coat. All equipment shall be touched up after installation.
C. Brand: Paints for primer and finishing coats shall be a recognized acceptable proprietary brand. Refer to PAINTING AND COATING for additional requirements.
D. Application: No paint shall be applied on wet, damp, frosted or dirty surfaces, or when the temperature of the air is below 40 degrees Fahrenheit.
E. Inaccessible Surfaces: Surfaces required to be painted and which shall be inaccessible after installation or erection shall be given two additional coats of paint before installation or erection.
F. Damage: If any surface, which has been painted, is damaged prior to the completion of the work under this Contract, such damaged surface shall be cleaned, touched-up, or completely repainted by the Contractor at no additional cost to the Contract.
2.40 STENCILING AND MARKING OF EQUIPMENT
A. Identification: Instrument cases, equipment and junction boxes shall have the name of each individual piece shown directly on the respective door, cover, or frame by means of permanently stenciled lettering.
2.41 NOT USED
2.42 NOT USED
2.43 NOT USED
2.44 NOT USED
2.45 DATA RADIOS
A. Radios: Radios provided for field locations shall be 900 MHz spread-spectrum units. They shall operate at a nominal 12 VDC and shall be provided with a DC-DC converter where required for isolation from signal battery. Radios shall be provided with required cabling, antenna and hardware to comprise a complete and functional system.
B. DC-DC converters shall be used to isolate Data Radios from the signal battery.
C. Antennae, Cable and Hardware for Data Radios.
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2.46 LIMIT SWITCHES
A. Limit switches for vital applications shall provide a 2 wire double-break circuit for detection. Switches shall be suitable for installation in rugged environments and resistance to oil and chemical exposure. Limit switches shall be Eaton E50, or equivalent. Limit switch arms and roller contact shall be selected based upon installation requirement.
END OF SECTION 34 42 23
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34 42 44 SIGNAL ENGINEERING REQUIREMENTS
PART 1 – GENERAL
1.1 WORK INCLUDED
A. This Section describes the engineering work required as needed to complete the design of rail signal system and includes the provision of engineering drawings, applications logic, a Software Management Control Plan, and a responsible Project Engineer.
1.2 PAYMENT PROCEDURE
A. Not Applicable.
1.3 ABBREVIATIONS AND DEFINITIONS
A. FRA. Federal Railroad Administration.
1.4 SUBMITTALS
A. Project Engineer: The resume of the nominated Project Engineer shall be submitted immediately following Notice to Proceed. The Railroad shall have the right of refusal for the Contractor’s nominated Project Engineer.
B. Signal Foremen. The resumes of the nominated Signal Foremen shall be submitted immediately following Notice to Proceed. The Railroad shall have the right of refusal for the Contractor’s nominated Signal Foremen.
C. Revisions to the Contract Drawings. Contract drawings that are revised to reflect the use of substituted materials or products shall be submitted and approved before the work is undertaken. Work undertaken without the approval of the Railroad is at the risk of the Contractor. The Railroad may, at its discretion, ask that work performed without approval be removed at the cost of the Contractor.
D. As-Wired Drawings: As-Wired Drawings shall be submitted that capture changes to the Contract Drawings that result from the wiring and factory testing processes.
E. As-Built Drawings: As-Built Drawings shall be submitted that capture the changes to the Contract Drawings that result from the installation and field testing processes.
F. Tie-In Plans: Where modified or otherwise not addressed in the Contract Drawings and necessary for new systems to tie into existing systems, the Contractor shall provide tie-in plans.
G. Phasing Narrative and Plans: Where it is necessary to phase the commissioning of the project, the Contractor shall provide for approval a phasing narrative and phasing plans.
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H. Applications Logic: Applications logic for ElectrologIXS shall be provided by the Engineer. Version control of applications logic shall be rigorously maintained and documented.
I. Software Management Control Plan: Contractor shall follow a Software Management Control Plan that is compliant with FRA rule 236.18.
PART 2 – PRODUCTS
Not Applicable.
PART 3 – EXECUTION
3.1 ENGINEERING DRAWINGS
A. The Contract Drawings represent a solution to the requirement for a complete working signal system and are developed around specific products and procedures. The Contractor may submit substitutions for the products and procedures shown in the contract drawings; however, revisions to the Contract Drawings to show the substitutions shall be the responsibility of the Contractor. Additionally, while the Contract Drawings are intended to be as correct as possible, it is the responsibility of the Contractor to assure that the signal systems provided work correctly and safely. Revisions required to the Contract Drawings to achieve this are the responsibility of the Contractor.
Contractor shall maintain accurate and legible drawings at the As-Wired and As-Built stages of the project.
Revised Drawings, or new drawings provided as part of the project will be drawn using AutoCad (Version 2021). All new drawings will utilize the titleblock used for the Contract Drawings.
B. Contractor shall nominate a Project Engineer to be responsible for the installation and testing of all systems. The Project Engineer shall have the authority to make decisions relating to progressing the project, and shall be the Railroad’s point of contact for the project. The Project Engineer shall have a minimum of 10 years experience in the installation and testing of signal systems of a similar size and scope. The Contractor shall submit the resume of the proposed Project Engineer to the Railroad for his approval. No work shall be performed until the Project Engineer has been approved.
C. Contractor shall provide the Railroad with the resumes of individuals designated as Signal Foremen. A Foreman is defined as an individual responsible for the day- to-day activities of working crews of signal installers and testers. Signal Foremen shall have a minimum of 5 years experience in the installation and testing of signal systems of a similar size and scope. No Signal Foreman shall be allowed to perform the work until approved.
D. Where not addressed in the Contract Drawings and determined that tie-in plans are required to interface existing systems to the new systems, the Contractor
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shall be responsible for the provision of those tie-in plans. The Contractor shall be responsible for assuring that tie-in plans are complete and accurate. The Contractor shall be responsible for assuring that the existing infrastructure depicted on the tie-in plans is available. Where uncertainty exists concerning existing infrastructure, the Contractor shall be responsible for assaying existing, or for the provision of new equipment for the tie-in circuits.
E. Contractor shall inform the Railroad of those situations where it is determined that the work should be installed in phases. Where phasing is considered necessary, the Contractor shall provide a narrative describing the work to be phased and its impact on overall operations. Where phased work causes impact to train movements, the Contractor shall explain why the phasing is necessary, its total impact on operations, and mitigations being undertaken to reduce the impact. Where phasing impacts highway grade crossing operations, the Contractor shall describe, and be responsible for providing, necessary mitigations to assure the safety of the general public.
D. Applications Logic: Contractor shall test all applications logic required for the solid- state interlockings and other programmable devices proposed for the project. Version control of applications logic shall be rigorously maintained and documented.
E. Software Management Control Plan: Contractor shall perform to a Software Management Control Plan that conforms to the requirements of FRA 236.18.
END OF SECTION 34 42 44
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34 42 45 SIGNAL INSTALLATION REQUIREMENTS
PART 1 - GENERAL
1.1 WORK INCLUDED
A. This section describes required processes and procedures for the installation of the railway signal system described in the contract drawings and in this specification.
1.2 PAYMENT ITEMS
A. Refer to 34 42 23 Part 1.2.
1.3 ABBREVIATIONS AND DEFINITIONS
A. AREMA. American Railway Engineering and Maintenance of Way Association.
B. FRA. Federal Railroad Administration.
1.4 SUBMITTALS
A. Not Applicable.
PART 2 – PRODUCTS
Not Applicable.
PART 3 - EXECUTION
3.1 EQUIPMENT BUNGALOWS
A. Install Equipment Bungalows as detailed in the Contract Drawings.
B. Provide clearances as detailed in the Contract Drawings.
C. All cables or wiring shall be neatly routed, and shall be securely fastened at 3 inch intervals with tie wraps.
D. Coordinate with Electrical Contractor on 120/ 240VAC feed. The main breaker of the load center shall be opened to remove the house load from the panel lugs while the feed cable is connected. Only after the feed cable been installed and terminated shall the main breaker be closed to power the Equipment Bungalow from the AC panel. F. Test all electrical circuits and outlets in the Equipment Bungalow. Assure that all house loads are connected to the panel through branch breakers and that the breakers exercise positive control over the loads. Test the function of the exhaust fan by setting the thermostat below the ambient temperature. After confirming the operation of the fan, set the thermostat at 90 degree F.
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3.2 SIGNALS
A. No part, either fixed or movable, of any signal layout shall project into the clearance envelope for the Railroad.
B. Minimum clearance of signals, including all parts, either fixed or movable, shall be maintained.
C. Signals shall be equipped with a background and hood.
D. Signals shall be aligned and focused, both horizontally and vertically, in conformance with the applicable recommendations of AREMA Communications and Signals.
3.3 TRACK CONNECTIONS
A. Rail connections for track circuits shall be made by means of a 3/16 inch insulated bond, strand length as required, Erico Products, or approved equivalent, with one end pressed into a copper sleeve for welding to the rail by the exothermic welding process at the neutral axis on the outside (fieldside) of the rail. Before applying the weld, rail shall be ground to a bright and clean condition by means of a grinding wheel. A file or handstone shall not be used for this purpose. Welds should be clean and should not have drips or voids. Any weld which shows any defect shall be replace at no cost by the Contractor. The Railroad shall have final judgment of the condition of welds. The other end of the bond shall be finished in a 3/16-to-3/16 sleeve. A length of 3/16 bondstrand shall be attached to the bond and run to a trackside bootleg where a 3/16-to-6 sleeve shall be used to attach the bondstrand to the twisted #6 U.G. trackwire. An appropriate crimping tool shall be used for crimping the sleeves. The sleeve shall be covered with 3 layers of fabric tape followed by 3 layers of rubber tape.
The bootleg shall be a 3 foot length of brake hose. The connection between the bondstrand and the trackwire shall be made within the bootleg. Before placing the connection into the bootleg, it shall be taped and painted. The bootleg shall be stapled to the end of the tie. Bondstrand shall be stapled to the tie at least 4 inches below its top surface. Rail clips shall be used to secure the bondstrand along the rail. Track connections shall be neatly dressed to reduce the likelihood of damage from dragging equipment or vandals.
3.4 TRACK CIRCUIT CONNECTORS
A. Take field measurements to make final determination of bar lengths for the Track Circuit Connectors. Install per Manufacturer’s recommendations. Connect Track Circuit Connectors to the respective rails using 3/16 bondstrand and methods in Part 3.3.
174 Arkansas River Lift Bridge, MP 410.6
3.5 INSTALLATION OF CABLE
A. Cable in exposed areas susceptible to damage shall be installed in conduit. All cable not enclosed in conduit shall be properly secured.
B. Wire must not be nicked or twisted when forming eyes or applying terminals. Formed wire eyes shall be placed on terminals to ensure closing of the eye when terminal nuts are tightened.
C. Wiring of all appliances shall conform to the applicable parts of the AREMA Communications and Signals Manual.
D. Precautions shall be taken to prevent the kinks or twisting of wire and cable during installation. Kinks or twists that unavoidably occur shall be removed by hand. Insulation shall not be injured or marred by dropping, stepping, or throwing materials or tools on wire or cable. Wire and cable shall not be pulled over rough surfaces.
3.6 RAIL BONDS (AS NEEDED)
A. Non-insulated joints shall be bonded with a rail-head bond. Before applying the weld, rail shall be ground to a bright and clean condition by means of a grinding wheel. A file or handstone shall not be used for this purpose. Welds should be clean and should not have drips or voids. Any weld which shows any defect shall be replaced at no cost by the Contractor. The Harbor Department shall have final judgment of the condition of welds.
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