ATTACHMENT W.3
TECHNICAL
SPECIFICATIONS
IFB No. 016-001
Drop Table System
Virginia Railway Express
Page 1 of 52 TABLE OF CONTENTS
PART 1 – GENERAL
4
1.01
GENERAL DESIGN AND FABRICATION REQUIREMENTS
4
1.02
GENERAL PROVISIONS
5
1.03
TECHNICAL SPECIFICATIONS
5
1.04
REFERENCES
7
1.05
QUALITY ASSURANCE
8
1.06
QUALITY CONTROL
11
1.07
SUBMITTALS
13
1.08
DELIVERABLES
18
1.09
OPERATION AND MAINTENANCE MANUALS
19
1.10
VERIFICATION OF DIMENSIONS
22
1.11
AS-BUILT DRAWINGS
23
1.12
TRAINING PROGRAM
23
1.13
HARDWARE AND SOFTWARE
25
1.14
COMMISSIONING DATA
25
1.15
EQUIPMENT IDENTIFICATION
26
1.16
NOISE AND VIBRATION ISOLATION
26
1.17
INSPECTION
27
PART 2 – PRODUCTS
27
2.01
EQUIPMENT
27
2.02
MANUFACTURER
27
2.03
DESIGN REQUIREMENTS
29
2.04
STRUCTURAL REQUIREMENTS
35
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 2 of 52
TABLE OF CONTENTS - Continued
2.05
ELECTRICAL REQUIREMENTS
36
2.06
CONCRETE FOUNDATIONS
42
2.07
SAFETY BARRICADES
42
2.08
GASKETS AND FASTENERS
43
2.09
HOLES, OPENINGS AND INSERTS
43
2.10
NOISE AND VIBRATION ISOLATION
44
2.11
PAINTING
44
PART 3 – EXECUTION
44
3.01
PREPARATION
44
3.02
FABRICATION
44
3.03
PRE-SHIPMENT INSPECTION AND TESTING
45
3.04
DELIVERY, STORAGE AND HANDLING
46
3.05
INSTALLATION
47
3.06
SETTING AND ALIGNING EQUIPMENT
49
3.07
CLEANING AND PROTECTION
49
3.08
EQUIPMENT FINAL ACCEPTANCE TEST
49
3.09
START-UP AND INSTRUCTIONS
52
3.10
FOLLOW-ON INSPECTION AND TESTING
52
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 3 of 52
TECHNICAL SPECIFICATIONS FOR DROP TABLE SYSTEM
PART 1 – GENERAL
1.01
GENERAL DESIGN AND FABRICATION REQUIREMENTS
A.
Equipment shall be designed, fabricated, installed and adjusted to achieve the
best results with respect to smooth, quiet, convenient and efficient operation,
durability, economy of maintenance and operation, as well as the highest
standards of safety.
B.
All components used in the assembly of the system shall be standard,
commercially available components and shall be manufactured by companies
regularly engaged in the manufacture of the components. The design shall
provide for the interchangeability of items to include, piping, equipment, subassemblies, motors, starters, relays and other devices.
C.
It is not the intent of these Technical Specifications to detail the design and
fabrication of the parts of the equipment, but it is expected that the type, material,
design, workmanship and fabrication of every part shall be fully adequate for the
service required, durable, properly coordinated with all other parts, in accordance
with the best industrial standards and of the highest efficiency. The components
of electric circuits shall be of proper size, design and material to avoid injurious
heating, arcing and all other objectionable effects that may reduce the efficiency
of operation and economy of maintenance. Minimum requirements are given
herein for certain parts of equipment. Equivalent requirements shall apply to all
equipment parts that are of special design, construction or material and to which
the specified requirements are not directly applicable, and shall be approved by
the Engineer. These minimum requirements as a whole shall also be considered
as establishing proportionate general minimum standards for all parts of the
equipment.
D.
The Engineer may permit variations from the requirements of these Technical
Specifications to permit the use of the Manufacturer’s standard equipment,
provided such standard equipment is adequate for the intended use and meets
the full intent of these Technical Specifications. All such variations proposed by
the Manufacturer shall be called to the attention of the Engineer in writing and
shall be made only if the Engineer approves such variations in advance and in
writing.
E.
Certain design limitations and tests are specified as a partial check on the
adequacy of design, fabrication and materials. These requirements do not cover
all features necessary to ensure satisfactory and approved operation of the
equipment. Conformity with these requirements shall, in no way, supersede the
general requirements as to satisfactory and efficient operation of the equipment.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 4 of 52
1.02
1.03
GENERAL PROVISIONS
A.
Attention is directed to SECTION E – SPECIAL TERMS AND CONDITIONS and
all Sections within Division 01 – General Requirements of ATTACHMENT W.2 GENERAL SPECIFICATIONS included in this solicitation, which are hereby
made a part of this Section of the Technical Specifications.
B.
The following are definitions of terms used in these Technical Specifications:
1.
Manufacturer or Contractor: The
firm
responsible
for
design,
manufacture, delivery, installation and commissioning of the Drop Table
System.
2.
Installer: The Manufacturer and any licensed Subcontractors acting
under its direction and supervision.
3.
Construction Contractor:
The general contractor responsible for
construction of the Lifecycle Overhaul and Upgrade (LOU) Facility (also
referred to herein as the Shop), having specific responsibilities related to
the Drop Table System as detailed herein.
4.
Engineer: Owner’s designated representative.
TECHNICAL SPECIFICATIONS
A.
Requirements for designing, furnishing and installing a one hundred (100) ton
capacity Drop Table System including, but not limited to, one (1) transfer table,
one (1) service track top with a single axle auxiliary section, one (1) bascule-type
release track top, body support beams, movable body supports, traction motor
dolly, pit-level progression system, spare parts and storage.
B.
Unless specifically noted otherwise, references herein to “equipment” or “system”
shall be understood to refer to the complete Drop Table System as described
above in SECTION 1.03A.
C.
Requirements for start-up, field testing and operation/maintenance training of
VRE employees.
D.
Requirements for the Manufacturer of the Drop Table System (hereinafter
referred to as the "Manufacturer") to coordinate with the Construction Contractor
who is responsible for construction of the facility and pit in which the Drop Table
System shall be installed.
E.
Requirements within this specification are directed to, and the responsibility of,
the Manufacturer, unless specifically noted otherwise.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 5 of 52
F.
Division of Work:
1.
2.
The Manufacturer of the Drop Table System shall furnish the following
materials for the Construction Contractor to install:
a.
Service top locking bar pockets
b.
Release track rail seats
c.
Release top guide post pocket assemblies
d.
Receptacle and back box for wireless control
e.
Curb angles for pit edges around service and release tops.
f.
Progression system runway embedments
g.
Shop drawings of pits with embedments per SECTION 1.06F.3.
The Manufacturer shall furnish and install all equipment including, but not
limited to, the following:
a.
Service top
b.
Transfer table
c.
Bascule release top and posts
d.
Load beams
e.
Body supports
f.
Traction motor dolly
g.
Main electrical enclosure
h.
Master control console
i.
Power and control cable
j.
Power and control cable reels
k.
Wireless control stations
l.
Limit switches
m.
Pit rails with anchorage
n.
Shims
o.
Pit-Level Progression System
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 6 of 52
3.
4.
1.04
The Construction Contractor will be responsible for:
a.
Coordinating the testing and commissioning of the equipment by
the Manufacturer, including but not limited to, making
arrangements with VRE for employees, rail vehicles and
classroom space, based upon requests from the Manufacturer.
This is to ensure that testing and commissioning activities do not
conflict with other LOU Facility construction activities.
b.
Constructing the equipment pit, installing embedded items and
providing all required electrical-mechanical and connectivity
services in the LOU Facility per the Manufacturer’s requirements,
to ensure that the equipment offers an optimal performance.
c.
Coordinating with the Manufacturer, taking into account the dates
for completion of scheduled manufacturing milestones, the
delivery of the equipment in order to meet the Construction
Contractor’s obligations and ensuring that the required pit,
embedments and utilities are complete and ready for installation of
the equipment.
The Construction Contractor will furnish and install the following (based
upon the Drop Table Manufacturer’s design):
a.
Embedded shop rail up to the edge of pit, to be installed after
machine rails are installed
b.
Anchor bolts for load beams
c.
Conduit with pull-wires for power and control wiring (embedded
conduit only)
d.
480V electrical power to a main panel/disconnect as designated
by the Manufacturer on the shop drawings
REFERENCES
A.
All equipment shall be manufactured and set up in accordance with all industrial
and safety standards that apply to the work, to include the following.
B.
Standards and Regulations:
1.
AAR - Association of American Railroads
2.
ABMA - American Bearing Manufacturers Association
3.
AFBMA - Anti-Friction Bearing Manufacturers Association
4.
AISC - American Institute of Steel Construction
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 7 of 52
C.
D.
1.05
5.
AREMA - American Railway Engineering and Maintenance of Way
Association
6.
ASME - American Society of Mechanical Engineers
7.
ASPE - American Society of Plumbing Engineers
8.
ASTM - American Society of Testing Materials
9.
AWS - American Welding Society
10.
IEEE - Institute of Electrical and Electronics Engineers
11.
ISO - International Standards Organization, ISO 9001, 2008 Edition
12.
NEMA - National Electrical Manufacturers Association
13.
NESC - National Electrical Safety Code
14.
UL - Underwriters Laboratory
Safety and Governmental Standards:
1.
OSHA - Occupational Safety and Health Administration
2.
ANSI - American National Standards Institute
3.
NEC - National Electric Code
4.
NFPA - National Fire Protection Association
5.
SAE - Society of Automotive Engineers
All applicable Federal, State and Local codes and regulations:
1.
If there is a conflict between codes and the Manufacturer’s standards, the
most stringent requirements shall take precedence and the best quality as
to materials and workmanship shall be supplied and applied.
2.
Material and equipment shall be manufactured in compliance with ISO
9001-2008 quality standards. This includes, but is not limited to, nuts,
bolts, threads and heads for the same, pipes, conduits and electrical
connectors.
QUALITY ASSURANCE
A.
All equipment shall be manufactured and set up in accordance with the following:
1.
All articles, materials, fittings, equipment and machinery incorporated in
the work shall be new and unused, of recent manufacture, free from
defects and imperfections, and as far as practicable, Manufacturer’s
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 8 of 52
standard make of first grade industrial quality, from reputable
manufacturers, suitable for the purpose intended and subject to approval
by the Engineer.
2.
All components used in the assembly of the system shall be standard,
commercially available components and shall be manufactured by
companies regularly engaged in the manufacture of the components. The
design shall provide for the interchangeability of items of piping,
equipment, sub-assemblies, motors, starters, relays and other devices.
3.
All replacement parts shall be readily available in the United States. Lists
of the sources for the parts shall be supplied for the maintenance and
repair of the system.
4.
Unless otherwise noted, the equipment shall be designed for installation
and proper operation in an indoor, shop environment.
5.
When installed, the layout of the new equipment shall be such that
workers shall have sufficient room to access all parts of the equipment.
6.
Fasteners shall comply with ANSI standards. This includes, but is not
limited to, threads for nuts and bolts, heads for same, pipe, conduit and
electrical connectors. Mixing of metric and United States Customary
Units (non-metric) standards on the same equipment is not permitted.
7.
Products or composite materials containing asbestos shall not be used.
8.
When two (2) or more items of the same equipment are required, they
shall be products of a single manufacturer.
9.
All work shall be performed in a neat and workmanlike manner by
workers skilled in their respective trades, and all material and equipment
shall be installed as recommended by the Manufacturer and in
accordance with all applicable codes and standards.
10.
Equipment shall be designed, fabricated, installed and adjusted to
achieve smooth, quiet, convenient and efficient operation, durability,
economy of maintenance and operation and the required standards of
safety.
11.
All piping, valves, fittings, conduits and wiring required for the equipment
installation shall be in accordance with all applicable codes. Supplied
connections shall properly interface with existing services.
12.
All items requiring maintenance shall be accessible for maintenance or
change-out without undue service interruption. Replaceable components
shall be provided with appropriate mechanical isolation to facilitate
change-out without extensive system shutdown.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 9 of 52
B.
13.
Materials and equipment shall be manufactured in compliance to the ISO
9001- 2008 quality standards. This includes, but it is not limited to, nuts,
bolts, threads and heads for the same, pipes, conduits and electrical
connectors.
14.
The language of the text for all documents shall be English.
15.
All dimensions shall be displayed in U.S Customary Units.
16.
All electrical equipment shall be UL listed and bear UL label.
Substitutions:
Requests for substitutions and approval of equipment items other than
those specified shall be made in accordance with the Contract.
C.
Permits and Tests:
Obtain all necessary permits from the Commonwealth of Virginia and
other authorities having jurisdiction, make application and file all drawings
required for such permits, and pay all permit fees. Arrange inspections
and tests required by governing authorities and by VRE, and pay all costs
connected therewith. Obtain and file with the Engineer written evidence
that all of the above requirements have been met.
D.
E.
Applicable Codes:
1.
Work shall conform to Federal, State, and Local governing rules and
regulations and ordinances including OSHA and NFPA, and shall pass
inspection by authorities having jurisdiction.
2.
Furnish all materials and labor required to meet all requirements and to
obtain approvals of inspections and tests required by jurisdictional
authorities.
Certificates:
1.
The Manufacturer shall furnish an affidavit certifying that all materials and
workmanship comply with all applicable code requirements.
2.
“Buy America” certification of compliance: Signed statement or form
certifying that the Drop Table System and its components meets the
requirements of 49 U.S.C. 5323(j)(1) and the applicable regulations in 49
CFR Part 661.5. This shall be included with each equipment submittal.
3.
Before acceptance, the Manufacturer shall furnish
documenting approval of all authorities having jurisdiction.
4.
Certificates of Compliance: A minimum of seven days prior to delivery of
the equipment, Manufacturer shall submit certificates of compliance.
Each certificate shall be signed by an authorized representative of the
IFB No. 016-001
DROP TABLE SYSTEM
certificates
TECHNICAL SPECIFICATIONS
Page 10 of 52
Manufacturer stating that the equipment complies in all respects with all
Contract requirements, including applicable codes and regulations, as
well as all approved design submittals.
F.
1.06
Warranty: All equipment shall be warranted in accordance with SECTION E –
SPECIAL TERMS AND CONDITIONS of this solicitation and the following
provisions:
1.
Warranty period: one (1) year from the date of final acceptance.
2.
The Manufacturer warrants that the work performed, and all materials and
equipment furnished hereunder by the Manufacturer or its Subcontractors
or suppliers shall be free from defects in design, material, workmanship
and operation for the warranty period.
3.
"Defects" are hereby defined to include, but not by way of limitation,
operation or control system failures, performances below required
minimums, excessive wear, unusual deterioration or aging of materials or
finished, unsafe conditions, the need for excessive maintenance,
abnormal noise or vibration and similar unusual, unexpected and
unsatisfactory conditions.
4.
The Drop Table System Manufacturer shall remedy any such defect at its
own expense.
5.
Work that has been abused or neglected by VRE is excluded from this
warranty.
6.
Furnish written warranties required by the respective sections of these
Technical Specifications for time stipulated therein. These warranties
shall be in writing, on Manufacturer’s or supplier’s letterhead, and fullyexecuted copies shall be included in the Operations and Maintenance
(O&M) manual(s).
7.
Major equipment components, specifically those manufactured by other
than the primary equipment supplier, shall be covered by their own
respective warranties, which shall not be less than the supplier’s standard
warranty. These warranties shall also be included in the O&M manual(s).
8.
Nothing in these requirements, conditions or specifications including
VRE’s right to a complete inspection shall constitute a disclaimer to or
limit, negate, exclude or modify in any way any warranty created
hereunder.
QUALITY CONTROL
A.
The information contained in these Technical Specification and in
ATTACHMENT W.4 – DESIGN DRAWINGS included in this solicitation is based
upon a typical installation. It is provided to describe the basic scope and
requirements of the Drop Table System and as a design guide for the completion
of the work. This specification may not provide all of the details associated with
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 11 of 52
the specific model of the selected Manufacturer. The Drop Table System
Manufacturer shall provide VRE with information and details associated with the
specific Drop Table System to be provided. This detail and information includes,
but is not limited to, the following:
1.
All of the components required for the proper operation of the Drop Table
System.
2.
The Manufacturer’s installation requirements needed for the design of all
supporting infrastructure such as concrete foundations, structural steel
supports, electrical service and grounding, other utility connections, safety
guarding and any temporary or permanent fixtures of the facility
necessary to allow installation, operation and maintenance to take place.
3.
Inserts and anchoring device requirements that must be set in concrete or
built into the construction by the Construction Contractor for the
installation of the Drop Table System.
B.
Design and manufacture the system for a minimum thirty (30) year life span
given that scheduled maintenance will be performed in accordance with the
Manufacturer’s instructions.
C.
Employ a quality assurance program that meets the requirements of ANSI and
that satisfies all safety-related quality assurance requirements imposed by
applicable government regulatory agencies.
D.
Assembled components purchased by the Manufacturer for this Contract, such
as motors, pumps and electrical devices, shall be the standard products of
qualified manufacturers.
E.
1.
A “qualified manufacturer” is defined as a firm having a minimum of five
(5) years documented experience in the manufacture of the component.
2.
All similar items shall be the products of a single manufacturer.
The Drop Table System Manufacturer shall coordinate the following with the
Construction Contractor:
1.
The design of systems, sub-systems and components with the building
structure and in matters of building and life/safety.
2.
The equipment to be located within the spaces allocated for such
equipment and verify that all dimensions and utility services are adequate
for the equipment.
3.
The design of inserts and anchoring devices, which must be set in
concrete or built into the construction for installation of the system.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 12 of 52
F.
G.
1.07
The Drop Table System Manufacturer shall:
1.
Operate an installation and repair department and shall maintain an
adequate supply of spare parts.
2.
Provide equipment of high quality and workmanship, which will perform
specified functions reliably and safely, and shall permit required
maintenance procedures with minimum interference of service or
degradation of reliability.
3.
Provide shop drawings and design calculations that pertain to the
structural design of the equipment required by this Section shall be
sealed by the Drop Table System Manufacturer's Professional Engineer
licensed to practice in the Commonwealth of Virginia.
The Drop Table System Manufacturer’s Field Representative shall:
1.
Be on site, for a minimum of two (2) days, to supervise/approve the
locations of the embedded items listed in SECTION 1.03F.3.b., including
all embedments, pipes and conduits related to the Drop Table System,
prior to placing in concrete.
2.
Supervise the installation of the equipment, conduct acceptance testing
and train VRE personnel and VRE’s contract-maintenance personnel in
the proper operation and maintenance of the equipment.
3.
Work with the Construction Contractor and be present at the site for all of
the installation work of the equipment being furnished.
SUBMITTALS
A.
For each package, include an electronic copy (Adobe Acrobat PDF) on CD-ROM
or flash drive. Scanned items shall be legible at normal one hundred percent
(100%) display. Color originals shall be scanned in color.
B.
Incomplete, partial or “piecemeal” submittals will be returned without review.
C.
Sequence of Approval:
1.
Conditional Approval of Equipment: Before submitting shop drawings, the
Manufacturer shall submit to the Engineer for conditional approval
drawings, specifications and lists of equipment to be incorporated in the
work. This list shall include catalog numbers, cuts, and other descriptive
data as may be required to ensure compliance with requirements
specified. No consideration will be given to partial lists. Conditional
approval of equipment based on this submittal will be subject to
submission of complete shop drawings indicating compliance with the
Contract Documents prior to final approval.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 13 of 52
2.
D.
Final Approval of Equipment: After receiving conditional approval of the
equipment lists, submit shop drawings, product data and installation
instructions for final approval.
Submit product data for all non-consumable purchased components, including:
1.
Catalog cuts, pamphlets, brochures, color samples and descriptive
literature
2.
Equipment and specifications
3.
Performance and test data
4.
Country of origin.
5.
Components not falling under this requirement are shop-fabricated items,
and items that appear on the list of spare parts for routine maintenance
under SECTION 1.07J. herein and/or items having a list unit price less
than fifty dollars ($50.00).
6.
Specific items included in this work shall be indicated on the
Manufacturer's product data sheets. Excluded items may be crossed out
if this configuration is more logical.
7.
The Manufacturer shall ensure that product data addressing the following
items is submitted along with all other requested product data:
a.
Hydraulic power unit for motor dolly, including performance curves
that indicate rate of delivery
b.
Programmable Logic Controller (PLC) (if utilized)
c.
Operator interface
d.
All motors
e.
Electrical starters, breakers and panels
f.
Transducers and sensors
E.
Detailed information on locations where fabrication and/or assembly operations
for the equipment to be furnished as part of this Contract are to take place.
F.
Submit Shop Drawings: Shop drawings and diagrams shall be prepared using
and showing scales and dimensions in the United States Customary Units (nonmetric). Metric conversions may be provided in parenthesis. Shop drawings may
include exploded-view diagrams and shall include but not be limited to the
following as applicable: ‘
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 14 of 52
1.
Drawings showing equipment layout, elevations, conduit runs, utility
layout and hook-ups, and all required dimensions including but not limited
to clearances and tolerances.
2.
Foundation drawings identifying the equipment footprint; required pit
dimensions and details including dimensions, depth, utility locations and
drain locations; base plate dimensions including length, width and depth;
floor loading; vibration isolation pads; anchor bolt details, including
locations, quantity, size, type and embedment; and elevations. The
information provided by the Drop Table System Manufacturer shall be
sufficient for VRE's Engineer to develop complete and detailed final
foundation requirements with embedded items. In addition to embedded
items, items that require coring and grouting/cementing of pit shall also be
identified, dimensionally located, detailed and coordinated with equipment
requirements.
3.
Pit wall clearance drawing(s) indicating areas, identified with hatching,
and associated clearances from the closest point of any part of the
moving Drop Table System to the walls of the pit. The drawing(s) shall be
to scale and fully dimensioned.
4.
Data for structural loads into pit/foundation.
5.
Design calculations for foundation and pit requirements, including loads
imposed on the foundation under maximum lift conditions, loads imposed
by the body supports and rolling (impact) loads across the pit floor,
service top and release top.
6.
Fabrication/assembly drawings, including bill of materials and material
specifications.
7.
Detail drawings of assemblies and components, other than assembly
drawings.
8.
Operation drawings showing the fixtures, and adapters used for the
operation of the service top, auxiliary (single wheelset) service top,
bascule top, motor support dolly, locking bars and pit-level progression
system.
9.
Operation narrative describing truck and wheelset replacement
operations including description of tooling, fixtures and adapters to be
used. Operation narrative shall include description of body supports,
service top and locking bars, pit-level progression system and any
associated safety interlocks.
10.
Utility connection plan showing utility requirements. The information in
this plan shall include, but not be limited to, the following, as applicable to
the particular equipment:
a.
Locations of existing utility services.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 15 of 52
b.
Location of required utility connections.
c.
Required sizes of pipes and conduits.
d.
Inverts and elevations.
e.
Required water pressure, velocity in cubic feet per second (cfs)
and flow in gallons per minute (gpm).
f.
Required gas pressure and cubic feet per hour (cfh).
g.
Required compressed air pressure and cubic feet per minute
(cfm).
h.
Required steam pressure and flow.
i.
Required size of electric service.
j.
Required size of wires.
k.
Required voltage and amperage (full load).
l.
Required insulation and/or insulators.
11.
Electrical control diagrams/schematics.
12.
Electrical wiring diagrams. The information in these diagrams shall
include, but not be limited to, the following:
13.
a.
Locations of existing utility services.
b.
Location of required utility connections.
c.
Required sizes of conduits.
d.
Inverts and elevations.
e.
Required size of electric service.
f.
Required size of wires.
g.
Required voltage and amperage (full load).
h.
Required insulation and/or insulators.
i.
Grounding connections.
Electrical equipment layouts, with all motors, limit switches, solenoid
valves, disconnects, control panels, etc. located and labeled.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 16 of 52
14.
G.
H.
I.
J.
Hydraulic system schematic diagram.
Submit equipment installation instructions including:
1.
Manufacturer’s recommended installation instructions.
2.
Manufacturer’s installation drawings.
3.
Installation schedule.
4.
Installation instructions shall include a detailed explanation of the
equipment installation process, and a listing of embedments and
fasteners, including torque requirements, accessories or other items
necessary for a complete installation.
5.
Installation schedule shall clearly describe installation steps that will be
performed by the Construction Contractor, and installation steps that shall
be performed by the Manufacturer/Installer along with estimated time
durations for these steps.
Submit Material Safety Data Sheets (MSDS), or 16-Section Safety Data Sheets if
available in this new format, of all chemical materials, substances and
compounds that will be used on this Contract and/or to maintain the equipment
This includes, but is not necessarily limited to, the following:
1.
All cements, caulks, sealants and paint products used in the installation
2.
Any recommended lubricant, oil, hydraulic fluid or chemical products to be
used in the operation and/or maintenance of the equipment, including
product trade name, chemical composition and physical properties.
Start-Up and Acceptance Testing Plan, procedures, and typical schedule.
1.
Identify all rail vehicles and other items needed for start-up and testing.
2.
Provide timely notification to the Construction Contractor to arrange for
rail vehicles and other items.
3.
Rail vehicles, wheelsets and assembled trucks required for testing, will be
furnished by VRE, as arranged and coordinated by the Construction
Contractor.
Submit Spare Parts List for Approval
1.
Submit a comprehensive list of all spare parts, supplies and consumables
for the equipment to be supplied, including tooling. Do not include in
pricing.
2.
Provide a recommendation for spare parts inventory, considered critical
and for which extended acquisition time would create excessive
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 17 of 52
downtime. Include part description, part number, quantity and list price,
for review by VRE. Do not include in pricing.
3.
K.
1.08
Provide spare parts list considered normal for routine maintenance of the
equipment for one (1) year. Each entry shall include corresponding
manufacturer’s part numbers, manufacturer’s name, supplier, supplier’s
part numbers, quantity, lead-time and estimated cost valid for a one (1)
year period from installation but not in Contract pricing. The list shall
clearly indicate entries on the list that fall into the following categories.
Submit List of Special Tools for Approval
1.
Submit a list all tools, fixtures, shims, adapters and other specialty
accessories required for proper operation of the Drop Table System.
2.
Provide two (2) complete sets to VRE, delivered directly to the Engineer’s
designated representative (not via the Construction Contractor). Obtain
receipt for delivery.
3.
Provide two (2) industrial-grade metal toolboxes for storage of these
items.
DELIVERABLES
A.
Installed Drop Table System and all accessories
B.
Shop drawings of equipment pit, within forty-five (45) calendar days of receipt of
order
C.
Embedments, for installation by the Construction Contractor. Deliver
embedments within sixty (60) days following approval of pit foundation shop
drawings.
D.
Operation and Maintenance (O&M) Manuals
E.
Training program and training plan
F.
Certificates of training completion
G.
As-Built Drawings
H.
Hardware and software
I.
Spare parts list
J.
Special Tools: Two (2) of each special tool, and instruments if any, required for
maintenance or adjustment, packed in two (2) appropriate steel tool boxes.
Furnish these tools at least twenty-one (21) days prior to commencement of
training program
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 18 of 52
1.09
K.
Matching touch-up paint for each color used to permit retouching, one (1) gallon,
prior to issuance of Substantial Completion Certificate.
L.
Warranties
M.
Commissioning data
OPERATION AND MAINTENANCE MANUALS
A.
B.
O&M Manuals shall address the following:
1.
Operations – Detailing safety instructions, proper operation and basic
troubleshooting of the supplied equipment. This data shall be targeted for
the daily equipment operator.
2.
Maintenance – Detailing both corrective and scheduled preventive
maintenance of the supplied equipment. This shall include in depth
troubleshooting, system functional description, theory of operation and
detailed illustrated parts catalog. The preventive maintenance information
shall include recommended service and replacement intervals for all
maintainable components up through system replacement.
O&M Manuals shall be submitted for each equipment system as follows:
1.
Outline Draft: A minimum of three (3) copies of sample formats and
outline of contents in draft form ninety (90) days prior to the earliest
scheduled equipment delivery to be submitted to the Engineer for
approval.
2.
Draft: A PDF version of complete manual in final form for Engineer
approval thirty (30) days before equipment initial delivery date.
3.
Pre-Final O&M Manual: A minimum of two (2) hardcopies of approved
manual after the equipment is installed, ready for acceptance test and to
perform training. In addition, an electronic version of the Manual on CDROM or flash drive, one (1) copy per employee to be trained plus two (2)
file copies.
4.
Final Manual: Three (3) hardcopies of final approved manual after the
equipment is installed, the acceptance test has been approved, and
training has been performed and completed.
a.
The manuals shall be updated based on input from VRE and the
Engineer during acceptance testing and training, for all sections of
the manual.
b.
The manuals shall show final as-built
conditions, procedures and drawings.
IFB No. 016-001
DROP TABLE SYSTEM
installed
material,
TECHNICAL SPECIFICATIONS
Page 19 of 52
5.
C.
c.
One (1) of the copies shall be configured for the harsh shop
environment by inserting all single pages in plastic laminate and
foldout pages individually enclosed in clear plastic pockets.
d.
Also include three (3) electronic versions of all manual contents.
Electronic version shall be non-editable but searchable Adobe
Acrobat PDF, stored on CD-ROM or flash memory drive.
Final Acceptance will not be granted until receipt of the print and
electronic copies of the approved manuals.
Hard copy O&M Manuals shall be prepared as follows:
1.
Front cover: Illustration of the equipment described in the O&M Manual
2.
Front cover, spine and title page include the name and function of the
equipment, manufacturer’s identification, project specification number and
title
3.
Loose leaf, on minimum 24-pound, punched paper
4.
Pages shall be 3-hole punched
5.
Entire length of margin with holes reinforced with plastic
6.
All pages, except for drawings, shall be 8.5 x 11 inches, portrait style.
Drawing pages shall be 8.5 x 11 inches or 11 x 17 inches.
7.
New sections and chapters shall begin on a right-hand facing page. At
the end of each chapter or section if there is a blank left-hand page, print
on the left-hand page, “This page intentionally left blank,” in the document
font style of the body of the text.
8.
Foldout diagrams and illustrations: Fan-fold 11 x 17 inches pages to 8.5 x
11 inches. For pages larger than 8.5 x 11 inches, display page
identification on last fold of folded page so as to be readable without
unfolding.
9.
Reproducible by dry copy xerography method
10.
Oil-, moisture-, and wear-resistant plastic covers
11.
Protruding plastic coated tabbed dividers, cross-referenced by number or
color to sections identified on the table of contents shall separate
sections.
12.
Manuals shall lie flat when opened. Pages shall not bind or join when
turned for normal reading.
13.
Manuals shall allow enough space for insertion of revised pages.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 20 of 52
D.
General Requirements for Manuals:
1.
Manufacturer’s operating manuals giving complete instruction relative to
assembly, installation, operation, adjustments, lubrication, maintenance and
complete parts list shall be furnished by the Manufacturer for every item of
machinery and equipment furnished by the Manufacturer. The information
shall be presented in a clear manner such as:
2.
a.
For operating type procedures, the nomenclature for control
positions, document test points and indicating devices having
panel nomenclature as it appears on the equipment panel,
placard, or structure (i.e., “Set Master Switch to ‘OFF’”).
b.
Enumerate and describe every component and its related parts,
including identifying numbers and commercial equivalents where
applicable.
c.
Include cut away and exploded view drawings for identification of
all parts.
Manual (or volume in the case of multi-volume manuals) shall contain a
table of contents and be organized into nine (9) specific chapters as
outlined below:
a.
Chapter 1 – General Information and Specification
b.
Chapter 2 – Theory of Operation
c.
Chapter 3 – Troubleshooting
d.
Chapter 4 – Primary Repair
e.
Chapter 5 – Secondary Repair (Component Level)
f.
Chapter 6 – Preventive Maintenance
g.
Chapter 7 – Illustrated Parts Catalog
h.
Chapter 8 – Miscellaneous
i.
Chapter 9 – Wiring Diagrams
3.
Manuals shall include copies of all approved shop drawings submitted.
They shall be provided in an Appendix Binder following the size and
format requirements herein. 11” x 17” drawings shall be fan-folded per
SECTION 1.09C.8. Larger drawings shall be folded to page size, with
title block information visible, and stored in three-ring clear plastic
pockets.
4.
Illustrations shall be clear, and printed matter, including dimensions and
lettering on drawings, shall be easily legible. If reduced drawings are
incorporated into manuals, original lines and letters shall be darkened and
have their light weight increased as necessary to retain their legibility after
reduction.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 21 of 52
E.
1.10
5.
All material shall be in the English language.
6.
Chapter 7 (“Illustrated Parts Catalog”) of each manual shall also contain a
list of nearest local suppliers of all equipment parts, as well as contact
information for the nearest factory-authorized service location.
7.
Chapter 8 (“Miscellaneous”) shall also contain copies of start-up and
acceptance test procedures and results/reports.
Operating Diagrams:
1.
Piping diagrams, electrical wiring diagrams, fuel oil, lubricating oil, water
capacity diagrams, and other diagrams necessary for operation of
machinery and equipment shall be furnished and installed where
designated by the Engineer.
2.
No single diagram shall show more than one (1) system, or parts thereof.
3.
Diagrams shall be reproduced by photographic process to a size no to
exceed eighteen (18) inches by twenty-four (24) inches and shall be
complete and legible in all respects. Systems shall be subdivided into
portions, which are operable from location where diagrams are installed,
and to provide intelligible information within specified size. They shall be
made on white paper and vacuum-sealed in transparent plastic material
impervious to moisture and oil, and resistant to abrasion. Other formats,
which are equal in clarity, sharpness, durability, and permanence, will be
considered.
VERIFICATION OF DIMENSIONS
A.
Verify the dimensions and vehicle/truck/wheel characteristics of VRE’s fleet of
locomotives and coaches to ensure proper operations of the equipment and
avoid clearance conflicts. The VRE revenue vehicle fleet to be serviced at the
LOU Facility will consist of the following:
1.
Locomotives: Twenty (20) MotivePower MP36PH-3C
2.
Coaches: One Hundred (100) Nippon Sharyo Gallery-Style
B.
The Manufacturer shall be responsible for coordination and proper relation of all
work to the equipment installation and to the work of all trades for the installation
of the equipment in the pit.
C.
The Manufacturer shall verify all dimensions of the site that relate to fabrication
and delivery of the Drop Table System and notify the Engineer of any
discrepancy before fabrication and delivery of the equipment to the site.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 22 of 52
D.
1.11
1.12
Surfaces to receive metal fabrications shall be sound, square and true. Such
surfaces shall be examined prior to the installation of the fabrications and all
defects that might impair the operability or shorten the life of any of the parts of
the item shall be brought to the attention of the Engineer in writing, and shall be
corrected by the Manufacturer.
AS-BUILT DRAWINGS
A.
One (1) complete hardcopy set of full size as-built shop drawings shall be
furnished with the specified equipment. As-built drawings shall reflect all
changes made during installation, testing and checkout.
B.
As-built drawings shall include all assembly drawings, exploded views of
assemblies, operation drawings, electrical drawings, wiring diagrams and
layouts, electrical schematics, control diagrams, and I/O drawings necessary for
the long-term operation and maintenance of the equipment.
C.
As-built drawings shall also be supplied on a CD-ROM in non-editable, Adobe
Acrobat (PDF) electronic file format.
D.
If no changes to the equipment occurred during installation, testing and checkout,
provide a written certification to that effect in lieu of as-built drawings. This does
not waive the requirement for shop drawings to be included with the O&M
Manuals.
TRAINING PROGRAM
A.
Identify all rail vehicles and other Engineer-supplied items needed for training.
B.
Provide timely notification to the Construction Contractor to arrange for rail
vehicles and other Engineer-supplied items, but not less than fifteen (15)
calendar days prior to the training date.
C.
The Manufacturer shall provide calibrated wheelsets, if required, for training and
testing.
D.
The Manufacturer shall be responsible for training as specified below:
1.
Maintenance management classes shall take place prior to the use of the
equipment by VRE.
2.
Mechanics’ operation and maintenance training shall commence only
after installation of the equipment is complete and equipment testing and
checkout has been successfully completed to the satisfaction of the
Engineer.
3.
Training shall be conducted at the equipment or in a classroom at the
jobsite, as appropriate. Other locations may be utilized with prior
approval of VRE.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 23 of 52
4.
Hours for training shall be between 7:00 A.M. and 3:00 P.M. EST unless
specifically permitted otherwise in writing by VRE.
5.
“Pre-Final” versions of the O&M Manuals shall be used in the training.
6.
Revise O&M Manuals to incorporate corrections, additions and other
feedback from the training.
E.
The instructor(s) shall be fluent in both spoken and written English and shall have
a thorough knowledge of the equipment and systems furnished. They shall be
able to utilize proper methods of instruction, training aids, audiovisuals, etc., to
ensure effective presentations. The instructor(s) shall have previous formal
classroom instruction training.
F.
The Manufacturer shall be responsible for providing all training aids, audiovisual
equipment and visual aids necessary to conduct the classes.
G.
All training materials (with the exception of calibrated wheelsets) will become the
property of VRE at the conclusion of training.
H.
Submission and Approval of Training Plans:
I.
1.
Meet with VRE at least four (4) weeks prior to the start of formal training.
At that time, the Manufacturer shall submit lesson plans and an outline of
the training program and demonstrate any training aids involved.
Handouts shall be presented for approval and provided later in a ratio of
one (1) per student. Each location shall receive a complete set of prints
and schematics.
2.
Submit in writing plans for meeting the specification training requirements.
VRE will approve and then coordinate and schedule all training involved.
Outline specific objectives for each of the courses:
1.
The course shall include sessions in safety, machine operation and a
comprehensive seminar on learning basic skills/knowledge of each
operation. The course shall include both classroom and practical
exercise sessions and shall provide the mechanic with the basic
knowledge necessary to operate and maintain the equipment. The
Manufacturer shall provide a detailed schedule outlining the length and
content of each of these sessions in accordance with the guidelines
established.
2.
The training program shall include familiarization with equipment
operation and performance and detailed instruction in operation,
maintenance, calibration of system and all test procedures. Maintenance
training shall include scheduled maintenance, unscheduled maintenance
(repair), adjustment, fine-tuning, troubleshooting and testing.
3.
The training program shall, as applicable, provide training for Engineering
and Management, Operating and Maintenance Personnel.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 24 of 52
4.
1.13
1.14
The training program duration shall be appropriate for the complexity of
the equipment, and subject to revision by the Engineer during review of
the Manufacturer’s submitted Training Program.
Typical minimum
durations are as follows, and would be superseded by requirements in a
specific equipment section:
a.
Off-The-Shelf Equipment - Operating Personnel: eight (8) hours;
Maintenance Personnel: eight (8) hours.
b.
Systems – Engineering and Management: eight (8) hours;
Operating Personnel: forty (40) hours; and Maintenance
Personnel: forty (40) hours.
HARDWARE AND SOFTWARE
A.
Provide three (3) copies of the final version of the control software, for back-up
purposes, in electronic format on separate flash memory devices with a standard
USB socket (2.0/3.0 compatible).
B.
Provide fully licensed versions of any and all software necessary to run and
process the control software.
C.
Provide any and all hardware necessary to run and process the control software.
COMMISSIONING DATA
As part of the final documentation, the Manufacturer shall provide a letter written
on the Manufacturer’s letterhead, and signed by an authorized representative of
the equipment Manufacturer, providing the following commissioning data:
A.
Equipment Description
B.
Location (of the installation)
C.
Original Equipment Manufacturer (OEM)
D.
Model Number
E.
Serial Number
F.
Nameplate Data (provide where applicable)
1.
Electric
a.
Volts
b.
Amps
c.
Phase
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 25 of 52
2.
3.
G.
1.15
Air
a.
CFM
b.
PSI
Water:
a.
GPM
b.
PSI
Dimensions:
1.
Length
2.
Width
3.
Height
H.
Weight
I.
PLC Controlled (provide model, if applicable)
J.
Date of Factory Test
K.
In-Service Date
L.
Warranty Expiration Date
M.
Equipment Cost
EQUIPMENT IDENTIFICATION
Provide a corrosion-resistant identification plate clearly marked and stamped with
the Manufacturer’s name and address, model number, serial number, date of
manufacture, and all pertinent utility and operating data (or ratings), and
permanently attach it at a prominent location on the equipment.
1.16
NOISE AND VIBRATION ISOLATION
A.
Noise and vibration isolation pads shall be provided as indicated and where
required, shall meet all requirements indicated, and shall be equipped with
necessary bearing plates and bolts. Noise and vibration pads shall be
specifically designed for the weights, speeds, and vibration characteristics of the
equipment supported. The pads shall provide proper weight distribution to avoid
distortion of the bedplates.
B.
Bolts and other fastening in connection with these pads shall be effectively
isolated.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 26 of 52
1.17
INSPECTION
A.
The Engineer and VRE will periodically inspect work during the course of the
construction.
B.
Provide for inspections by all others having jurisdiction over the work.
C.
At time of final inspection, furnish certificate or certificates of final approval by all
others having jurisdiction as applicable.
PART 2 – PRODUCTS
2.01
2.02
EQUIPMENT
A.
Provide piping, fittings, valves, connections, etc., of a type and size in
accordance with approved shop drawings and installation instructions that will
properly interface with the piped services.
B.
All piping, valves, fittings, conduits and wiring required for the equipment
installation shall be in accordance with requirements specified in the Contract
Documents and approved shop drawings.
MANUFACTURER
A.
B.
The Drop Table System shall be provided by the following Manufacturer or
approved equal:
1.
The Macton Corporation
116 Willenbrook Road
Oxford, CT 06478
Tel. No. (203) 267-1500
www.macton.com
2.
Whiting Corporation
26000 Whiting Way
Monee, IL 60449
Tel. No. (888) 944-8464
www.whitingcorp.com
The equipment shall be used to transfer a truck (or wheelset) to and from the
service track to an adjacent set of rails on the release track leading to the truck
repair area. The equipment shall also handle a Head End Power (HEP) extractor
device to and from a below-ground equipment storage area located under the
release track.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 27 of 52
C.
The system shall be an electrically driven, mechanical jack, four-screw drop table
capable of lowering the service top with a truck while supporting the locomotive
or coach on body supports, conveying the service top and truck to the release
track and elevating the service top and truck to the shop floor elevation.
1.
Accommodate trucks of all locomotives and coaches operated by VRE.
Verify with VRE the weights, dimensions, clearance requirements and
other characteristics required for design of the Drop Table System.
a.
Maximum truck height including springs: 6’-0”
b.
Maximum truck length: 17’-0” (not including traction bar)
c.
Maximum dimensions of HEP extractor: 10'-0" wide by 16'-0" long,
which must pass between the spacer post guides with minimum 2inch clearance on each side at the release top to enter the belowground-equipment storage area.
2.
At the service top location, provide two (2) wheeled movable body
supports, each fitted with appropriate retractable vehicle supporting
fixtures and each mounted on a support beam spanning the equipment
pit.
3.
The service top shall be sectionalized so that a smaller segment can be
utilized to handle individual locomotive wheelsets with a traction motor.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 28 of 52
4.
Item No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2.03
Dimensions and Capacities:
DROP TABLE SYSTEM CHARACTERISTICS
Characteristic
Dimension / Capacity
Lifting Capacity
100 tons
Body Support Capacity
50 tons (each)
Number of Service Tops
1
Number of Release Tops
1
Service / Release Top Rail Length
20’-0”
Service Top - Side Floor
3’-6” below Top of Rail
Service Top - Center Pit
5’-6” below Top of Rail
Depth of Pit
~24’ below Top of Rail based on
the Manufacturer’s Minimum
Requirements
Track Gauge
4’ 8-1/2 “
Track Spacing
As Indicated on the Drawings
Minimum 5’ 8” (retracted)
Service Track Centerline to Face of Body
Support Arm
12.
Body Support Travel
13.
14.
Lifting/Lowering Speed
Racking Speed
16’ to Both Ends of Service Top
(minimum)
2.8 feet per Minute (minimum)
30 feet per Minute
(minimum, variable)
5.
Gaps between the shop rails and the service, auxiliary or release top
rails, and between the auxiliary top rail and service top rail, shall not
exceed 1/4 inch. These gaps shall not be out of horizontal or vertical
alignment with each other by more than 1/8 inch.
6.
Gaps between plated surfaces, service top, release top, support beam or
other Drop Table System equipment and shop surfaces, shall not exceed
1/2 inch.
7.
Provide a minimum of four (4) threaded inserts and screw-in lifting eyes,
sized and reinforced to lift the service, single axle auxiliary or release
tops. Position the inserts so that lifting of these parts can be performed
safely.
DESIGN REQUIREMENTS
A.
Transfer Table Features:
1.
Capable of raising a 100-ton load a minimum of 1 inch above the shop
rails to allow for the insertion of the body support brackets.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 29 of 52
B.
2.
Designed so that at a specified point during the upward movement on the
service track, the table may be laterally shifted by up to 2 inches to align
the truck with the vehicle body. Once the truck is aligned with the vehicle,
the transfer table shall then shift the table back in line with the shop
tracks. These movements shall be controlled by the operator.
3.
Four (4) elevating jack screws arranged in an inverted mode based within
jack support columns.
4.
Jack screws shall be self-locking, requiring power to be applied for
movement.
5.
Jack mechanism shall be totally covered to prevent debris from
contacting jack surfaces.
6.
The jack nut housings shall be provided with a system of guide rollers to
guide the load carrying lifting beam along the support column. The guide
rollers shall transmit bending loads into the support column and not into
the jack screws.
7.
Provide a continuous lubrication system for the jack screws, applying
lubrication when in the lifting cycle only.
8.
Drive shafting shall be self-aligning.
Service Top:
1.
Center Pit Floor: 5’-6” below top of rail. Minimum 6 inch wide continuous
shelf angle on each side of pit, 1’-0” above pit floor.
2.
Depressed Side Pit Floor (on the field side of the rails): 3’-6” below top of
rail.
3.
Rail Size: SAE 1040 CRS bar stock, chamfered on gauge side top edges
or standard railroad section rail, minimum 115 #/yd.
4.
Rollover Capacity: 72,000 pound axle load
5.
Flooring: Minimum 3/4 inch thick non-skid diamond steel plate. Apply
silica epoxy grit coating to all walkable surfaces of exposed plates to
provide a non-slip surface.
6.
Floor opening gaps and gaps between service top and shop floor curb
angles and pit surfaces: Not to exceed 1/2 inch.
7.
Provide plate steel on non-walking horizontal and vertical surfaces to
reduce gaps to not exceed 1/2 inch.
8.
Locking bar pockets, guide rails and all other items required to be
embedded in the pit walls or foundation (except where noted) shall be
designed and furnished by the Manufacturer. Provide locking bar pockets
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 30 of 52
for the service and sectionalized tops and positive visual indication with
raised letter labeling when the locking bars are fully engaged in each
pocket.
9.
When the service top is completely lowered, provide a minimum of 6’-6”
clearance from the service top (top of rail) to the underside of any
obstruction within the pit that the service top (with truck) must pass
beneath during normal operation.
10.
Auxiliary (Sectionalized) Top:
a.
The auxiliary top shall have lock sensors to indicate that the top is
properly locked or released. The locking bars shall be able to be
visually verified that they are locked in or released from the
locking bar pockets on both the end wall and the service top.
b.
The Drop Table System shall be provided with a remote means of
engaging the auxiliary top for wheelset removal without having to
enter the drop table pit below the service top.
c.
Provide a minimum of 5’-0” clearance from the auxiliary service
top (top of rail) to the underside of any obstruction within the pit
that the auxiliary service top (with wheelset) must pass beneath
during normal operation.
d.
Provide a traction motor dolly for the auxiliary top to support a
traction motor when a wheelset is supported on the auxiliary top.
i.
The traction motor dolly shall be supported on rollers and
be easily positioned at 2-inch lockable increments along
the length of the auxiliary top with evenly spaced holes and
a plunger-style locking device on each side.
ii.
The height of the support for the traction motor shall be
variable with the use of an electrically-powered hydraulic
pump with minimum 25-ton capacity and 14” of stroke.
iii.
The pump shall include an adjustable relief valve with
gauge to limit the load on the cylinder to the actual
resistance of lifting the traction motor.
iv.
Provide a roller clevis at the top of the cylinder. The roller
clevis shall automatically disengage when the cylinder rod
is fully retracted.
v.
The traction motor dolly lifting operation shall be controlled
from the control pendent with a 12-foot long coiled cord.
Provide a shelf, below the rail, on the auxiliary top to locate
the pump during operation and to store the cord and
pendent when not in use.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 31 of 52
vi.
C.
The pump shall operate from a Manufacturer-installed 120
volt receptacle on the service top by a 12-foot coiled cord.
11.
Provide ladder rungs attached to the rail support pedestals at each of four
(4) corners of the service/auxiliary top to ensure safe stepping down onto
the depressed side pit of the service top when it is at the release top
position. Provide an extendable vertical post (3’-6” extension above top
of rail) built into the ladder post closest to the edge of the service/auxiliary
Top for workers to grab while descending or ascending the ladder.
12.
Provide galvanized steel curb angles around all edges of the surrounding
concrete track pit floor that will be installed by the Contractor to provide
the specified gaps between the Drop Table System equipment and the
building construction.
Release Top:
1.
Provide a bascule-type release top designed to open as the service top is
raised at the release track location and to close as the service top is
lowered. The top shall be arranged to open with the upward movement of
the Drop Table and service top. This movement shall result from the
engagement of lugs attached to the spacer posts contacting and
engaging with a contact pad or roller on each of four (4) jack nut
housings, causing the spacer posts to rise within structural steel guides
embedded in the pit walls.
2.
The release top shall provide a flush surface with the top of rail and shop
floor when in the closed position.
3.
The release top shall be constructed of minimum 3/4-inch thick solid, nonskid diamond plate steel and steel framing set flush with adjacent floor
surfaces, able to support a uniform load of 300 PSF or a 6,000 LBS
concentrated load over a 6 inch diameter area. Apply silica epoxy grit
coating to the top surface of the release top for a non-slip surface.
4.
The release top rails shall be designed with a rollover capacity of a
50,000 pound loading in a 2-axle truck.
5.
The release top shall have rails flush with the top of cover that are
minimum SAE 1040 Cold Rolled Steel (CRS) bar stock (chamfered on
gauge side) or standard railroad section rail, minimum 115 #/yd. and that
shall align with the shop release track rails.
6.
Provide spacer post guides, release top guides, support plates and all
other items required to be embedded in the pit walls or foundations.
7.
The overhead beam between spacer posts shall provide a minimum 6’-6”
clearance to top of rail when fully raised.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 32 of 52
D.
8.
Provide stainless steel cables, tensioned to 5,000 pounds, across and
under the top of the spacer posts, on each end of the Drop Table, to
provide fall-arrest connection points (two (2) persons per cable) in the
release track area.
9.
Provide a rolling cart with foot brake and flanged wheels that can be
placed on the shop tracks and pushed to the unloading position of the
wheelset on the auxiliary top at the release track position. This cart shall
be constructed of aluminum components to be light weight. The walking
surface of the cart shall be non-slip expanded planking, with a channel
frame. Handrails shall be provided on the sides with a slot in the center
to allow the traction motor to be supported by a Drop Table dolly. Provide
a dimensioned shop drawing for the cart.
10.
Furnish galvanized steel curb angles around all edges of the surrounding
concrete shop floor that will be installed by the Contractor to provide the
specified gaps between Drop Table equipment and the shop floor. Edge
angle shall be 2” x 2” x ¼” with welded Nelson studs spaced as required
for durability. Provide detailed installation drawing in shop drawings.
Body Support Beam:
1.
Designed to support the loads of the body supports and vehicle.
2.
Body support beams shall be designed to permit the removal of the body
supports at one (1) end of the beam. Beams shall have removable end
stops to prevent accidental over-travel of the body supports. The slot for
the removal of the body support shall be filled with a solid structural
section with welded on cover and screw insert.
3.
Provide solid, non-skid diamond plate steel with silica epoxy grit coating
to the top surface of the beams (except where the body support flanged
wheels travel).
4.
Place anchor bolts no closer than 1 foot to the edge of the Drop Table pit.
5.
The top of the body support beam shall be at the same level as the
depressed side floor of the service top
6.
The field side of the floor shall not be widened in the area of the anchor
bolts for bolting them down.
7.
Provide continuous ½”-16 expanded galvanized metal sheets supported
by intermediate framing at a minimum 4 feet on center to fill the field side
gap between the top of the body support beams and the underside of the
adjacent concrete shop floor.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 33 of 52
E.
F.
Body Supports:
1.
Provide moveable body supports, flanged wheel-mounted on each body
support beam, with the ability and capacity to support each locomotive
and coach in the VRE fleet.
2.
The body supports shall have a capacity of 50-tons each. The capacity of
each support shall be marked clearly on each piece.
3.
The body support arms shall have vertical and horizontal adjustment to
contact and support all jacking pad locations of all locomotives and
coaches in the VRE fleet. Make field measurements to determine the
size, vertical and horizontal dimensions.
4.
Body support arms for coaches may be nested into the locomotive body
support arms.
5.
Vertical and horizontal adjustment shall be provided by means of rotating
12-inch diameter steel hand wheels or handle ratchet. Pin the handles to
allow for removal and alternate operation by pneumatic tool. Tether the
handle and provide a storage bracket.
6.
Floor openings shall provide a maximum ½-inch clearance for the
movable body support structures.
7.
Each body support shall be moved mechanically along the beam by
manually rotating a minimum 12-inch diameter steel handle (hand wheel)
or handle ratchet.
Progression System:
1.
The progression system shall be an electro-mechanical machine
designed to move coach or locomotive trucks or the HEP extractor
between the Drop Table service top and a storage position on rails
located at the pit-level pocket track. The system shall include storage
rails, end wheel stops, mounting plates and all hardware.
2.
The progression system shall permit locomotive and coach trucks and
VRE’s HEP extractor to be moved to/from the Drop Table service top
to/from the pocket track that extends from the Drop Table pit. This shall
only be permitted when the service top is at the release track position and
is fully lowered. The pocket track shall have sufficient length to store
either one coach or locomotive truck or VRE’s HEP extractor.
3.
Fabricate the runway from structural shapes to create a housing. The
housing shall act as a guide for the continuous chain drive and a track for
the carriage. Anchor the runway to the concrete floor.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 34 of 52
2.04
4.
The carriage shall be a steel weldment attached to the drive chain to
move back and forth along the runway when powered. The carriage shall
run on four (4) roller bearing wheel assemblies with provision to mount
pulling and pushing adapters for the trucks to be removed.
5.
Provide adapters mounted to the traveling carriage with a quick release
pin through a pivot mechanism mounted on the carriage for moving the
trucks or HEP extractor in and out of storage area. Adapters shall be
supplied for all truck types and the HEP extractor device.
6.
The drive system shall include a continuous chain driven by a sprocket
mounted to a combination motor/reducer. The chain shall be tensioned
by a spring loaded sprocket to allow driving in both directions while under
load.
7.
Provide guide rails and all other items required to be embedded in the pit
walls or foundation to accommodate the truck transfer operation at the
pocket track position.
8.
Provide rails and anchoring system for the storage track in the pit. Rails
shall be surface mounted SAE 1040 CRS bar stock, chamfered on gauge
side top edges or standard railroad section rail, minimum 115 #/yd.,
matching rail on service top. Provide rail end wheel stops.
9.
Gaps between the service top rails and pocket track rails shall not be
greater than 1/4 inch. These gaps shall not be out of horizontal or vertical
alignment with each other by more than 1/8 inch.
10.
Control of the progression system shall be through the main electrical
cabinet for the Drop Table System.
11.
The progression system shall be electrically interlocked with the Drop
Table to prohibit simultaneous operation of both.
12.
A wireless controller, located in the below floor storage area, shall be
provided to operate the progression system.
STRUCTURAL REQUIREMENTS
A.
Verify dimensions prior to fabrication and construction.
B.
Provide ASTM A36 or ASTM A572 Grade 50, tube steel to ASTM A500 Grade B,
and pipe steel to the provisions of ASTM A501.
C.
High Strength Bolts: ASTM A325.
D.
Anchor Bolts: ASTM A 36 steel with heavy hexagonal nuts and standard
washers.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 35 of 52
2.05
E.
Welding Requirements: American Welding Society Structural Welding Code AWS
D1.1 and welding electrodes shall be E70XX classification of AWS A5.1.
F.
Surfaces to receive metal fabrications shall be sound, square and true, free from
dirt, oil, grease, objectionable coatings, loose detached, or unsound fragments
and all other foreign material.
G.
Drilled in Anchors: HILTI, or approved equal, Stainless Steel Model HAS Rods
with Model HVU Adhesive System, placed in accordance with Manufacturer’s
recommendations.
H.
Grout: Epoxy grout for areas subject to vibration or impact loading.
ELECTRICAL REQUIREMENTS
A.
General
1.
Power supply for equipment shall be a single 480 volts, 3-phase, 60 hertz
feed unless otherwise indicated.
2.
Provide transformers for equipment as required to step down the
specified supply voltage to provide lower voltage for controls and
accessories and to provide voltage compatible with equipment as
required.
3.
Equipment grounding shall be accomplished by means of separate
grounding conductor in each conduit sized according to code. The
grounding conductor shall have green insulation.
4.
Starters, controllers, disconnect switches and start-stop stations shall be
provided for all equipment. Correct sizing of starters and disconnect
switches shall be joint responsibility of the Construction Contractor and
the equipment or apparatus Manufacturer.
5.
a.
Electrical enclosures shall be NEMA 12 for indoor units above the
rail and NEMA 4 for outdoor and below the rail indoors units
unless otherwise indicated.
b.
Starters shall be complete with two (2) sets of auxiliary contacts;
one (1) set normally open; one (1) set normally closed.
c.
For motors 25 HP or greater provide autotransformer type
reduced voltage starters unless otherwise indicated.
Control devices necessary for proper operation shall be provided and
shall be located to permit efficient operation of the equipment, and where
possible shall be ground in a factory fabricated NEMA approved control
panel complying with requirements indicated.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 36 of 52
6.
Switches, lights and control functions shall be identified with legend
plates. The plates shall be constructed of polyvinyl chloride material of
laminated multiple constructions, and engraved with appropriate legends.
The legend plates, including size of letters, colors, and legend shall be
submitted to the Engineer for approval. The legend plates shall be
mounted on the equipment in an approved manner. No decals will be
accepted.
7.
Permanently label all equipment items including but not limited to,
switches, starters, controllers and start-stop stations with engraved PVC
labels with minimum 1 inch high lettering to identify corresponding
equipment items.
8.
Wiring shall be provided for complete installation of all equipment and
accessories and shall be adequate for proper operation of equipment.
9.
Wire and cable for light, power and control circuits shall conform to those
specified in the National Electrical Code. In no case shall maximum
current carried exceed that specified by the National Electrical Code for
the type of conductor used. Provide conduit where required; all wiring
and conduit shall be in accordance with the requirements of National
Electric Code.
10.
Make connection to secondary side of disconnect switch and provide all
wiring and conduit with supports from this point, including wiring to
controller and starters.
11.
Wire harnesses shall be used to the greatest extent possible.
12.
Provide conduit where required; all wiring and conduit shall be in
accordance with the requirements indicated.
a.
The minimum conduit size permissible shall be ¾ inch.
b.
All wires shall be properly insulated and all conduit edges shall be
protected to prevent wire chafing.
c.
All wiring for the controls and motors shall be coordinated for use
of type MTW, THWN, and THHN standard wire.
d.
Conduit: Supply rigid galvanized steel conduit, or liquid tight
flexible metal conduit. Liquid tight flexible metal conduit shall be
used in lengths not exceeding 6 feet.
e.
Identify wiring by a wire tag with a number corresponding to the
wiring diagram.
f.
Control Wiring Conductors: Not less than #14 AWG, strand
copper, 600 volt insulated, water and oil resistant.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 37 of 52
13.
B.
g.
Power Wiring Conductors: Not less than #12 AWG or larger as
required for power wiring.
h.
All bus work and windings shall be copper.
Provide grounding devices to accommodate connection of the equipment
to the existing building grounding system. Ground all equipment by
means of a conduit ground according to NEC Article 250. The grounding
conductor shall have green insulation.
Motors:
1.
Motors shall be high efficiency makes, each bearing the UL label and
constructed to standard of NEMA, IEEE, ANSI, and ABMA.
2.
Motors shall be suitable for operation on the electrical service indicated.
3.
Horsepower ratings and sizes shall be selected at 40° C ambient
temperature for open motors, with service factor of 1.15 for open motors
and unity for service factor for totally enclosed or drip-proof motors.
Provide motors with epoxy encapsulated for severe usage in a corrosive
atmosphere.
4.
Motors rated one (1) horsepower or greater shall have a full-load power
factor of eighty-five percent (85%) or higher. Motors rated 25 HP and
over shall be designed for reduced voltage starting.
5.
Installation instructions shall have details regarding correct rotation and
alignment of motor shafts. Motors shall include identification of the correct
direction of rotation.
6.
The motors shall be protected by overload devices to permit operation
within their rating under all design load conditions. Provide each individual
motor circuit with branch circuit over current protection in all three phases.
7.
All motors shall be totally enclosed heavy-duty type equipped with sealed
ball bearings, magnetic brake and overload protection. Enclosures shall
be steel or cast iron only. Aluminum end bells are permitted.
8.
Provide overload protection for motors to permit operation within their
rating under all design load conditions.
9.
Motors over three (3) HP shall operate at one hundred and fifteen percent
(115%) percent service factor.
10.
Insulation shall be Class "F". Temperature rating of motors shall not
exceed that permitted by Class "B" insulation. Motor windings shall be
copper wire.
11.
Equip each motor circuit with individual branch circuit overcurrent
protection in all three (3) phases via circuit breakers.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 38 of 52
C.
D.
12.
Provide bimetal thermal type starters with overload elements on each
phase.
13.
Equip motors with magnetic brakes so that all movement is automatically
locked unless power is applied.
14.
Each motor shall have an emergency safety stop station wired in the
control circuit and installed at the motor location with maintained contact
device and NEMA 4X enclosure. Stations shall be connected to prevent
operation of the motor when the station is in the "OFF" position, with
provision for padlocking in the "OFF" position. When one (1) motor switch
in a set is in the "OFF" position, the other motors shall be inoperative.
Drives
1.
Guards shall be provided for each coupling and belt drive in conformance
with applicable codes.
2.
Belt drives shall have adjustable motor drive pulleys.
3.
Belt drives shall be adjusted and work belts replaced in sets. Speed
adjustment shall be subject to approval of the Engineer.
4.
Provide sliding motor bases where adjustable motor drive pulleys are
provided.
5.
Motors and drives shall be checked carefully for correct rotation and
alignment before placing equipment into operation.
6.
Couplings shall be disconnected and realigned before placing into service
or testing.
Motor Control Enclosure and Cabinets:
1.
Motor control enclosures and cabinets above the floor shall be
constructed to minimum NEMA 12 Standards.
2.
All below track level electrical enclosures shall be constructed to NEMA
4X Standards.
3.
The main electrical enclosure shall include all overload breakers, starters,
circuit breakers, control transformers and disconnect switching.
4.
Provide an auxiliary contact in the main electrical enclosure for
connection to external safety systems. This contact shall be a normally
open contact on a relay; the relay shall be energized when the Drop
Table is in the up and locked position on the service track, suitable for rail
equipment to cross.
5.
The main electrical enclosure shall be placed as shown on the
Contractor’s Drawings.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 39 of 52
6.
The main electrical enclosure door shall contain a second set of indication
lights and pushbuttons similar to the pedestal-mounted Master Control
Console for controls testing and/or operation. Control voltage shall be
120 V or less.
7.
Make power connections to the main electrical enclosure, power and
control connections in the equipment pit, control connections at each of
the receptacles, and connections to the limit switches in the pit. Provide
interconnecting wiring that is embedded in the foundation or slab and
exposed conduit and wiring.
8.
Equipment shall be totally wired by the Manufacturer starting at the power
supply point and including a main disconnect switch.
9.
Equipment grounding shall be accomplished by means of a separate
grounding conductor in each conduit, sized according to Code. The
grounding conductor shall have green insulation.
10.
Provide conduit where required as follows:
a.
Minimum exposed conduit size: ¾ inch
b.
Minimum embedded conduit size: 1 inch
11.
Supply service will be 480 V, 3 phase, 60 Hz.
12.
Provide spring retracting cable reels or heavy duty festooned cable
system with sufficient conductors to facilitate 120 Volt 20 amp power
receptacle and lighting on the service top of the Drop Table through the
full range of travel.
13.
Provide a minimum of eight (8) linear feet of fluorescent lighting fixtures
mounted to the service top rail support beams to provide general
illumination to the underside of a vehicle truck comparable to that
provided for the adjacent shop pits.
14.
a.
Lighting Fixtures: 120 V enclosed gasketed waterproof fluorescent
fixture with impact resistant clear non-clouding polycarbonate lens
sealed against the ingress of dust, oil and water.
b.
Fixture Ballast: Remotely mounted, provide fixture design for the
minimum obstruction to personnel working in the confined area.
c.
Provide toggle switches on the service top for turning the lights
ON and OFF.
Motors and drives shall be checked carefully for correct rotation and
alignment before placing equipment into operation.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 40 of 52
E.
Controls:
1.
The pedestal-mounted Master Control Console shall be located near the
release track on the shop floor adjacent to the pit. The exact location will
be determined by VRE as part of shop drawing review.
2.
The Master Control Console shall be equipped with pole mounted strobe
lights, indication lights and horn. The console top shall also contain
indicator lights and operating pushbuttons. A hanger shall be located on
the console pedestal post to hold a wireless controller. An oversized red
mushroom emergency stop button with pull to re-set shall be provided
close to a corner of the console. All controllers shall have the following
features:
a.
Voltage shall not exceed 120 V.
b.
Constant pressure pushbuttons shall activate movement of the
selected component. Release of pressure on the button shall
result in stopping the movement.
c.
Permanent name plates shall be affixed for each operating button.
d.
An oversized red mushroom emergency stop button with pull to
re-set shall be provided at each controller.
3.
Indicator lights on the pole shall be provided to indicate the Drop Table’s
status, location and when the table is raised and in the locked/unlocked
condition. Strobe light and horn shall activate only when the transfer table
is raised or lowered. Strobe light colors shall change for racking and
raising/lowering. A separate indicator light shall illuminate on the control
console when the service top is within the upper racking range.
4.
A multi-positioned keyed switch at the master control console shall
determine which wireless controller or master control console controls the
operation of the Drop Table System at any time. Each wireless remote
controller shall be numbered and have its own individual “ON-OFF” key
for operation.
5.
Progression System Controls shall be mounted on a wall mounted control
box along with a wireless remote controller within the pocket track area.
The control shall have a key switch to select power, variable speed
control, direction control and emergency-stop. The controller shall be
locked out unless the transfer table is down and at the progression
system location.
6.
Remote Control: A portable, hand-held wireless controller which shall
control the raising, lowering and racking of the transfer table shall be
provided in the track pit adjacent to the service top. The wireless control
shall give the operator the ability to control all movements of the Drop
Table from any location around the perimeter of the service and release
track without having to enter the pit. Provide two (2) wireless remote
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 41 of 52
controllers; one (1) controller will be used at a time in conjunction with the
pedestal-mounted master control console. The second remote controller
is a backup. Provide charging stations for each wireless remote
controller.
2.06
2.07
7.
Top and bottom limit switches shall automatically stop the Drop Table at
its highest and lowest points on both the service and release tracks.
Auxiliary upper mechanical stops shall stop the motion and sound a
warning horn if the primary limit switch fails. The limit switches at the
release top shall stop the service top in line with the shop rail and the
pocket track rail. The limit switches at the service top location shall stop
the service top down in line with the pocket track and up a minimum 1
inch above the shop rail. The rail elevation at the service top shall be
manually leveled with the shop rail.
8.
Controls shall be interlocked to prohibit racking (horizontal travel) of the
Drop Table unless it is in the fully lowered position or at the upper racking
position and prohibit raising and lowering of the Drop Table unless it is
aligned with the service top or release top.
9.
Provide necessary cams and switches for accurately positioning the Drop
Table. Racking motion controlled by an inverter programmed for soft
acceleration and deceleration and limit switches to automatically stop the
racking movement when the Drop Table is properly positioned at the
service track or the release track.
CONCRETE FOUNDATIONS
A.
The Construction Contractor will provide anchor bolts as required for equipment
to be mounted. The Manufacturer shall provide data for anchor bolts including
material, diameter and length of embedment.
B.
The Construction Contractor will provide grouting as necessary to stabilize
equipment bases to concrete foundations.
C.
The Construction Contractor will provide hard rubber shims and dampening pads
as required for leveling of equipment and dampening of equipment vibration
transmission.
SAFETY BARRICADES
A.
Provide outward swinging safety handrails mounted to the pit wall on both sides
of the service top and on both field sides of the rail on the shop pit wall to prevent
personnel from entering the open pit when the service top is in the lowered
position.
B.
Provide safety retractable belts across both sides of the release track opening.
Belts will be supported on removable posts that extend 3’-6” above the floor. The
belts will be 6-inch wide polyester with diagonal yellow and black stripes.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 42 of 52
2.08
2.09
GASKETS AND FASTENERS
A.
Provide new gaskets wherever gasketed mating equipment items or pipe
connections have been dismantled.
B.
Replace all assembly bolts, studs, nuts and fasteners of any kind, which are
bent, flattened, corroded or have their threads, heads or slots damaged.
C.
Furnish all bolts, studs, nuts and other fasteners for make-up of all connections
to equipment and replace any of these items damaged in storage, shipment or
moving. Bolts shall comply with applicable SAE requirements including the
manufacturer’s identification and certification of testing.
D.
All torque fasteners shall be torque-marked.
HOLES, OPENINGS AND INSERTS
A.
Provide holes and openings in floors and walls as required, coordinating work
with the Construction Contractor constructing the LOU Facility.
B.
Core drill holes in existing work using dustless method. Grout in holes in
concrete walls, floor and roof slabs after installation of equipment, and leave
them in a completely neat and sealed condition
C.
Install concrete inserts and flashing as required.
D.
The following are modifications with structural implications:
1.
Do not perform any work that will alter existing structural elements unless
it is shown on the Facility Drawings or proposed alterations have been
approved in writing by the Architect.
2.
Structural elements include, but are not limited to, the following: steel
beams and columns, structural masonry walls and reinforced concrete
slabs.
E.
Provide sealing and flashing for all penetrations through exterior walls.
F.
The Contractor will provide holes and openings in floors, walls, ceilings and
roofs.
G.
The Contractor will use dustless methods, grout holes in concrete pit walls and
floor after installation of equipment, and will leave them in a completely neat and
sealed condition.
H.
The Contractor will install concrete inserts.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 43 of 52
2.10
NOISE AND VIBRATION ISOLATION
The noise level shall not exceed 80 dBA at the operator’s main console location
when the Drop Table is in operation.
2.11
PAINTING
A.
Equipment shall be given one (1) shop prime coat of approved rust-inhibitive
paint containing at least fifty percent (50%) rust-inhibitive pigments and
Manufacturer’s standard finish coat system unless otherwise indicated. Shop
drawings shall indicate brand and type of paint for both the prime coat and finish
coat systems. Finish coating system shall be Pittsburgh Paints 409-2 or
equivalent for all major equipment items, unless otherwise indicated. All color
selections shall be approved by the Engineer.
B.
Surfaces shall be free of rust, scale, dirt and oil before painting. Matching touchup paint shall be provided in the amount of one (1) gallon of each color used to
permit retouching. The touch-up paint shall be provided prior to Substantial
Completion.
C.
Field painting equipment including touch-up painting, if any, is included and the
equipment shall be factory-finished.
D.
Where factory finishes are provided on equipment and no additional field painting
is specified, all marred or damaged surfaces shall be touched up or refinished to
leave a smooth, uniform finish at the time of final inspection.
PART 3 – EXECUTION
3.01
3.02
PREPARATION
A.
Transmit submittals and deliverables as indicated.
B.
Furnish products as indicated.
C.
Inspect pits, embeds and utility connections and notify the Engineer if corrections
are needed prior to equipment installation.
D.
Coordinate and verify dimensions, loads, clearances and utility requirements
relating to the fabrication of the equipment and building construction with the
Contractor.
FABRICATION
A.
Fabrication shall be in accordance with all requirements specified and approved
on shop drawings.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 44 of 52
3.03
B.
Fabricate equipment from newly manufactured materials, products and
components. Do not utilize used, refurbished or remanufactured materials,
products or components. Surfaces shall not be warped (unless by design) and
free of dents and distortions.
C.
Pre-assemble units to greatest extent feasible for shipping. Grind exposed welds
flush. Remove all sharp edges.
D.
Field check for clearance and interferences before fabrication and relocate
material and equipment furnished as required (if approved by the Engineer) to
eliminate interferences.
PRE-SHIPMENT INSPECTION AND TESTING
A.
B.
Pre-shipment inspection and testing shall be performed at the Manufacturer’s
factory to determine conformance with the requirements in the specifications as
indicated and as follows:
1.
Prior to painting the equipment, the Manufacturer shall make the
equipment ready for a comprehensive pre-shipment inspection and
testing by the Engineer.
2.
The equipment shall be laid-out in its final configuration to the extent
possible to allow for all performance and functionality to be observed
before shipment.
3.
The pre-shipment inspection shall also allow for confirmation of
compliance with all documentation submitted to the Engineer.
The Manufacturer shall prepare and submit for the Engineer’s approval a
schedule and comprehensive procedure for functional testing and inspection.
The submittal shall be submitted for review and approved not less than four (4)
weeks prior to the start of the pre-shipment inspection and testing and shall
include step by step procedures, pass/fail criteria, all referenced documentation
and any other information necessary to perform one (1) successful
demonstration of the equipment’s operation and performance. At a minimum the
pre-shipment inspection and testing shall demonstrate:
1.
Equipment performs the work for which it is intended.
2.
Ability of the control logic to protect the mechanical and electrical
equipment from common operator and other types of errors and problems
shall be verified.
3.
All safety features.
4.
Basic functions of the equipment.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 45 of 52
3.04
C.
The Manufacturer shall bear all expenses of all tests, including the furnishing of
all necessary instruments, lubricants, hydraulic fluids, test weights, supplies, data
recorders and operating personnel.
D.
Any issues or discrepancies identified during the pre-shipment inspection and
testing shall be documented in a written report, prepared by the Manufacturer,
detailing the issues or discrepancies identified and the Manufacturer’s proposed
corrective actions. This report shall be submitted to the Engineer within two (2)
weeks after the completion of the pre-shipment inspection and testing and the
Manufacturer must obtain approval from the Engineer before corrective actions
may be implemented. All issues or discrepancies identified shall be resolved
before the equipment is shipped to the LOU jobsite.
E.
Upon acceptance of the factory test by the Engineer, the Manufacturer shall then
submit a site installation acceptance testing program at least thirty (30) calendar
days prior to the test, allowing the Engineer to witness the test, demonstrating
how the equipment complies with all specified requirements. Provide material
and manpower required for the program. VRE will provide rail vehicles and
components.
F.
After successful completion of in-plant testing VRE may elect to order spare
parts. Upon receipt of any order for parts, the Manufacturer shall furnish five (5)
copies of the approved spare parts lists as adjuncts of the Operations and
Maintenance Manuals within thirty (30) days.
DELIVERY, STORAGE AND HANDLING
A.
Coordinate with the Construction Contractor for the delivery and handling.
B.
The Manufacturer shall be responsible for storing the equipment at its facility or
at a bonded warehouse until such time that it is required for installation within the
LOU Facility.
C.
Provide a weekly storage rate as indicated in ATTACHMENT W.7 – BID FORM
included in this solicitation.
D.
Damage to equipment caused by negligence of Manufacturer’s forces shall be
compensated by the Manufacturer.
E.
Damage to equipment caused by negligence of the Construction Contractor’s
forces shall be compensated by the Construction Contractor.
F.
The Construction Contractor shall be responsible for off-site storage charges that
result from a postponement of delivery due to the Construction Contractor
delays.
G.
Pre-assemble system to the greatest extent possible to minimize field assembly.
Disassemble only as necessary for shipping and handling limitations. Clearly
mark units for re-assembly and coordinated installation. Re-assemble on the
jobsite according to the installation instructions.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 46 of 52
3.05
H.
Equipment and components shall be suitably crated to prevent damage in transit
or during handling. Items shall be carefully stored as required in a manner to
avoid misalignment or distortion, and shall be adequately protected against
damage by weather, construction exposure or other cause. Any items damaged
during delivery, storage or handling, shall be repaired to the Engineer’s
satisfaction or replaced at the Manufacturer’s expense.
I.
Special precautions shall be taken to prevent damage to electrical components
such as motors, controls and conductors.
J.
All materials shall be delivered to the jobsite with their original manufacturer’s
markings and identification intact. The Engineer will reject materials that are
damaged, improperly identified or not in conformance with reviewed shop
drawings and catalog cuts.
K.
The Manufacturer shall protect equipment during storage and prior to start-up,
which shall include covering of openings, protection against rust and other
damage. Equipment may not be stored outdoors.
L.
Equipment items/components that are furnished for installation by the
Construction Contractor shall be provided when needed on site so that they may
be installed within the building’s infrastructure. The Drop Table Manufacturer
shall provide the Construction Contractor with instructions for the proper storage
and handling of the items/components, and obtain a signature on the Bill of
Lading from the Construction Contractor’s representative acknowledging receipt
of the items/components.
M.
Delivery of equipment items/components furnished for installation by the
Construction Contractor shall be coordinated with the Construction Contractor to
ensure that items/components are delivered when they are needed by the
Construction Contractor and will not cause delays.
N.
All major components shall be delivered fully match marked.
O.
Upon completion of work and delivery, leave the jobsite and premises in good
order. This includes removal of Manufacturer-owned materials, and shipping and
packaging materials used in support of delivery of the equipment.
INSTALLATION
A.
It shall be the Manufacturer’s responsibility to assure that all information
regarding the scheduling, delivery and preparations necessary for setting up the
equipment to be supplied under this Technical Specifications Section is
coordinated with the Construction Contractor and reviewed by the Engineer prior
to delivery.
B.
Details listed in these Technical Specifications are given for a better
understanding of the work required by the Manufacturer, and do not place a
limitation on the amount of work to be done nor do they relieve the Manufacturer
of additional work that may be required for a complete installation.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 47 of 52
C.
Pre-Installation Conference: VRE, the Construction Contractor and the
Manufacturer shall meet at least one (1) week in advance of the scheduled date
for installation of the equipment, and after submittals have been approved. The
requirements for the equipment installation and conditions which could possibly
interfere with successful performance of the work will be reviewed at this time.
All individuals concerned with the equipment installation, or required to
coordinate with it or to protect it thereafter, are required to attend the conference.
D.
Prior to installation of Drop Table equipment, inspect the pit for proper installation
of anchor bolts and conduits as indicated on the approved drawings.
E.
Fit equipment and appurtenances to the space provided and make readily
serviceable. The Construction Contractor and Manufacturer shall coordinate
work with other trades.
F.
Furnish and install additional supports and hangers as may be required for the
proper installation of the equipment.
G.
The Drop Table System and all appurtenances shall be installed by the
Manufacturer or its authorized agent in accordance with the drawings and
approved Manufacturer's instructions.
H.
Make power connections to the main electrical panel, power and control
connections in the pit, control connections to the Master Control Console and at
each of the receptacles, and connections to the limit switches in the pit.
I.
Field Touch Up-Painting: Re-touch surfaces where the shop coat has been
damaged, using the same paint film thickness as the original shop coat.
J.
Furnish common and skilled labor, tools, rigging equipment, scaffolding, shims
and other materials necessary to make complete installation of equipment
indicated.
K.
All personnel provided by the Manufacturer during the course of the Contract that
require access to VRE’s property shall be Railroad Safety Trained (RST) through
mandatory completion of the VRE Roadway Worker Protection Class, and wear
required personal protective equipment and company photo ID at all times while
on the property.
L.
Receive, unload, check and store equipment in suitable facilities. All equipment
should be kept clean, dry and free from damage and be marked and tagged with
equipment item numbers.
M.
Examine equipment for concealed damage and report any damage.
N.
Be responsible for safety and protection from loss or damage of equipment
received until work is complete.
O.
Pay demurrage charges and claims for damage resulting from unloading
operations.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 48 of 52
3.06
3.07
3.08
P.
Reassemble equipment items that were dismantled for shipment or moving.
Assemble items that are delivered knocked down or disassembled.
Q.
Coordinate the installation of equipment with the Construction Contractor
constructing the LOU Facility.
R.
Install equipment in accordance with approved installation instructions and
approved shop drawings.
S.
Provide grout, shim material and miscellaneous steel necessary for brackets,
anchors or supports required in installation of equipment.
T.
Accomplish field machining that might be required to fit equipment together or to
install equipment.
U.
Lubricate apparatus before start-up.
V.
Field check for clearance and interferences before fabrication or installation and
relocate material and equipment furnished as required to eliminate interferences.
W.
Perform mechanical and electrical work required to install the equipment in
accordance with the requirements of the jurisdictional authorities and the current
applicable codes and standards of practice employed by these trades.
SETTING AND ALIGNING EQUIPMENT
A.
Equipment shall be set and aligned in accordance with Manufacturer’s
instructions, approved shop drawings and applicable standards of trade practice.
B.
Equipment shall be set true and level.
installed equipment.
C.
Retighten bolted connections after installation.
Demonstrate adequate leveling of
CLEANING AND PROTECTION
A.
Clean fabricated assemblies and equipment items thoroughly before and after
operating and testing.
B.
Protect equipment from damage, deterioration, paint or coating spills or spots,
corrosion or harm from any source.
EQUIPMENT FINAL ACCEPTANCE TEST
A.
Submit an acceptance test procedure to the Engineer for approval a minimum of
sixty (60) days prior to the start of the equipment test and checkout.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 49 of 52
B.
After approval of the site test procedure by VRE, notify the Engineer at least two
(2) weeks in advance of making the site test.
C.
The final acceptance testing shall be performed in the presence of the Engineer
and demonstrated to the Engineer’s satisfaction to be correctly connected,
functioning and installed.
D.
Testing and checkout procedures of the Manufacturer shall be carried out
completely.
E.
The final acceptance tests shall not only be performed to demonstrate that the
equipment has been properly installed and connected and operates properly but
also to demonstrate that the equipment performs the work for which it is
intended. It shall also demonstrate the operation of all pertinent safety devices
including, but not limited to, the operations of limit switches and warning devices.
F.
Tested equipment found to be defective or inoperable to any extent shall be
reported to the Engineer immediately.
G.
Any operating difficulty or defective item shall be repaired or replaced and put
into proper operation by the Manufacturer immediately, at no additional expense
to VRE.
H.
Protect equipment and surrounding areas from damage resulting from testing
operations. Clean-up spills or leakage from testing.
I.
All materials for acceptance testing shall be provided by the Manufacturer with
the exception of VRE’s rail vehicles, and/or major vehicle components.
J.
The Manufacturer shall bear all expenses of all tests, including the furnishing of
all necessary instruments, lubricants, hydraulic fluids, supplies, data recorders
and operating personnel. Provide and bear all expenses for fuel/power required
to operate the equipment during the tests.
K.
VRE will provide all pertinent railroad vehicle and/or components required for
acceptance testing.
L.
At the sole discretion of the Engineer, the Manufacturer shall be required to
repeat any test, or portion of the test, at no additional cost to VRE. Reasons for
repeating a test include, but are not limited to, the following:
1.
Software or hardware malfunction, alarm or shut-down during any part of
the test.
2.
Test results/data not accurately recorded. This includes failure of video
equipment, if utilized to record the test.
M.
The Engineer shall determine final acceptance of the installed equipment.
N.
Conformed copies of the acceptance test procedure shall be available at the start
of acceptance testing.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 50 of 52
O.
Perform the tests in accordance with the
include at a minimum:
1.
approved
procedures which shall
Electrical Controls:
a.
Pushbutton station
controllers).
testing
(wireless
control
and
remote
b.
Drop Table traverse.
c.
Drop Table lowering and raising at the service top and release
top, including smooth operation of locking bars.
d.
Drop Table lowering and raising with sectionalized auxiliary
service top. Demonstrate vertical and horizontal alignment with
shop rails at completion.
2.
Limit switches.
3.
Verify the proper operation of all positioning lights and safety and
annunciator devices.
4.
Place each locomotive and coach type on the Drop Table and place body
supports at jacking pad locations for removal of a truck. Alternate using
north and south trucks.
5.
Disconnect truck from vehicle by VRE personnel.
6.
With truck on the service top, operate the service top and traverse the pit.
Raise the service top to the floor level at the release track position.
7.
Reverse the process (steps 4, 5 and 6).
8.
Place of one (1) locomotive and coach type on the Drop Table and place
body supports at jacking pad locations for removal of a traction motor/axle
combination and single axle.
9.
The disconnect of the traction motor/axle from the vehicle will be
performed by VRE personnel.
10.
With traction motor/axle on the service top, operate the service top and
traverse the pit. Raise the service top to the floor level at the release
track position.
11.
Reverse the process (steps 8, 9 and 10).
12.
Pit-Level Progression System: Demonstrate the process used to move
the HEP extractor or a locomotive truck to the storage area located
beneath the release track. Operate system by means of wall mounted
control station as well as the wireless remote controller.
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 51 of 52
13.
14.
3.09
3.10
Repeat tests over three (3), eight (8) hour days as part of training of VRE
personnel to include the following:
a.
Transfer of a wheelset using the sectionalized auxiliary service
top.
b.
Testing with coach types.
Submit the test results to the Engineer.
START-UP AND INSTRUCTIONS
A.
Unless otherwise specified, all lubricants, cleaning compounds and similar
operating materials shall be furnished by the Manufacturer during instruction of
VRE personnel.
B.
After all equipment and systems have been installed, connected and tested,
proceed with the instruction of VRE personnel in the operation and maintenance
of equipment. Provide sufficient personnel to adequately complement personnel
made available by VRE.
C.
During this period, provide qualified representatives for instruction of VRE
personnel in the operation and maintenance of the equipment.
FOLLOW-ON INSPECTION AND TESTING
A.
B.
Provide two (2) complete follow-on inspections of the equipment as follows:
1.
First inspection shall be performed by the Manufacturer and witnessed by
the Engineer six (6) months after the date of Final Acceptance of the Drop
Table System. At this time, a re-alignment and/or adjustment of all critical
equipment elements shall be made at the Manufacturer’s expense. All
machine functions shall be tested for proper operation. Provide a written
report to the Engineer of all findings, maintenance and operating
recommendations and any items in need of repair or modification.
2.
At twelve (12) months after Final Acceptance of the Drop Table System,
all machine functions shall be tested by the Manufacturer for proper
operation. Provide a written report to the Engineer of all findings,
maintenance and operating recommendations and any items in need of
repair or modification, which shall be made by the Manufacturer.
A twenty-four (24) month follow-on inspection and test shall be made by an
authorized Manufacturer's factory service technician, with assistance.
END OF TECHNICAL SPECIFICATIONS
IFB No. 016-001
DROP TABLE SYSTEM
TECHNICAL SPECIFICATIONS
Page 52 of 52