TECHNICAL SPECIFICATIONS
SECTION 07840
FIRESTOPPING
PART 1 – GENERAL
1.01
DESCRIPTION
A.
The work of this Section consists of furnishing and installing of firestopping
materials as indicated.
B.
Provide firestopping as indicated, in all the following applications unless
otherwise directed:
1.
Penetrations through all fire rated walls and partitions.
2.
Locations where specifically shown on the Contract Drawings or where
specified in other sections of these Specifications.
1.02
RELATED SECTIONS
1.03
QUALITY ASSURANCE
A.
Reference Standards
1.
2.
American Society for Testing and Materials (ASTM):
a.
E 84, Test Method for Surface Burning Characteristics of
Building Materials.
b.
E 136, Behavior of Materials in a Vertical Tube Furnace at 750
Degrees Celsius.
c.
E 814, Test Method for Fire Tests of Through-Penetration Fire
Stops.
National Fire Protection Association (NFPA):
a.
B.
1.04
70, National Electrical Code (NEC).
When requested, the Contractor shall submit his Quality Assurance Program
Procedures for review and approval prior to commencing any work required by
this Specification.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
December 2013
Technical Specifications
07840-1
Contract No. 14-017X
FIRESTOPPING
1.05
1.06
B.
Manufacturer's Catalog Data: Data shall be submitted for firestopping including
composition and performance characteristics.
C.
Manufacturer's Instructions: Published application instructions for firestopping
materials shall be submitted.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Manufacturer's Catalog Data: Data shall be submitted for firestopping including
composition and performance characteristics.
C.
Manufacturer's Instructions: Published application instructions for firestopping
material shall be submitted.
D.
Test Reports: Test reports from a certified independent laboratory shall be
submitted, attesting that firestopping material and test data for the time rated
construction meet the requirements specified herein.
E.
Certificate:
asbestos.
Submit certificate stating that firestopping products contain no
DELIVERY, STORAGE AND HANDLING
A.
Deliver materials in the original unopened packages or containers showing name
of the manufacturer and the brand name. Store materials off the ground and
protect from damage and exposure to elements. Remove damaged and
deteriorated materials from the site.
PART 2 – PRODUCTS
2.01
MATERIALS
A.
2.02
Provide asbestos-free firestopping material capable of maintaining an effective
barrier against flame and gases.
SOURCE QUALITY CONTROL
A.
Fire Hazard Classification: Material shall have a flame spread of 25 or less, a
smoke developed rating of 50 or less, and a fuel contribution of 50 or less in
accordance with ASTM E 84.
B.
Fire Resistance and Hose Stream Tests: Firestopping materials shall be rated
"F" and "T" in accordance with ASTM E 814, except that the "T" rating may be
based on thermocouples placed one inch from a penetrating item in lieu of direct
attachment to penetrating items. Rating periods shall conform to the following:
1.
December 2013
Technical Specifications
Time rated floor or wall assemblies shall be rated as indicated.
07840-2
Contract No. 14-017X
FIRESTOPPING
2.
Openings between floor slabs and walls shall be rated as indicated on
the Contract Drawings.
C.
Activate Seal: Material shall not require a rise in temperature to install or activate
seal.
D.
Non-Toxicity: Non-toxic to human beings during installation.
E.
Combustibility: Non-combustible, ASTM E 136.
PART 3 – EXECUTION
3.01
GENERAL
A.
3.02
3.03
Install products in accordance with manufacturer's instructions.
PREPARATION
A.
Coordination: Coordinate the work with other trades. Apply firestopping
materials at penetrations of pipes and ducts, prior to insulating, unless the
insulation meets the requirements specified for firestopping.
B.
Use forced air ventilation when installing in areas having less than two cubic feet
of free air for each pound of liquid mixture being foamed. Ventilate areas to
dissipate the amount of hydrogen gas released as foam cures.
C.
Surface Preparation: Remove, dirt, grease, oil, loose material, rust, or other
substances that may affect proper fitting or the required fire resistance from
surfaces in contact with firestopping materials, unless otherwise directed by the
manufacturer's instructions.
INSTALLATION
A.
Install at locations shown or specified in accordance with manufacturer's written
instructions and fire test report. Thoroughly mix components in accordance with
manufacturer's instructions.
B.
Filling of Voids: Completely fill voids at the surface in accordance with ASTM E
814. Firestopping for filling voids in floors in which the smallest dimension of the
void is four inches or more shall support the same load that the floor was
designed to support or shall be protected by a permanent barrier to prevent
loading of traffic in the firestopped area.
C.
Insulated Pipes and Ducts: Insulate pipes and ducts penetrating fire rated floors
and walls with materials, which provide the same performance as the firestopping
material. Extend this material a minimum of six inches on each side of the
opening. The vapor barrier of the insulation material shall have a maximum perm
rating of 0.03.
December 2013
Technical Specifications
07840-3
Contract No. 14-017X
FIRESTOPPING
D.
3.04
FIELD QUALITY CONTROL
A.
3.05
Electrical Cables or Conduits: Firestopping at penetrations shall comply with the
requirements of NFPA 70.
To ensure proper installation, firestopped areas shall not be covered or enclosed
until inspection is complete and approval has been received.
CLEAN-UP
A.
Clean-up all excess firestopping materials, rubbish and debris caused by this
work.
B.
Clean spills from liquid components with high flash mineral spirit solvent,
following instructions on container label.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in related items of work
shown on the Contract Drawings, described in the Specifications and required for
completion of work under this Contract.
END OF SECTION 07840
December 2013
Technical Specifications
07840-4
Contract No. 14-017X
SECTION 13080
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
PART 1 - GENERAL
1.01
DESCRIPTION
A.
B.
The work of this Section consists of furnishing and installing seismic anchors and
vibration isolators as shown on the Contract Drawings or as specified herein.
1.
All mechanical equipment as noted on the equipment schedule, shown
on plans and sections or noted in the Specifications shall be mounted on
vibration isolators to prevent the transmission of vibration and
mechanically transmitted sound to the building structure. Vibration
isolators shall be selected in accordance with the weight distribution so
as to produce reasonably uniform deflections.
2.
All isolators and isolation materials shall be of the same manufacturer
and shall be certified by the manufacturer.
3.
It is the intent of the seismic portion of this Specification to keep all
mechanical and electrical building system components in place during a
seismic event, and remain functional after the event.
4.
All such systems must be installed in strict accordance with seismic
codes, component manufacturer's and building construction standards.
Whenever a conflict occurs between the manufacturer's or construction
standards, the most stringent shall apply.
5.
This Specification is considered to be minimum requirements for seismic
consideration and is not intended as a substitute for legislated, more
stringent, Federal, State or local construction requirements (i.e. NJUCC,
local codes or other requirements).
6.
Any variance or non-compliance with these Specification requirements
shall be submitted by the Contractor for approval by the Construction
Manager.
The work includes, but is not limited to, the following:
1.
Vibration isolation and seismic restraints for mechanical equipment.
2.
Seismic restraints for non-isolated electrical equipment.
3.
Certification of seismic restrain designs and installation supervision.
December 2013
Technical Specifications
13080-1
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
C.
Definitions:
1.
D.
1.02
Life Safety Systems:
a.
All systems involved with fire protection or smoke control,
including emergency ventilation equipment, fire dampers and
smoke exhaust systems.
b.
All systems involved with and/or connected to emergency or
dual power supply including switchgear, transfer switches,
transformers and all flow paths to fire protection, emergency
lighting systems and/or emergency ventilation systems.
c.
Fresh air relief systems on emergency control sequence
including fans, conduit, duct, dampers, etc. This includes all
substation and electrical room HVAC Systems from the
connection to an intake gratings, air intake ductwork, fans, and
relief air duct from the room to point of discharge to ambient.
2.
Positive Attachment: A positive attachment is defined as a cast-in-place
anchor, a drill-in wedge anchor, a double sided beam clamp loaded
perpendicular to a beam, or a welded or bolted connection to structure.
Single sided "C" type beam clamps for support rods of overhead piping,
ductwork, fire protection, electrical conduit, bus duct, or cable trays, or
any other equipment are not acceptable on this project as seismic
anchor points.
3.
Transverse Bracing: Restraint(s) applied to limit motion perpendicular to
the centerline of the pipe, duct or conduit.
4.
Longitudinal Bracing: Restraint(s) applied to limit motion parallel to the
centerline of the pipe, duct or conduit.
Manufacturer of vibration isolation and seismic restrain sizes and locations.
1.
Determine vibration isolation and seismic restrain sizes and locations.
2.
Provide vibration isolation and seismic restraints as scheduled or
specified.
3.
Provide calculations and materials, if required, for restraint of unisolated
equipment.
4.
Provide installation instructions, drawings and trained field supervision to
insure proper installation and performance.
RELATED SECTIONS
A.
Section 15830 – Tunnel Ventilation Fan Purchase
December 2013
Technical Specifications
13080-2
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
B.
C.
1.03
QUALITY ASSURANCE
A.
1.04
Section 15831 – Tunnel Ventilation Fan Installation
Section 16445 – Motor Control Centers and Motor Starters
Reference Standards
1.
New Jersey Uniform Construction Code (NJUCC).
2.
American Society of Heating, Refrigeration, and Air Conditioning
Engineers (ASHRAE) – Practical Guide to Seismic Restraint.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Description Data:
C.
1.
Catalog cuts or data sheets on vibration isolators and seismic restraints
detailing compliance with the Specifications.
2.
Detailed schedules of flexible and rigidly mounted equipment, showing
vibration isolators and seismic restraints by referencing numbered
descriptive drawings.
Shop Drawings:
1.
Submit fabrication details for equipment bases including dimensions,
structural member sizes and support point locations.
2.
Restraint manufacturers' submittals must include spacing, static loads
and seismic loads at all attachment and support points.
3.
Provide specific details of seismic restrains and anchors, include
number, size and locations for each piece of equipment.
December 2013
Technical Specifications
13080-3
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
D.
E.
Seismic Certification and Analysis:
1.
Seismic restrain calculations must be provided for all connections of
equipment to the structure. Calculations must be stamped by a
registered professional engineer with at least five years of seismic
design experience, licensed in the State of New Jersey.
2.
All restraining devices shall have a pre-approval number from California
OSHPD or some other recognized government agency showing
maximum restraint ratings. Pre-approvals based on independent testing
are preferred to pre-approvals based on calculations. Where preapproved devices are not available, submittals based on independent
testing are preferred. Calculations (including the combining of tensile
and shear loadings) to support seismic restraint designs must be
stamped by a registered professional engineer, with at least five years of
seismic design experience and licensed in the State of New Jersey.
Testing and calculations must include both shear and tensile loads as
well as one test of analysis at 45 degrees to the weakest mode.
3.
Analysis must indicate calculated dead loads, static seismic loads and
capacity of materials utilized for connections to equipment and structure.
Analysis must detail anchoring methods, bolt diameter, embedments
and/or welded length. All seismic restraint devices shall be designed to
accept without failure, the forces detailed elsewhere herein acting
through the equipment center of gravity. Overturning moments may
exceed forces at ground level.
Related Items of Work:
1.
2.
December 2013
Technical Specifications
Housekeeping Pads:
a.
Housekeeping pad reinforcement and monolithic pad
attachment to the structure details and design shall be prepared
by the restraint vendor if not already indicated on the drawings.
b.
Housekeeping pads shall be coordinated with restraint vendor
and sized to provide a minimum edge distance of ten bolt
diameters all around the outermost anchor bolt to allow
development of full drill-in wedge anchor ratings. If cast-in
anchors are to be used, the housekeeping pads shall be sized to
accommodate the ACI requirements for bolt coverage and
embedment.
Supplementary Support Steel: Contractor shall supply supplementary
support steel for all equipment, piping, ductwork, etc. including roof
mounted equipment, as required or specified.
13080-4
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
3.
Attachments: Contractor shall supply restraint attachment plates cast
into housekeeping pads, concrete inserts, double sided beam clamps,
etc. in accordance with the requirements of the vibration vendor's
calculations.
4.
Seismic Classification: The mechanical and electrical equipment and
systems to be installed under this Contract are classified as "Life Safety
Systems". Use factors applicable to "Fire Protection Equipment and
Systems" or "Emergency or Standby Electrical Systems". Importance
factor (Ip) is 1.5.
PART 2 - PRODUCTS
2.01
2.02
MANUFACTURERS
A.
All vibration isolators and seismic restraints described in this Section shall be the
product of a single manufacturer. Mason industry's products are the basis of
these Specifications; approved equal products of other manufacturers (e.g.,
Kinetics, Vibrex, etc.) will be acceptable provided their systems strictly comply
with the Specifications and are approved by the Construction Manager.
Submittals and certification sheets shall be in accordance with Article 1.03
herein.
B.
For the purposes of this project, failure is defined as the discontinuance of any
attachment point between equipment or structure, vertical permanent
deformation greater than 1/8 inch and/or horizontal permanent deformation
greater than ¼ inch.
VIBRATION ISOLATORS AND SEISMIC RESTRAINTS
A.
Type 3: Sheet metal panels shall be bolted to the walls or supporting structure
by assemblies consisting of a neoprene brushing cushioned between two steel
sleeves. The outer sleeve prevents the sheet metal from cutting into the
neoprene. Enlarge panel holes as required. Neoprene elements pass over the
bushing to cushion the back panel horizontally. A steel disc covers the inside
neoprene element and the inner steel sleeve is elongated to act as a stop so
tightening the anchor bolts does not interfere with panel isolation in three planes.
Bushing assemblies can be applied to the ends of steel cross members where
applicable. All neoprene shall be bridge-bearing quality. Bushing assemblies
shall be Type PB as manufactured by Mason Industries, Inc., or approved equal.
B.
Type 4: A one piece molded bridge bearing neoprene washer/bushing. The
bushing shall surround the anchor bolt and have a flat washer face to avoid
metal to metal contact. Neoprene bushings shall be Type HG as manufactured
by Mason Industries, Inc., or approved equal.
December 2013
Technical Specifications
13080-5
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
C.
Type 5: Spring isolators shall be free standing and laterally stable without any
housing and complete with a molded neoprene cup or ¼ inch neoprene
acoustical friction pad between the baseplate and the support. All mountings
shall have leveling bolts that must be rigidly bolted to the equipment. Spring
diameters shall be no less than 0.8 of the compressed height of the spring at
rated load. Springs shall have a minimum additional travel to solid equal to 50
percent of the rated deflection. Submittals shall include spring diameters,
deflection, compressed spring height and solid spring height. Mountings shall be
Type SLF as manufactured by Mason Industries, Inc., or approved equal.
D.
Type 10: Hangers shall consist of rigid steel frames containing minimum 1-1/4
inch thick neoprene elements at the top and a steel spring with general
characteristics seated in a steel washer reinforced neoprene cup on the bottom.
The neoprene element and the cup shall have neoprene bushings projecting
through the steel box. To maintain stability the boxes shall not be articulated as
clevis hangers nor the neoprene element stacked on top of the spring. Spring
diameters and hanger box lower hole sizes shall be large enough to permit the
hanger rod to swing through a 30 degree arc from side to side before contacting
the rod bushing and short circuiting the spring. Submittals shall include a hanger
drawing showing the 30 degree capability. Hangers shall be Type 30N as
manufactured by Mason Industries, Inc., or approved equal.
E.
Type 12: Seismic cable restraints shall consist of galvanized steel aircraft
cables sized to resist seismic loads with a minimum safety factor of two and
arranged to provide all-directional restraint. Cable end connections shall be
steel assemblies that swivel to final installation angle and utilize two clamping
bolts to provide proper cable engagement. Cables must not be allowed to bend
across sharp edges. Cable assemblies shall have an Anchorage Preapproval
"R" Number from OSHPD in the State California verifying the maximum certified
load ratings. Cable assemblies shall be Type SCB at the ceiling and at the
clevis bolt, SCBH between the hanger rod nut and the clevis or SCBV if clamped
to a beam all as manufactured by Mason Industries, Inc., or approved equal.
F.
Type 13: Seismic solid braces shall consist of steel angles or channels to resist
seismic loads with a minimum safety factor of two and arranged to provide all
directional restraint.
Seismic solid brace end connectors shall be steel
assemblies that swivel to the final installation angle and utilize two through bolts
to provide proper attachment. Seismic solid brace assembly shall have
anchorage preapproval "R" number from OSHPD in the State of California
verifying the maximum certified load ratings. Solid seismic brace assemblies
shall be Type SSB as manufactured by Mason Industries, Inc., or approved
equal.
G.
Type 14: Steel angles, sized to prevent buckling, shall be clamped to pipe or
equipment rods utilizing a minimum of three ductile iron clamps at each restraint
location when required. Welding of support rods is not acceptable. Rod clamp
assemblies shall have an Anchorage Preapproval "R" Number from OSHPD in
the State of California. Rod clamp assemblies shall be Type SRC as
manufactured by Mason Industries, Inc., or approved equal.
December 2013
Technical Specifications
13080-6
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
H.
Type 18: Stud wedge anchors shall be manufactured from full diameter wire,
not from undersized wire that is "rolled up" to create the thread. The stud anchor
shall also have a safety shoulder which fully supports the wedge ring under load.
The stud anchors shall have an evaluation report number from the I.C.B.O.
Evaluation Service, Inc. verifying its allowable loads. Drill-in stud wedge
anchors shall be Type SAS as manufactured by Mason Industries, Inc., or
approved equal. Anchors and hardware shall be Type 304 stainless steel.
I.
Type 19: Female wedge anchors are preferred in floor locations so isolators or
equipment can be slid into place after the anchors are installed. Anchors shall
be manufactured from full diameter wire, and shall have a safety shoulder to
fully support the wedge ring under load. Female wedge anchors shall have an
evaluation report number from the I.C.B.O. Evaluation Service, Inc. verifying to
its allowable loads. Drill-in female wedge anchors shall be Type SAB as
manufactured by Mason Industries, Inc., or approved equal. Anchors and
hardware shall be Type 304 stainless steel.
PART 3 – EXECUTION
3.01
GENERAL
A.
All vibration isolators and seismic restrain systems must be installed in strict
accordance with the manufacturers written instructions and all certified submittal
data.
B.
Installation of vibration isolators and seismic restraints must not cause any
change of position of equipment, piping or duct work resulting in stresses or
misalignment.
C.
Bring to the Construction Manager's attention any discrepancies between the
Specifications and the field conditions or changes required due to specific
equipment selection, prior to installation. Corrective work necessitated by
discrepancies after installation shall be at the Contractor's expense.
D.
Correct, at no additional cost, all installations which are deemed defective in
workmanship and materials at the Contractor's expense.
E.
Type 12 cable restraints shall be installed slightly slack to avoid vibration shortcircuiting the isolated suspended equipment, piping or conduit.
F.
Type 12 cable assemblies are installed taut on non-isolated systems. Type 13
seismic solid braces may be used in place of cables on rigidly attached systems
only.
G.
At locations where Type 12 or Type 13 restraints are located, the support rods
shall be braced when necessary to accept compressive loads with Type 14
braces.
December 2013
Technical Specifications
13080-7
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
H.
Drill-in concrete anchors for ceiling and wall installation shall be Type 18 and
Type 19 female wedge type for floor mounted equipment.
I.
Seismic Restraint of Ductwork:
1.
J.
Seismically restrain all ductwork with Type 12 or 13 restraints as listed
below:
a.
Restrain rectangular ducts with cross sectional area of six
square feet or larger.
b.
Restrain round ducts with diameters of 28 inches or larger.
c.
Restrain flat oval ducts the same as rectangular ducts of the
same nominal size.
2.
Transverse restraints shall occur at 30 foot intervals or at both ends of
the duct run if less than the specified interval. Transverse restraints
shall be installed at each duct turn and at each end of a duct run.
3.
Longitudinal restraints shall occur at 60 foot intervals with at least one
restraint per duct run. Transverse restraints for one duct section may
also act as a longitudinal restraint for a duct section connected
perpendicular to it if the restraints are installed within four feet of the
intersection of the ducts and if the restraints are sized for the larger duct.
Duct joints shall conform to SMACNA duct construction standards and
seismic support based on details shown in the SMACNA practical guide
to seismic restraint.
4.
The ductwork must be reinforced at the restraint locations.
Reinforcement shall consist of an additional angle on top of the ductwork
that is attached to the support hanger rods. Ductwork is to be attached
to both upper angle and lower trapeze.
5.
A group of ducts may be combined in a larger frame so that the
combined weights and dimensions of the ducts are less than or equal to
the maximum weight and dimensions of the duct for which bracing
details are selected.
6.
Walls, including gypsum board non bearing partitions, which have ducts
running through them may replace a typical transverse brace. Provide
channel framing around ducts and solid blocking between the duct and
frame.
Seismic Restraint of Electrical Services:
1.
December 2013
Technical Specifications
All electrical conduit 2-1/2 inches in diameter and larger shall be
restrained with Type 12 seismic cable restraints or Type 13 seismic solid
brace restraints.
13080-8
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
K.
3.03
2.
All electrical bus ducts, cable trays and ladder trays shall be restrained
with Type 12 seismic cable restraints or Type 13 seismic solid brace
restraints.
3.
Transverse restraints shall occur at 30 foot intervals or both ends if the
electrical run is less than the specified interval. Transverse restraints
shall be installed at each electrical services turn and at each end of the
electric run.
4.
Longitudinal restraints shall occur at 60 foot intervals with at least one
restraint per electric run. Transverse restraints for one electric section
may also act as a longitudinal restraint for a duct for an electric section
connected perpendicular to it if the restraints are installed within four
feet of the intersection of the electric section connected perpendicular to
it if the restraints are installed within four feet of the intersection of the
electric run and if the restraints are sized for the larger electric run.
5.
All rigid floor mounted equipment must have a resilient media between
the equipment mounting hole and the anchor bolt. Anchor bolts shall be
designed in accordance with this Section. Neoprene bushings shall be
Type 4 and anchor bolts shall be Type 18 or Type 19.
6.
Wall mounted panels shall be mounted with Type 3 bushings. Floor
mounted panels shall be mounted on Type 4 bushings. Anchor bolts
shall be Type 18 or Type 19.
All fire protection equipment is considered life safety equipment and shall be
seismically restrained using the seismic force levels for life safety equipment.
SEISMIC RESTRAINT EXCLUSIONS
A.
Piping:
1.
All piping less than 2-1/2 inches in diameter except those listed below.
2.
All gas piping and medical gas piping less than one inch inside diameter.
3.
All piping boiler and mechanical equipment rooms less than 1-1/4 inch
inside diameter.
4.
All clevis or trapeze supported piping suspended from hanger rods
where the point of attachment is less than the 12 inches in length from
the structure to the structural connection of the clevis or trapeze.
5.
All PVC and fiberglass suspended waste or vent pipe 6 inches in
diameter and smaller.
December 2013
Technical Specifications
13080-9
Contract No. 14-017X
SEISMIC ANCHORING AND VIBRATION ISOLATION
FOR MECHANICAL AND ELECTRICAL EQUIPMENT
B.
C.
D.
Ductwork:
1.
Rectangular, square or oval ducts less than six square feet in cross
sectional area.
2.
Round duct less than 28 inches in diameter.
3.
Duct supported by hanger rods where the point of attachment is less
than 12 inches in length from the structure to the structural connection of
the ductwork.
Electrical:
1.
All conduits less than 2-1/2 inches diameter suspended by individual
hanger rods.
2.
All clevis or trapeze supported conduits suspended by hanger rods
where the point of attachment is less than 12 inches in length from the
structure to the structural connection of the clevis or trapeze.
Suspended Equipment: VAV boxes and fan powered equipment weighing less
than 50 pounds and rigidly connected to the supply side of the duct system and
supported with a minimum of four hanger rods.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in related items of work
shown on the Contract Drawings and described in the Specifications and
required for completion of work under this Contract.
END OF SECTION 13080
December 2013
Technical Specifications
13080-10
Contract No. 14-017X
SECTION 13450
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM
FOR MECHANICAL/ELECTRICAL
PART 1 - GENERAL
1.01
DESCRIPTION
A.
B.
The work of this Section consists of furnishing, installing, modifying, connecting and
testing hardware and software as necessary for the integration of replaced Motor Control
Centers MCC-V1A, MCC-V1B, MCC-V5, MCC-V6, and the associated dampers with the
existing RTU (Siemens Simatic S7-300 PLC with redundant processors) at Raymond
Plaza West at Newark Penn Station and the SCADA system for the tunnel ventilation
system for Newark Light Rail, in order to re-establish complete ventilation control and
monitoring system capabilities of the system as they existed prior to the equipment
damage due to the Hurricane Sandy.
1.
The rehabilitated part of the ventilation control center (VCC) shall be furnished
and installed such as to permit full reimplementation of the original VCC system
operational functionalities including, but not limited to the original emergency
ventilation, normal ventilation, and maintenance operational modes, ventilation
monitoring functions, and all other original VCC system features.
2.
The original VCC system included independent operation of the ventilation
system from the maintenance and operational control center situated at the NJT
Vehicle Base Facility (VBF) at Bloomfield/Belleville and from a fallback alternate
VCC control position situated at Penn Station.
3.
New equipment shall be connected to existing Local Control Panel (LCP) that
controls the fans and dampers, and provides indication of ventilation equipment
status.
The rehabilitated part of the SCADA system shall include, but not be limited to the
following components:
1.
Upgrade of the hardware and software of the existing remote terminal unit
(RTU) and cabinet, to integrate I/O from the four new MCCs.
2.
Re-enabled operation of the Local Control Panel (LCP).
3.
Distributed input/output (I/O) equipment and terminations in the new MCC’s, with
the associated fiber optics and wiring equipment, including software
programming as necessary.
4.
All required fiber optic interface, switches, optical media converter modules,
power supplies and communication equipment, suitable for an industrial
environment, equal or better than the non-operational existing components to be
replaced.
5.
Maintain all existing VCC system operational functionality as part of this work
December 2013
Technical Specifications
13450-1
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
C.
1.02
6.
Provide monitored redundant paths for data transmission between distributed I/O
and RTU.
7.
SCADA shall be re-tested for the correct operational and functional
implementation of the original entire ventilation system requirements as part of
the overall ventilation system acceptance test.
8.
**NOTE: 20% additional I/O shall be maintained at RTU and provided at each
new distributed I/O (DIO) drop.
Coordination with SCADA and RTU hardware and software
1.
The RTU cabinet hardware will be modified if/as necessary by others, to
accommodate addition of four replacement MCCs. Integration of dampers
associated with MCC-V5 and MCC-V6, and LCP, if not already done, will also be
done by others.
2.
The contractor shall be responsible for connecting new hardwired MCCs' status
and controls to LCP, as specified in the contract drawings.
3.
The SCADA software shall be modified as deemed necessary by NJ TRANSIT
to accommodate the addition of the four replacement MCCs, and, as necessary,
the associated dampers and LCP.
4.
RTU software may be modified as necessary by NJ TRANSIT under other
contract work; Contractor shall be responsible to incorporate at both hardware
and software levels the new local replacement ventilation control systems in
coordination with the other on-going contract work.
5.
The contractor shall configure/program the new MCCs' Distributed I/O in
accordance with requirements by RTU/SCADA side. Connection protocol, I/O
map (bit layout), and other necessary parameter will be provided by others.
6.
The contractor shall provide all necessary labor and material and qualified
technical staff to assist in the integration of the new MCCs (i.e. new distributed
I/O at MCCs) and existing LCP to the exiting RTU/SCADA systems, and shall
coordinate this integration work with NJ TRANSIT and other RTU/SCADA
contracting personnel as designated by NJ TRANSIT.
RELATED SECTIONS
The requirements and materials given in the following specification sections shall be complied
with:
A.
Section 16010 – Electrical General Requirements
December 2013
Technical Specifications
13450-2
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
1.03
B.
Section 16050 – Basic Electrical materials and Methods
C.
Section 16061 - Grounding
D.
Section 16445 - Motor Control Centers and Motor Starters
E.
Section 16960 - Electrical Acceptance and Start-Up Testing and Training
QUALITY ASSURANCE
A.
Reference Standards:
1.
2.
American National Standards Institute (ANSI):
a.
C2, National Electrical Safety Code (NESC).
b.
C37.1, Definition, Specification and Analysis of Manual, Automatic and
Supervisory Station Control and Data Acquisition.
c.
C37.90a, Guide for Surge Withstand Capability (SWC) Test.
American Society of Testing Materials (ASTM):
a.
3.
4.
December 2013
Technical Specifications
E 662, Test Method for Specific Optical Density of Smoke Generated by
Solid Materials.
Electronic Institute of America (EIA):
a.
FOTP-26, Fiber Optic Test Procedure No. 26.
b.
FOTP-82, Fiber Optic Test Procedure No. 82.
c.
TIA-455-32A, Discontinuity.
d.
TIA-526-3, Data Terminal Equipment-Maximum RX Input.
e.
TIA-526-3, Inspection.
Institute of Electrical and Electronic Engineers (IEEE):
a.
383, Section 2.5, Standard for Type Test of Class IE Electric Cables,
Field Splices and Connections for Nuclear Power Generating Stations.
b.
802.3, Information Processing Systems - Local Area Networks - Part 3:
Carrier Sense Multiple Access with Collision Detection (CSMA/CD)
Access Method and Physical Layer Specifications.
c.
802.2, Logical Link Control.
13450-3
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
5.
6.
7.
1.04
a.
ICS-4, Terminal Blocks for Industrial Control.
b.
ICS06, Enclosures for Industrial Controls and Systems.
National Fire Protection Association (NFPA):
a.
70, National Electrical Code (NEC).
b.
130, Fixed Guideway Transit Systems.
Software/Firmware Quality Assurance:
The Contractor’s software quality assurance program and a software verification
and validation program, consistent with the intent and scope defined in
ANSI/IEEE Standard 730 and ANSI/IEEE Standard 1012 respectively, shall
apply to all software and firmware developed or modified under this Contract,
and all software and firmware which is not a copyrighted commercially available
off-the-shelf product.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Submit the following to the Construction Manager as a prerequisite to approval of the
proposed Control/Communication equipment manufacturer:
1.
2.
1.05
National Electrical Manufacturers Association (NEMA):
Specific identity of the manufacturer and proof that the control/communication
equipment manufacturer has, within the last five years, performed at least two
contracts involving the design, fabrication, and installation of control equipment.
The system must be in satisfactory operation for at least one year. Provide
proof of satisfactory operation when required by the Construction Manager.
a.
Include names of owner's representatives familiar with the work, title,
telephone number, locations of work, dollar amounts of contracts,
description of system(s) and scheduled and actual start and completion
dates.
b.
An organizational chart shall be submitted showing staff who will be
involved in the production and testing of the software, and details of the
company quality assurance policy and status.
The quality assurance programs of the manufacturer of the control equipment
which are set forth in quality assurance manuals and address manufacture at the
component assembly and sub-assembly levels.
DELIVERY, STORAGE AND HANDLING
December 2013
Technical Specifications
13450-4
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
1.06
A.
Deliver, store, handle and install all materials and equipment in such a manner as not to
degrade quality, serviceability or appearance.
B.
Store materials and equipment in a clean, dry location free from construction dust,
precipitation and excess moisture.
C.
Replace damaged materials and equipment, as determined by the Construction
Manager, at no additional cost to NJ Transit.
D.
Do not store fiber optic cable equipment and components in areas where hydrogen is
present, such as battery rooms, battery storage areas, garages or areas where
combustion products are present.
E.
Store cable so that no violation of the minimum bend radius occurs.
GUARANTEE/WARRANTY
A.
1.07
ENVIRONMENTAL REQUIREMENTS
A.
1.08
In addition to the specific warranty requirement specified elsewhere in these
Specifications, obtain, in NJ Transit’s name, the standard written manufacturer's
guarantee/warranty of all materials furnished under this Section where such
guarantee/warranties are offered in the manufacturer's published product data. All these
guarantees/warranties shall be in addition to, and not in lieu of, other liabilities which the
Contractor may have by law or other provisions of the Contract Documents.
Equipment and systems installed in the tunnel and outdoors:
1.
Storage temperature range: minus 20 to plus 140 degrees Fahrenheit.
2.
Operating temperatures range: minus 20 to plus 140 degrees Fahrenheit.
3.
Operation shall be reliable in an environment with 20 to 95 percent noncondensing relative humidity.
ELECTRICAL REQUIREMENTS
A.
Operate system from a 120 volt AC single phase, 60 Hertz electrical power distribution
system.
B.
The system manufacturer shall be capable of providing factory trained engineers fully
capable of providing instructions, routine maintenance, and emergency maintenance
service on all system components within 12 hours after notification.
December 2013
Technical Specifications
13450-5
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
PART 2 - PRODUCTS
2.01
GENERAL
A.
Distributed I/O and communication equipment shall be new and of the finest production
quality. Items shall be commercially available off the shelf and in general use, to
provide proven reliability, future support, parts, and upgrades over the anticipated life of
the control center. Items or parts that are designed specifically for this application and
for which no commercially available off-the-shelf alternative is available shall not be
acceptable.
B.
Equipment and accessories shall be essentially the standard cataloged products of
manufacturers regularly engaged in production of such equipment and accessories, and
shall be the manufacturer's latest standard design that complies with Specification
requirements. The Manufacturer shall be Siemens Industrial Automation Inc. "Simatic"
or approved equal.
C.
To mitigate against future obsolescence of SCADA software the contractor shall ensure
SCADA system vendor shall have a formal contractual partnership that includes:
D.
2.02
1.
The services of a certified software engineer approved and working with the
operating system vendor.
2.
Design interfaces to industry standards using open communication protocols as
directed by NJT or RTU/SCADA contractor designated by NJT.
Distributed I/O integration work should not interfere with the normal running of the
subway system.
REMOTE TERMINAL UNITS (RTU’s)
A.
The existing RTU system with redundant logic/communication processors at Raymond
Plaza West shall integrate RTU I/O subsystems associated with four restored MCCs. If
necessary, it shall be modify by others to satisfy following requirements:
1.
Power supplies, for each PLC and redundant power supply arrangement for
optical link and switch units.
2.
Two programmable controllers with Ethernet communication card.
3.
Two redundant optical switch modules (OSM) communication interfaces to the
central control room.
4.
I/O communication port in each PLC to implement a redundant communications.
December 2013
Technical Specifications
13450-6
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
5.
Interposing relays for PLC outputs and LCP control relays shall be standard or
miniature plug-in type relays rated at 120 VAC with 10A resistive load rated
contacts .
6.
Hardwired relay circuits for LCP manual control of fans, as shown in the design
drawings.
7.
Each card shall provide an indication of the operating status through LED’s
visible from the front of the RTU. Label each component on the card to identify
the part for troubleshooting and replacement. Uniquely label, serialize, and
identify all systems, subsystems and products in the record drawings to show the
configuration of each RTU system.
B.
C.
8.
RTU communications shall be Ethernet fiber interface operating at 100 Mbs.
One of the communication lines shall be a primary link while the other shall be a
back-up. In case of failure of the primary link the backup link shall automatically
switchover. The status of the backup communications shall be monitored by the
system. The back-up link shall switchover within 250 ms. Commercial Ethernet
switches with slow switchover times are not permitted.
9.
RTU system power supplies shall operate on 120 volts AC plus or minus 20
percent, 60 Hertz power. Failure of any power supply shall generate an alarm.
Properly ground all systems as shown on the Contract Drawings.
RTU I/O:
1.
New distributed modular I/O associated with and located within the restored
MCCs with a redundant communication network configuration using a nonproprietary open standard such as Profibus DP Fieldbus shall be installed by the
contractor. Specific protocol requirements will be provided by NJT. The power
supply arrangement shall meet the availability requirements specified elsewhere
in this Specification.
2.
Each I/O card shall provide an indication of the operating status through a LED
visible from the front of the MCC cubicle. Label each component to identify the
part type/number. Identify and uniquely serialize each card rack, major
component, and all products. The record copies shall identify where each
uniquely serialized item is located.
3.
The RTU/IO System shall operate in the temperature range of minus 20 to plus
140 degrees Fahrenheit.
4.
RTU/IO system power supplies shall operate on 120 volts AC plus or minus 20
percent, 60 Hertz power.
Enclosure Components:
1.
December 2013
Technical Specifications
Distributed I/O and redundant communication equipment shall be housed in the
new MCC cubicle line-ups, in a compartment with a sealed transparent plastic
13450-7
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
window for observation of the I/O and communication components' status
indicating lights.
2.
Circulation fans capable of properly circulating the air to prevent the distributed
I/O from overheating shall be provided as/if necessary. The fans shall have a
fail-safe contact that transmits an alarm to central SCADA when the fan fails.
3.
A temperature switch with contact set to fail open when the temperature in the
cubicle exceed a certain setting shall be wired to distributed I/O unit and alarm
SCADA accordingly..
4.
Wiring Terminal Blocks and Fiber Optic Patch Panels:
5.
2.03
a.
All hardwired connections between equipment and primary power, as
well as all connections between equipment within the distributed I/O
MCC compartment and outside the compartment shall be through
terminal blocks in the compartment. Terminal blocks for input power
shall be rated as appropriate for the power required by the equipment.
b.
All fiber connections to the equipment residing in MCC compartments
shall be through the compartments' fiber patch panels.
c.
All terminal blocks, fiber patch panel ports, and copper wires and fiber
links connected to them shall be clearly labeled.
d.
Extra 15' fiber optic cable slack shall be provided at each end (before it
is terminated at a patch panel). The slack will be neatly coiled with
radius 1.5 of the minimum allowable and secured from accidental
damage.
Wiring: Neatly arrange wiring within enclosures and do not directly fasten to the
compartment frame. Use non-flammable, self-extinguishing, plastic wire troughs
and wiring. PVC is not an acceptable material. Metal clamps must have
insulating inserts between the clamps and must have insulating inserts between
the clamps and the wiring. Allow wiring between stationary and movable
components, such as wiring across door hinges or to components mounted on
extension slides, for full movement of the component without binding or chafing
of wiring.
SCADA SYSTEM
A.
The existing integrated SCADA system at VCC Bloomfield and Alternate VCC Penn
Station shall be modified to fully incorporate in its operation modes the restored four
MCCs. The needed modifications may include changing of I/O communication maps,
SCADA database, individual ventilation system operation mode logic, data logging
schemes, and all affected operator HMI screens at all operator locations. All necessary
SCADA modifications shall be done by others.
December 2013
Technical Specifications
13450-8
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
1.
2.07
FIBER OPTIC COMMUNICATION SYSTEM
A.
B.
C.
The fiber optic links between new distributed I/O located in the four new (restored) MCC
shall be redundant, and shall comply with parameters that will be provided by NJT.
Only Siemens or approved equal communication equipment classified as industrial shall
be used.
Redundancy:
1.
2.
2.08
The contractor shall coordinate with NJT and/or with RTU/SCADA contractor
designated by NJT integration of the restored MCCs, associated fans, dampers,
and LCP with the existing RTU/SCADA system and shall provide and pay
qualified personnel that will assist in the integration task.
The Control Communication equipment shall have two transmitter/receiver pairs
connected to two separate optical fiber pairs within the cable or cables.
Automatically switch the equipment from the primary channel to the secondary
channel under the following conditions:
a.
Loss of signal at receiver.
b.
Loss of optical output at transmitter.
c.
Loss of multiplexer (if applicable).
Networks including distributed I/O communications shall be carried in separate
conduits, and shall be routed separately and physically apart, wherever
practicable.
D.
Optical Budget: The allowable optical link loss budget margin between each node-tonode link around the ring for the Control equipment shall be a minimum of three
decibels. The optical interface receiver shall have a bit error rate not less than 10-9
E.
The contractor shall be responsible for providing control communication equipment at
MCCs side only (with distributed I/O); the corresponding equipment at RTU end will be
provided by others.
FIBER OPTIC CABLE
A.
The contractor shall install cables between distributed I/O at MCCs and the existing RTU
that will satisfy the following design and performance requirements:
1.
General:
a.
December 2013
Technical Specifications
Fiber optic cable running between RTU’s shall be loose tube cable
designed for both outside and inside applications. The fiber optic cable
used for distributed I/O shall be riser rated tight buffered construction.
Unless specifically stated otherwise the following requirements apply to
both loose tube and tight buffered cable.
13450-9
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
B.
b.
The fiber optic cable shall be suitable for installation in new conduits or
in existing conduits occupied by existing cables.
c.
The cable shall meet EIA FOTP 26 standard for crush resistance with a
value of 450 pounds per inch.
d.
The cable shall sustain a maximum pulling tensile load of 600 pounds
with no irreversible change in attenuation and a normal operation tensile
load of 135 pounds with no measurable change in attenuation.
e.
The cable shall have a minimum bend radius of 20 times its diameter for
installation at maximum pulling load and a minimum static bend radius
of ten times its diameter.
f.
Fiber optic cables shall run within high-density polyethylene inner duct
for all ductbank runs.
2.
Minimum Number of Fibers: At least 50% spare fibers and no less than 6 spare
fibers (whichever is larger) shall be provided per cable. All fibers shall be
terminated and made available on patch or distribution panels.
3.
Cable Requirements – Loose Tube: Fiber optic cable for the installation shall
conform to the following:
a.
Cable shall be loose tube gel filled water blocked cable.
b.
NEC OFNP rated having adequate fire-resistant and low smoke
producing characteristics.
c.
The cable shall be water blocked, duct type cable and shall meet
ANSI/EIA/TIA-455-82B-92 Standard FOTP-82 Fluid Penetration Test.
d.
The cable shall be completely non-metallic in construction and shall not
contain any jacketing materials which may be damaged by prolonged
exposure to water.
Fiber Optic optical characteristics shall be:
1.
Fiber optic cable shall consist of multi-mode 62.5/125 micron fibers.
2.
Fiber for distributed I/O bandwidth and dB loss optical specification shall not be
less than:
December 2013
Technical Specifications
a.
850nm wavelength: 3.0 dB/km, 220 MHz/km
b.
1300nm wavelength: 1.0 dB/km, 500 MHz/km
13450-10
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
C.
D.
E.
All materials used in the cable shall be suitable for use under the following climatic
conditions:
1.
Temperatures of minus 20 to plus 140 degrees Fahrenheit.
2.
Relative humidity 5 to 100 percent condensing.
Cable Jacket Labeling:
1.
Label the cable jacket using environment-resistant printing in the range of two to
four foot intervals.
2.
The label shall indicate:
a.
The length to the end of the cable in feet.
b.
The number of optical fibers in the cable.
c.
The date of manufacture.
d.
The manufacturer's name and part number.
Reel Length, Labeling, and Marking:
1.
Verify the exact distances through conduit by measurements taken in the field.
Determine the amount of cable required on each reel subsequent to field
investigation.
2.
Stencil each side of every reel of cable, in minimum one inch high lettering with
the Contractor's address, Contract number, cable part number and cable type,
length, number of optical fibers within the cable, and cable segment number.
3.
Equip each reel with access ways so that both ends of the cable can be easily
accessed for testing. Equip the access ways with covers to protect the cable
when being transported and stored.
Cable on each reel shall be continuous and without any splices. Tandem reels
with continuous cable may be used if required to accommodate long pull
segments.
4.
5.
Equip the outermost end of the cable on each reel with a pulling eye
appropriately attached to the strength member and jacket to ensure no cable
damage during cable installation.
6.
Provide the cable jacket with non-metallic rip cord.
F.
Pulling Lubricant: Certify that pulling lubricants to be used are compatible with the cable
jacketing materials.
G.
Tests:
December 2013
Technical Specifications
13450-11
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
1.
Factory Inspection: The Construction Manager may inspect the manufacturer's
quality control, manufacturing, and testing facilities at any time during the
procurement process. This inspection may include visual examination of the
fiber strand, the cable, the reel, and all related documentation to ensure that the
fiber optic cable is being fabricated in accordance with these Specifications.
2.
Test Plan: Submit a test plan for the fiber optic cable for the Construction
Manager's approval prior to the start of the factory test. The test plan shall
include test schedule, lists of tests to be conducted during factory test and field
test, test equipment to be used, expected test results and test documents
produced, and copies of any certified test data to be used in lieu of the testing.
3.
Fiber Optic:
a.
Fiber optic tests shall be carried out in the factory and after installation
Test each fiber for each link. All fibers shall be tested in both directions.
The Construction Manager will have the right to witness any or all such
tests.
b.
Shipment of fiber optic cable shall start only after the factory test has
been satisfactorily completed and the fiber optic cable is approved by
the Construction Manager.
c.
Tests shall include, but not necessarily be limited to, the following and
shall be carried out in both directions:
d.
(1)
Attenuation of each fiber in dBm, carried out with a power meter
in both directions.
(2)
Optical Time Domain Reflectometer (OTDR) image of each
fiber.
Test results shall be provided on both hard copy, and Excel
spreadsheet.
PART 3 - EXECUTION
3.01
REMOTE TERMINAL UNITS
A.
RTU subsystems (distributed I/O) shall reside in MCC compartments large enough to
accommodate all equipment, instruments, wires, terminal strips, fiber optic patch panel
and fiber slack, and still have 25 percent excess space for proper air circulation.
B.
All MCC compartments with distributed I/O components shall have fans and temperature
switches installed as necessary.
December 2013
Technical Specifications
13450-12
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
3.02
FIBER OPTIC COMMUNICATION SYSTEM ("CONTROL") EQUIPMENT
A.
3.03
Install Control equipment, fiber optic patch panels, patch cords, etc. in accordance with
manufacturer's instructions in locations as shown on the Contract Drawings and as
directed by the Construction Manager.
FIBER OPTICS
A.
Install fiber optic cable in locations as shown on Contract Drawings by certified
experienced workers. Provide Technicians names, and qualifications to NJT before
connecting fiber optic work on site.
B.
Documentation: Furnish the following documentation at the time of delivery of the cable.
The Construction Manager will be the sole judge of the completeness of the
documentation.
1.
Detailed specification of the fiber optic cable including optical and physical
characteristics of the fiber strand, cable design and construction, mechanical
and environmental specifications, and labeling and marking description.
2.
Test Document:
a.
Certification data as stipulated herein.
b.
Training manuals.
c.
Test equipment manual.
C.
Fiber Optic Cable Installation Phasing. Fiber optic cable bend radius shall be greater
than 20 times the diameter of the cable regardless if the cable is under stress or not. No
slices shall occur on the cable between RTU and distributed I/O compartments at MCCs,
it shall be continuous. Record cable terminations and splices losses for maintenance
purposes and submit to NJ Transit.
D.
Fiber Optic Cable Terminations. Make fiber optic cable terminations with ST, SMA, or
FC connector types as directed by NJT, to be compatible with existing RTU installation.
Epoxy ceramic connectors only shall be used, mechanical crimped types are not
permitted.
1.
E.
Maximum acceptable losses: connectors < 1.0 dB in both directions.
Fiber Optic Splices:
1.
All splices shall be the fusion type, within a splice tray or organizer.
Combination splice tray and termination panel is an acceptable alternative.
Protection for splices shall be per manufacturer's instructions.
2.
Maximum acceptable losses: splices within splice tray < 0.3 dB in both
directions.
December 2013
Technical Specifications
13450-13
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
F.
G.
3.04
Fiber Optic Patch/Distribution Panels:
1.
Provide fiber optic patch/distribution panels at each Control equipment location.
The fiber optic cable shall enter the panel.
2.
Distribution panels shall be capable of accommodating twice the total number of
cable fibers for distributed I/O fiber optic cable. All fiber optic equipment
connections shall be via factory assembled patch cords to the distribution/patch
panel. Direct connection of fiber optic cable to equipment is not permitted.
3.
Tight buffered ( 900mm) fibers for distributed I/O can be terminated directly to a
connector mounted at the back of the distribution/patch panel without need for
fusion splicing to a pigtail.
4.
Epoxy ceramic connectors only shall be used.
5.
Breakout kits shall be used where outer secondary buffer is less than 900
micron.
6.
Loose tube cable shall be fusion spliced on a splice tray to factory assembled
pigtails to the distribution/patch panel.
7.
Make provisions in the fiber optic distribution panel for the future addition of fiber
optic splice trays.
8.
Splice Trays: Splice trays shall be capable of orderly storage of splices, power
splitters and other devices that are spliced into the backbone cable.
Patch Cords: Provide patch cords shall be factory assembled and of sufficient length and
adequate type of inter-connect the Control equipment to the distribution panel or to
interconnect two fibers connected to the distribution panel. A minimum of ten patch
panel cords shall be provided (four at RTU side, four at distributed I/O, and two spare
cords).
TESTING AND COMMISSIONING
A.
Provide all equipment, personnel, and supervision necessary to conduct the field test.
B.
Test Plans and Procedures:
1.
Test plans define the features and capabilities which shall be tested to
demonstrate complete conformance with the Specification. Test plans shall
reference the particular section of the Specification which applies to each test.
Test plans shall contain sufficient detail to determine that the tests defined
demonstrate all aspects of the system.
2.
Test plans shall include the following information:
December 2013
Technical Specifications
13450-14
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
a.
The test schedule.
b.
The purpose and scope of each test.
c.
The function to be tested.
d.
Expected results.
e.
Estimated duration of each test.
f.
A copy of the Contractor's or manufacturer's quality assurance
procedures and standards, which are pertinent to the communications
equipment project.
g.
Record keeping procedures and general definition of forms to be used.
3.
Test procedures define the procedures to be followed by the test team to inspect
ant to setup, select and exercise the equipment and all firmware to verify
conformance to the Specifications.
4.
Test procedures shall contain the following information:
5.
a.
The test set-up, equipment, and conditions for each part of the test.
b.
Block diagrams of the hardware test configuration including any test
using simulation hardware.
c.
The detailed step-by-step actions to be followed.
d.
All test inputs and outputs.
e.
How the test results are reported.
f.
The acceptance criteria.
g.
Record keeping forms.
Test Records:
a.
December 2013
Technical Specifications
Maintain a complete record of all factory and field test results. Make the
test records available to the Construction Manager at all times and
submit to the Construction Manager upon successful completion of all
testing procedures and include the signatures of the Contractor's test
engineer(s) and the Construction Manager's representatives witnessing
each of the tests and retests, any special test conditions or actions
taken, test results, and the test date. Provide space for comments by
the witnesses.
13450-15
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
6.
b.
Prepare a variance report and include in the test record each time a
deviation from Specification requirements is detected. Include in the
report a complete description of the variance, and indicate whether the
variance is to be corrected immediately, at the end of the current test
session, or at some identified point in the future.
c.
Document corrective actions taken to eliminate each variance by
providing sufficient information to enable the Construction Manager to
determine the need for retesting the equipment, for testing interactions
with any previously tested equipment, and for updating documentation
as a result of the corrective action. The variance is considered
eliminated when the Contractor and the Construction Manager
acknowledge, by signatures, correction of the variance.
Site Tests:
(a)
3.05
Equipment Functional Performance Tests. Test each completed final
assembly to verify conformity to this Specification and the
manufacturer's published specifications for the equipment. The tests
shall include:
(1)
Check proper functioning of all hardware and firmware/software
by thoroughly exercising of all equipment functions, both
individually and collectively.
(2)
Simulate failure conditions and failover of unit communication
channel.
(3)
Test spare communication channel slots if provided.
(4)
Demonstrate the use of diagnostics and test procedures.
(5)
Demonstrate recovery from power failures.
(6)
Demonstrate the proper interface circuit characteristics.
(7)
Verify the accuracy
documentation.
of
hardware
and
firmware/software
FIBER OPTIC CABLE TESTING
A.
Field Tests: Test the attenuation of each fiber of each cable after the cable has been
installed. The Construction Manager reserves the right to require Optical Time Domain
Reflectometer (OTDR) tests to be repeated in the field on any fibers that show evidence
of physical damage or out-of-specification attenuation. If the field test results indicate
that one or more fibers in any segment do not meet the attenuation requirements of this
Specification, replace the segment at no cost to NJ Transit.
B.
Inspection and Test:
December 2013
Technical Specifications
13450-16
Contract No. 14-017X
SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM FOR MECHANICAL/ELECTRICAL
1.
General Requirements: Furnish all Control equipment materials, hardware, and
firmware/software and perform all work subject to inspections and tests.
2.
Inspection: Inspections by the Construction Manager will include visual
examination of the physical appearance of the equipment hardware, cable
dressings, and equipment and cable labeling. Contractor documentation shall
be examined to verify that it adequately identifies and describes all equipment
hardware, firmware/software, and spare parts. The Construction Manager will
have access to inspect the Contractor's and manufacturer's quality assurance
standards, procedures, and records which are applicable to this project.
Inspection shall not relieve the Contractor of the responsibility for furnishing
material and equipment conforming to the requirements of the Specification, nor
shall such inspection invalidate any claim which the Construction Manager may
make because of defective or unsatisfactory equipment hardware or firmware.
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will be measured for payment as follows:
Pay Item
Description
13450.1
13450.2
13450.3
SCADA (Distributed I/O components) Equipment and Software
Distributed I/O equipment installation, configuration/programming, and wiring
Testing, acceptance, and training
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum Price for all
the work shown on the Contract Drawings, described in the Specifications and required
for completion of work under this Contract.
END OF SECTION 13450
December 2013
Technical Specifications
13450-17
Contract No. 14-017X
SECTION 15050
BASIC MECHANICAL MATERIALS AND METHODS
PART 1 - GENERAL
1.01
1.02
1.03
DESCRIPTION
A.
This Section includes specifications for basic materials, fabrication and installation for
mechanical work as necessary to support the Sections in Division 15, which specify
particular categories of mechanical work.
B.
The Contract Drawings show facilities diagrammatically and do not show offsets,
fittings, and accessories that may be required. Investigate carefully the structural and
finish conditions affecting the work, and provide such fittings and accessories as
required.
C.
Without intending to limit and/or restrict the volume of work required by the Contract
Documents, the work under this Contract shall generally consist of:
1.
Tunnel ventilation fans, and accessories.
2.
Tunnel ventilation dampers and accessories.
3.
Controls.
D.
Work Sequence: Install work in stages in accordance with the Special Provisions for
Construction; and during the construction period, coordinate mechanical schedule and
operations with the Engineer.
E.
Work of this contract will be performed on an operating light rail transit system. Contract
to coordinate with New Jersey Transit for training and scheduling of work.
RELATED SECTIONS
A.
Section 07840 – Firestopping
B.
Section 13080 – Seismic Anchoring and Vibration Isolation for Mechanical and
Electrical Equipment
C.
Section 15190 – Mechanical Identification
REFERENCE STANDARDS
A.
American Society of Mechanical Engineers (ASME):
Section IX of Boiler
And Pressure
Vessel Code
December 2013
Technical Specifications
Welding and Brazing Qualifications
15050-1
Contract No. 14-017X
B.
C.
American Society for Testing and Materials (ASTM):
ASTM A183
Carbon Steel Track Bolts and Nuts
ASTM B32
Solder Metal
ASTM E814
Methods for Fire Tests of Through-Penetration Fire Stops
American Welding Society (AWS):
ANSI/AWS A5
D.
New Jersey Uniform Construction Code (NJUCC)
E.
New Jersey Uniform Fire Code (NJUFC)
F.
Sheet Metal and Air Conditioning Contractor's National Association (SMACNA)
G.
Underwriters Laboratories Inc. (UL):
1.
1.04
Welding Rods, Electrodes, and Filler Metals Series
Building Materials Directory
SUBMITTALS
A.
General: General Provisions for Construction, for submittal requirements and
procedures.
B.
List of Materials: Within 30 calendar days after receipt of Notice to Proceed, submit to
the Construction Manager a list of materials and equipment proposed for use together
with applicable standards. Give name of manufacturer, brand name and catalog
number of each item. Submit the list complete at one time, with items arranged and
identified in numerical sequence by Technical Provision Section and Paragraph
number.
C.
Compliance with Applicable Codes and Standards:
1.
Where equipment or materials are specified to conform to the standards of
organizations such as ANSI, ASHRAE, ASME, and ASTM, submit evidence
of such conformance for review and record purposes.
2.
The label or listing of the specified agency will be acceptable evidence.
3.
Instead of the label or listing, the Contractor may submit a written certificate
from an approved, nationally recognized testing organization, adequately
equipped and competent to perform such services, stating that the items
have been tested and that the units conform to the specified standard.
December 2013
Technical Specifications
15050-2
Contract No. 14-017X
D.
E.
F.
1.05
Factory Test and Inspection Certification:
1.
Except as otherwise specified herein, where factory tests and inspections for
materials and equipment for which tests and inspections specified in
referenced documents are waived, provide certified copies of reports for tests
performed on previously manufactured identical materials or equipment
within the previous 12 months.
2.
Accompany test reports by signed statements from the manufacturer
certifying that the previously tested material or equipment is physically,
mechanically, and electrically identical to that proposed for the project.
Include wiring and control diagrams.
Shop Drawings: Show complete details of the following, as applicable, for installation
of equipment, including equipment furnished by others:
1.
Foundations for equipment mounting.
2.
Information for setting bolts in foundations.
3.
Mounting methods, including isolation pads, showing adjustment and
alignment.
4.
Details of installation of temporary materials and equipment to be used in the
work.
5.
Plan for performing the work, including the sequence of operations. Verify by
field measurements and show the exact locations of existing utilities.
6.
Factory certified performance curves showing capacity and horsepower
requirements.
7.
Wiring and control diagrams and logic diagrams when solid state controllers
are provided.
8.
Submit calculations and designs for seismic requirements as required in
Section 13080.
Operation and Maintenance Manuals: Submit operation and maintenance data for
equipment provided, in accordance with General Provisions for Construction.
QUALITY ASSURANCE
A.
General: Perform installation and testing of mechanical work in accordance with the
Specifications and the instructions provided by equipment suppliers.
B.
Inspection, Certification, and Testing of Coatings:
1.
December 2013
Technical Specifications
Furnish a manufacturer's certificate of compliance for all coating materials.
Include in the certificate: material identification, quantity, batch number, date
15050-3
Contract No. 14-017X
of manufacture, and other laboratory data covering requirements of technical
provisions under which the material is furnished.
1.06
1.07
1.08
2.
Surface preparation, cleanliness, application, and adhesion shall conform to
coating manufacturers' specifications.
3.
Inspection of the coating will be conducted by a NACE qualified coatings
inspector or personnel with equivalent training and/or experience. Conduct a
visual inspection to locate holidays, disbondment, and improper application.
Before installation, conduct a high voltage electrical inspection of the coating
in accordance with NACE RP-02-74.
PRODUCT DELIVERY, HANDLING AND STORAGE
A.
Protecting Machined Surfaces: Apply a rust preventive on machined surfaces such as
flanges and shafts. Use material of a type, which is easily removable with solvent
during equipment installation.
B.
Protecting Openings: Close pipe connections and other openings with easily
removable plugs, stoppers, or flange covers.
PROJECT CONDITIONS
A.
Install work in locations shown on Contract Drawings, unless prevented by project
conditions.
B.
Prepare drawings showing proposed rearrangement of work to meet project
conditions, including changes to work specified in other sections of the Technical
Specifications. Obtain permission of the Engineer before proceeding.
C.
Cause as little interference or interruption of existing utilities and services as possible.
Schedule work, which will cause interference or interruption to other contracts, other
disciplines, or to NJ Transit in advance with the Engineer for his approval.
D.
Examine Contract Documents to determine how work of other disciplines, other
contracts, or NJ Transit will affect execution of mechanical work.
E.
Determine and verify locations of all existing utilities.
DRAWINGS – USE AND INTERPRETATION
A.
Drawings are diagrammatic and indicate general arrangement of systems and
equipment, except when specifically dimensioned or detailed.
B.
For exact locations of building elements, refer to dimensioned architectural and
structural drawings.
C.
Field measurements take precedence over dimensioned drawings.
D.
Mechanical plans are intended to show size, capacity, approximate location, direction
and general relationship of one work phase to another, but not the exact detail or
arrangement.
December 2013
Technical Specifications
15050-4
Contract No. 14-017X
1.09
E.
Field verify locations and arrangement of all existing systems and equipment.
F.
Field measure existing dimensions and verify site conditions.
INSTALLATION
A.
Installation of all systems and equipment is subject to clarification as indicated in
reviewed shop drawings with field coordination.
B.
This procedure is intended to promote orderly installation, but not to establish trade
precedence.
Dimensions indicated are limited dimensions to determine equipment clearances.
C.
D.
1.10
RECORD DRAWINGS
A.
1.11
Do not use equipment exceeding dimensions indicated on detail drawings or
arrangements that reduce required clearances or exceed specified maximum
dimensions.
Record drawings shall be in accordance with the General Provisions for Construction
and the following:
1.
Keep a complete set of all Mechanical Drawings at the job site for showing
actual installation of mechanical systems and equipment.
2.
Where any material, equipment, or system components are installed
differently from that shown, indicate such differences clearly and neatly.
WARRANTIES
A.
All equipment, materials, and workmanship shall be warranted for a period of one
year unless otherwise noted, beginning with the date of acceptance of the project in
writing. This warranty shall be in writing and shall include written copies of factory
warranties with expiration dates on items of equipment where the warranty date differs
from the acceptable date.
B.
The Contractor's warranty shall include at least two inspections of the system to repair
and replace any items found to be defective during this period. The first shall be
approximately six months after the acceptance of the system and the second at the
end of the first year.
PART 2 - PRODUCTS
2.14
EQUIPMENT GUARDS
A.
Use suitable structural frames with minimum 12 gauge, ¾ inch galvanized mesh, or
expanded metal mesh.
B.
Attach to equipment by removable clips and bolts with swing nuts, or other approved
connectors.
December 2013
15050-5
Contract No. 14-017X
Technical Specifications
C.
At pulleys and sheaves provide opening for measuring revolutions per minute.
D.
Provide guards for all belts, couplings, moving machinery and equipment in
accordance with OSHA.
E.
Design for easy access to belts and other items requiring replacement.
PART 3 - EXECUTION
3.01
GENERAL
A.
When changes in location of any work are required, obtain approval of Construction
Manager before making change.
B.
Do not change indicated size without approval of Engineer.
C.
Examine areas and conditions under which mechanical system materials and
products are to be installed. Do not proceed with work until unsatisfactory conditions
have been corrected in manner acceptable to installer.
D.
Protection of the Work:
E.
3.02
1.
Cover openings in ductwork, conduits, and temporarily seal to protect from
contamination.
2.
Protect materials and equipment from damage due to environmental
conditions. Use protective cover, and protect from surface water by using
raised platforms.
3.
Protect unfinished work at the end of each work day from damage,
contamination, and moisture by the use of plugs, caps, or covers.
4.
Protect installed thermometers and gauges from accidental damage by
construction activity.
Locations of Fixtures and Equipment:
1.
The mechanical sheets of the Contract Drawings are diagrammatical and not
intended for use in determining the exact locations of the components of
mechanical and electrical systems.
2.
Refer to applicable sheets of the Contract Drawings to determine the exact
locations of fixtures and equipment to be installed under the Contract as well
as the locations of items indicated to be installed by others.
CUTTING AND PATCHING
December 2013
Technical Specifications
15050-6
Contract No. 14-017X
A.
General: Be responsible for costs of cutting and patching caused by improper
coordination or notification.
B.
Cutting:
C.
1.
Coordinate and supervise cutting required.
2.
If required, provide concrete core drilling for passage of mechanical items.
Patching: Seal openings and repair and refinish damage to building elements; use
skills mechanics of trades involved.
1.
Waterproofed Surfaces:
waterproofed area.
Patch as required to maintain integrity of
2. Fire Rated Assemblies: In accordance with Section 07840.
3.06
EQUIPMENT INSTALLATION
A.
Install all equipment in accordance with the manufacturer's recommendations.
B.
Provide all necessary anchoring devices and supports.
C.
1.
Use structural supports suitable for equipment, or as indicated.
2.
Check loadings and dimensions of equipment with shop drawings.
3.
Do not cut or weld to building structural members.
4.
Provide all equipment supports not detailed on architectural and mechanical
drawings.
Verify that equipment will fit support layouts indicated.
1.
2.
D.
3.13
Where substitute equipment is used, revise indicated supports to fit.
Coordinate size and location of roof penetrations and wall openings with work
of other sections.
Install equipment to permit easy access for normal maintenance.
1.
Maintain easy access to filters, motors, drives, valves, etc.
2.
Relocate items, which interfere with access.
SEISMIC DESIGN
Refer to Section 13080
3.14
PAINTING
December 2013
Technical Specifications
15050-7
Contract No. 14-017X
Paint all piping, ductwork and HVAC equipment exposed to view, to the elements or where
indicated as specified in Section 09900.
3.15
FIELD QUALITY CONTROL
A.
B.
3.16
Perform indicated tests to demonstrate workmanship, operation, and performance.
1.
Conduct tests in presence of inspectors of agencies having jurisdiction, if
required.
2.
Furnish all lubricating materials required for test.
Repair or replace equipment and systems found inoperative or defective and re-test.
1.
If equipment or system fails re-test, replace it with products, which conform
with Contract Documents.
2.
Continue remedial measures and re-tests until satisfactory results are
obtained.
ADJUST AND CLEAN
A.
Inspect all equipment and put in good working order.
B.
Clean all exposed and concealed items.
Clean all surfaces of fans (including fan wheel and motor), and air plenums.
Equipment and Materials: Remove foreign materials including dirt, grease, splashed
paint and plaster, etc. Restore to original condition and finish.
December 2013
Technical Specifications
15050-8
Contract No. 14-017X
3.17
PUTTING SYSTEMS IN OPERATION – START-UP
A.
Prior to substantial completion, at time agreed to by NJ Transit and the Engineer, put
all systems into satisfactory operation in accordance with details covered under
specific section dealing with the aspect of this work.
B.
Perform services in accordance with manufacturer's written start-up instructions. Test
control and demonstrate compliance with requirements. Replace damaged or
malfunctioning controls and equipment.
C.
Six hours of maintenance and operation training for NJ Transit Maintenance Crew
shall be performed by this Contractor.
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in related items of work shown
on the Contract Drawings, described in the Specifications and required for completion
of work under this Contract.
END OF SECTION 15050
December 2013
Technical Specifications
15050-9
Contract No. 14-017X
SECTION 15190
MECHANICAL IDENTIFICATION
PART 1 - GENERAL
1.01
DESCRIPTION
A.
This Section includes technical provisions for furnishing and installing identification for
tunnel ventilation equipment, and controls.
1.02
RELATED SECTIONS
1.03
REFERENCE STANDARDS
None
1.04
SUBMITTALS
A.
Refer to General Provisions for Construction, for submittal requirements and
procedures.
B.
Submit manufacturers' product data of equipment nameplates.
C.
Samples: Submit samples of each color, lettering style and other graphic
representation required for each identification material or system.
PART 2 - PRODUCTS
2.01
MATERIALS
.
A
B.
Equipment Nameplates: Aluminum or stainless steel, where indicated, 2 inches by 4
inches, with a black enamel background and either etched or engraved lettering.
Lettering shall be as indicated. Nameplates shall bear notations corresponding to the
same notations on the framed wiring diagrams and operating instructions.
Control Nameplates: Laminated colored plastic with white lettering. Each switch shall
have its switch positions clearly indicated and identified. Nameplates shall be worded
to identify the respective item and function.
PART 3 - EXECUTION
3.01
INSTALLATION
A.
Equipment Nameplates: Mount with corrosion-resistant fasteners.
B.
Control Nameplates: mount with corrosion-resistant fasteners.
December 2013
Technical Specifications
15190-1
Contract No. 14-017X
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum Price for
all the work, labor and materials necessary therefore and incidental thereto as shown
on the Contract Drawings and described in these Specifications.
END OF SECTION 15190
December 2013
Technical Specifications
15190-2
Contract No. 14-017X
SECTION 15831
TUNNEL VENTILATION FAN INSTALLATION
PART 1 - GENERAL
1.01
1.02
1.03
DESCRIPTION
A.
The work of this Section consists of removing 12 existing Flakt Woods Model
#94JMTS/40/4/9 tunnel ventilation fans at the V1 ventilator location and, installing and
testing of 12 replacement Flakt Woods Model #94JMTS/40/4/9 tunnel ventilation fans
and related equipment as specified herein, complete and ready for operation. Tunnel
ventilation fans will be provided by New Jersey Transit.
B.
Testing and restoring to operation Jet fans JF-9 and JF-10.
C.
Testing and restoring to operation the tunnel ventilation fans in ventilators V5 and V6.
Both V5 and V6 consist of seven 27 inch diameter single speed 7.4 hp fans axial fans.
D.
Testing and restoring to operation ventilator damper banks V2 and V3. Ventilator V2
has four dampers and operators. Ventilator V3 has five dampers and operators.
RELATED SECTIONS
A.
Section 13450 – Supervisory Control and Data Acquisition (SCADA) System for
Mechanical/Electrical
B.
Section 15050 – Basic Mechanical Materials and Methods
C.
Section 15990 – HVAC Testing, Adjusting and Balancing
QUALITY ASSURANCE
A.
Reference Standards:
1.
2.
December 2013
Technical Specifications
Air Moving and Control Association (AMCA):
a.
210, Laboratory Methods of Testing Fans for Rating.
b.
204-96, Balance Quality and Vibration
American Society for Testing and Materials (ASTM)
a.
A 123, Zinc (Hot-Galvanized) Coatings on Iron and Steel Products.
b.
A 239, Test Method for Locating the Thinnest Spot in a Zinc
(Galvanized) Coating on Iron or Steel Articles by the Preece Test
(Copper Sulfate Dip).
15831-1
Contract No. 14-017X
3.
B.
1.04
American Welding Society (AWS):
a.
D1.1, Structural Welding Code – Steel.
b.
D1.2, Structural Welding Code – Aluminum
c.
D1.3, Structural Welding Code – Sheet Steel.
All welding and welders qualification shall conform to the requirements of AWS D1.1
thru D1.3.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Within 30 days after NTP, Contractor shall submit the following:
C.
1.
Fan and sound attenuator installation details.
2.
Fan installation schedule (coordinated with NJT operations)
3.
Field service engineer resume.
4.
Field test procedure.
5.
Tunnel airflow test procedure.
Within 30 days after successful completion of all tests specified herein and of any
additional tests conducted at the Contractor's own option, Contractor shall submit the
following:
1.
Field test results.
PART 2 - PRODUCTS
2.01
TUNNEL VENTILATION FANS
A.
Description:
1.
Tunnel ventilation fans will be provided to the contractor by New Jersey
Transit. The fans will be 37 inch diameter 94JMTS/40/4/9 3.7/30 HP, two
speed motors manufactured by FlaktWoods 1701 Terminal Road, Suite B,
Niles Michigan, 49120-1253 (www.flaktwoods.com). The fans will be
provided with 30/3.7HP WEG motor, acoustical diffuser cone with screen,
split casing for mounting to panel, vibration sensors, temperature sensors
and motor side screen.
2.
Contractor to provide a local common instrument panel for the V1 fans to
house the signal conditioning units for bearing vibration and winding
temperature alarms. Panel instruments shall provide local indication of
December 2013
Technical Specifications
15831-2
Contract No. 14-017X
values and contact for remote alarm indication on high value. Panel to be
similar to NERL V1 Alarm Panel as shown in reference FlaktWoods
Ventilation Fans Maintenance, Installation and Operation Manual.
D.
3.
Each motor bearing for 12 tunnel ventilation fans at Ventilator V1 shall be
provided with a vibration detector for measuring bearing vibration. The
detector shall be permanently encapsulated coated electronics. Detectors
shall interface with cabling to match transducer requirements to the signal
conditioning units housed within the local instrument panel. The accuracy of
the detector shall be a maximum of 20 percent of detector level within
temperature range. Provide an adjustable time delay for alarm indication on
high value. The signal conditioning electronics shall be provided with an
adjustable alarm level for remote indication of a bearing trouble condition.
4.
Motors for 12 tunnel ventilation fans at Ventilator V1 shall be provided with six
(two per phase, 1 active and 1 spare) resistance temperature detectors
(RTD’s) wired to the local instrument panel with cabling to match transducer
requirements. Provide an analog-derived alarm unit with local digital
indication of winding high temperature for three RTD. Wire alarm contacts in
series to allow monitoring of common high temperature alarm. Locate
analog derived alarm unit in the local instrument panel. The signal
conditioning electronics shall be provided with an adjustable alarm level for
remote indication of a winding temperature trouble condition.
Sound Attenuators – Tunnel Ventilation Fans:
1.
2.05
Sound attenuator units for tunnel ventilation fans shall be furnished with the
fan. Contractor to install them as shown on the drawings.
MOTOR COMPONENTS AND CONSTRUCTION
A. General Requirements:
1.
Motors shall be equipped with factory installed resistance space heaters
within the motor enclosure to prevent condensation of moisture in the motor
windings. The heaters shall be energized whenever the motor is not in
operation and shall be automatically de-energized whenever the motor is in
operation. Heaters shall be 480 volts, single phase. The heaters shall be
provided with leads terminated in the terminal box described herein above,
external to the fan housing.
Motor space heaters shall be energized when the unit is delivered to the
contractor within 24 hours. Heaters shall be energized whenever fan is in
storage, at the site, or installed.
PART 3 - EXECUTION
3.01
INSTALLATION METHODS
A.
All existing V1 tunnel ventilation fans shall be removed from the existing mounting
plates by using the manufacturer’s fan removal procedure. Any damage to the
existing mounting plates caused by the removal of the existing fans shall be repaired
December 2013
Technical Specifications
15831-3
Contract No. 14-017X
at the contractor’s expense. Contractor shall clean existing mounting plates of old
gaskets and vent shafts of debris.
3.02
B.
Removed existing V1 tunnel ventilation fans shall be sold as scrap with the proceeds
going to NJ Transit. The contractor will provide documentation in accordance with the
Special Provisions SP 9.
C.
All fans shall be furnished and installed as specified herein and as indicated on the
Contract Drawings. The manufacturer's rigging instructions shall be carefully
followed. The Contractor shall make certain that the installation of all supports,
gaskets, hardware, etc., are accomplished with precision and the exercise of extreme
care so as to assure safe, accurate and trouble-free fan installation.
D.
The Field Service Engineer shall inspect fan installation.
E.
Prior to proceeding with the work described above, the Contractor shall submit for the
Construction Manager's approval eight copies of detailed drawings showing all fan
installations including dimensions, supports, hardware, installation methods, and all
other pertinent data. Contractor shall field verify actual fan and attenuator dimensions
with train clearance envelope to confirm physical and electrical clearances.
F.
Fans shall be connected to cone and transition companion flanges with new ¼ inch
thick solid silicone gasket between provided with the fan.
G.
When installed, the orientation of each fan, as to motor end, shall be as indicated on
the Contract Drawings. Fans, which are improperly installed, shall be removed and
reinstalled at the Contractor's expense.
FIELD ENGINEERING SERVICE
A.
The Contractor shall provide 10 days, eight hours per day of field service engineering
and inspection to NJ Transit to ensure that the fans supplied hereunder are properly
installed and tested. Requests for this field service will be made by the Construction
Manager.
B.
Field Service Engineer shall work under the direction of the Construction Manager.
C.
Contractor to submit for approval name and resume of proposed field service
engineer. Submit description of at least five similar tunnel airflow test he has
completed in the past 10 years, and description of the tunnel dimensions and number
of traverse points. Also submit a sample tunnel ventilation test report.
D.
Field service shall be performed periodically as required during the period of
performance of the NJ Transit construction contracts.
E.
NJ Transit shall be advised in writing of the name and title of the proposed field
service engineer.
F.
The duties, responsibilities, and qualifications of the field service engineer shall be:
December 2013
Technical Specifications
15831-4
Contract No. 14-017X
3.03
1.
Advise installation contractor's on the proper procedures for the installation of
the fan equipment.
2.
To have a thorough knowledge of the ventilation systems.
3.
To have a thorough knowledge of the test results and performance
requirements of all material and equipment supplied.
4.
To prepare and submit to the Construction Manager a typewritten report on
the activities and findings for each visit made within fifteen working days of the
visit. No payment for services is to be authorized until written service reports
have been received and accepted by the Construction Manager.
FIELD TEST
A.
At the initiation of the contract, the contractor shall inspect Jet Fans JF-9 and JF-10,
tunnel ventilation fans at ventilators V5 and V6 and tunnel ventilation dampers at
ventilators V2 and V3 to determine operational condition. Report any defects to the
construction manager.
B.
At the initiation of the contract, the contractor shall provide temporary power to the
heater in Jet Fans JF-9 and JF-10 and, tunnel ventilation fans at ventilators V5 and V6
until permanent power is restored. Contractor shall obtain from the fan manufacturer
maintenance and start up procedures for fans that have been out of service for
prolonged periods of time. The contractor shall follow the manufacturer’s procedures
to dry fan motors, rotate fans and perform all other steps to preserve and prepare the
fans for service.
C.
Contractor shall provide temporary power to the heaters in the damper motors in V2
and V3. Contractor shall follow manufacturer’s start-up procedures for drying out and
energizing this equipment.
D.
Upon completion of the installation of the ventilation equipment at the fan room and
the installation and verification of the power and local control wiring, the Contractor
shall notify the Construction Manager in writing at least two weeks prior to the field
testing to have the Construction Manager present to witness the tests. The Contractor
shall also notify the fan manufacturer to obtain assistance in the performance of the
tests. The fan manufacturer shall furnish written instructions for testing of the fan
motor units in the field. This instruction shall be submitted as a part of the operating
and maintenance instruction.
E.
Field tests shall be performed under the technical guidance and supervision of the
Field Service Engineer. Testing shall be performed per section 15990, who will
provide the field test instrumentation and perform the tests. The Contractor shall
measure and record the vibration amplitude; power consumption; no-load, starting
and full load voltages; starting and full load currents; and acceleration time.
F.
Time of operational testing shall be two eight hour periods per fan; four hours in each
flow direction. Where multiple fans are installed in one ventilator group, all fans shall
be operating simultaneously when determining and recording the electrical
measurement. Two speed fans shall be tested an additional two eight hour periods at
the second speed. Prior to the operational tests the vibration and electrical
December 2013
Technical Specifications
15831-5
Contract No. 14-017X
measurements shall be recorded for each fan motor unit at design speeds in each
direction.
G.
3.04
Testing for the new ventilation equipment shall not be undertaken until electric service
and local controls can be provided for testing.
1.
Each fan motor unit shall be checked for obviously rough operation after the
fans are installed. Defective bearings shall be replaced with new bearings
and the fan(s) shall be rechecked. Amplitude and frequency of radial and
axial vibrations at the bearings shall be measured, recorded, and checked for
conformity to the Specifications.
2.
Each fan motor unit on which the specified vibration field tests have been
successfully performed shall be tested to confirm that such fans are
operational. Each fan motor unit shall be proven operational in both
directions of airflow, including one reversing of direction of rotation.
3.
Electricians shall energize the ventilation equipment where required and
assist the Contractor during testing shall be provided by the Contractor.
4.
Any defect that develops within the ventilation equipment during the test shall
be corrected by the Contractor at no additional cost to NJ Transit.
5.
Any defect that develops with the installation work during the test shall be
corrected by the Contractor at no additional cost to NJ Transit.
H.
After completion of all field tests and after the final visit by the field service engineer,
Contractor shall submit a field test and inspection report. Field test report shall
include copies of raw data, measured results, calculations, and all data derived from
tests to confirm compliance with specified performance, noise, vibration and
equipment efficiencies.
I.
The Contractor shall energize the motor space heaters when the fan is delivered to
the site (within 24 hours). Contractor shall comply with all fan manufacturers
requirements in moving, storage and installation of fans to preserve and maximize
manufacturer’s warranty.
TUNNEL AIRFLOW PERFORMANCE TEST
1.
Tunnel Airflow Performance shall be conducted by a person with a minimum
for ten years experience in airflow measurement testing and has performed
at least three successful railroad tunnel airflow performance tests in the last
10 years. Railroad tunnel experience shall include simultaneous operation of
multiple fan/damper locations, and stopped trains.
2.
Submit resume of proposed person to perform the tunnel airflow test. Submit
details of at least three similar tests. Submit sample test report from a similar
project.
3.
The last field tests shall be the measurement of air movement within the
tunnel produced by the ventilation system. These measurements shall serve
December 2013
Technical Specifications
15831-6
Contract No. 14-017X
as verification that the ventilation system would produce velocity in the
tunnel/train annular area during a fire to satisfy emergency ventilation criteria.
4.
Tunnel Airflow Performance Test Information is provided in the reference
documents. This document details the one location for the measurements,
the testing conditions (such as ventilation system operating requirements and
the location of stopped trains), and the test results required for the Tunnel
Airflow Performance Test. Anemometer traverses of the entire tunnel cross
section shall be performed in order to measure the average airflow (in cubic
feet per minute) through the cross section. A minimum of two air velocity
transverses of the entire cross section shall be taken and averaged, and the
averaged measurements shall not vary by more than 5 percent. If two sets of
measurements vary by more than 5 percent, additional measurements shall
be taken until two consecutive sets of measurements do not vary by more
than 5 percent. The measurements shall account for the effects of the
tunnel portals, changes in horizontal curvature, and location and distance
from the stopped train. Contractor shall make the necessary arrangements
with NJ Transit to schedule the tests and to use stopped trains during the
actual testing period. The train location is detailed in the Tunnel Airflow
Performance Test Information document.
5.
Contractor shall provide the Construction Manager with the measured test
results. If the Construction Manager determines that the measured air
velocities are less than the required “cold” air velocities, Contractor shall be
notified in writing to increase the fan blade angles in order to produce the
required tunnel airflow velocities. Adjustments to fan blade angles shall be
performed only by the fan manufacturer representative. Cost of fan blade
angle adjustment to be invoiced to NJ Transit. Repeat field test on fans that
have been adjusted. The tunnel airflow performance test shall then be
repeated in order to verify that the required tunnel airflows have been
achieved. If the increased fan airflows cause overloading of the fan motors,
Contractor shall advise the Construction Manager in writing on the extent of
the overload.
6.
Construction Manager shall be notified in writing at least 2 weeks before the
initiation of this testing phase in order to coordinate the use of train(s) and to
program the appropriate ventilation system operation.
7.
Contractor shall submit to the Construction Manager, for approval by the
Construction Manager, a written test program at least 45 days before the
scheduled date of test initiation. This test program shall contain, as a
minimum, the resumes of the key personnel participating in the test phase,
the specific make and model numbers of the test equipment to be used, and
a general procedure to be followed for the set-up of equipment and for the
sampling recording, and reduction of the test data.
December 2013
Technical Specifications
15831-7
Contract No. 14-017X
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will be measured for payment as follows.
Pay Item
Description
15831.1
New TVF Installation (3.01)
15831.2
Field Engineering Service (3.02)
15831.3
Field Test (28 Fans and 9 Dampers) (3.03)
15831.4
Tunnel Airflow Test
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum Price for
all the work, labor and materials necessary therefore and incidental thereto as shown
on the Contract Drawings and described in these Specifications.
END OF SECTION 15830
December 2013
Technical Specifications
15831-8
Contract No. 14-017X
SECTION 15990
HVAC TESTING, ADJUSTING, AND BALANCING
PART 1 - GENERAL
1.01
1.02
DESCRIPTION
A.
This Section includes technical provisions for furnishing all labor, portable
instrumentation, tools, and reports for the complete testing, balancing, and adjusting
of all devices associated with the movement of air, for tunnel ventilating systems.
B.
Testing shall determine quantitative performance. Balancing shall establish specified
volumes of flow within a distribution system, and adjusting shall produce specified
flows from fan units.
C.
Furnish all labor, portable instrumentation, ladders, scaffolding, extension cords,
tools, and other material and equipment to perform and complete the tests of all
devices and equipment associated with the tunnel ventilating system.
D.
For information and requirements applicable to the work specified in this section see
Division 1, General Requirements.
RELATED SECTIONS
A.
1.03
Section 15830 – Tunnel Ventilation Fan Purchase
REFERENCE STANDARDS
A.
Associated Air Balance Council (AABC):
AABC National Standards for Field Measurements and Instrumentation - Total
System Balance
B.
American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc.
(ASHRAE):
C.
ASHRAE Systems Handbook, HVAC Systems and Applications Volume
D.
National Environmental Balancing Bureau (NEBB):
1.
Procedural Standards for Testing, Adjusting, and Balancing of Environmental
Systems
2.
Testing, Adjusting, Balancing Manual for Technicians
December 2013
Technical Specifications
15990-1
Contract No. 14-017X
HVAC TESTING, ADJUSTING, AND BALANCING
E.
Sheet Metal and Air Conditioning Contractors' National Association (SMACNA):
1.
1.04
1.05
HVAC Systems - Testing, Adjusting, and Balancing
SUBMITTALS
A.
Refer General Provisions for Construction, for submittal requirements and
procedures.
B.
Submit AABC National Warranty Certificate for the completed installation.
C.
The Contract Drawings and specifications shall be reviewed prior to installation of any
of the affected systems, and a written preliminary report submitted to the Construction
Manager indicating any deficiencies in the systems that would preclude the proper
adjusting, balancing, and testing of the systems.
D.
The Contractor shall submit an agenda for review by the Construction Manager prior
to start of testing and balancing work. The agenda shall include the following:
1.
General description of each system with its associated equipment and
operation cycles. Where different cycles are used they shall be described
separately.
2.
A complete listing of all air flow and air terminal measurements to be
performed.
3.
Proposed selection points for sound measurements.
4.
Specific test procedures and parameters for determining specified quantities
(e.g., flow, drafts, sound levels) from the actual field measurements to
establish compliance with contract requirements.
5.
Samples of report forms with blank spaces for all data specified hereinafter.
These forms shall demonstrate applications of procedures and calculations
to typical systems.
E.
Sample Forms: Submit sample forms, if other than those standard forms prepared
by the AABC or NEBB are proposed.
F.
Submit certified documentation showing test instrument calibration data and date.
G.
Submit certified test reports including information as specified.
H.
Calibration Reports: Submit proof that all required instrumentation has been
calibrated to tolerances specified in the referenced standards, within a period of six
months prior to starting the project.
QUALITY ASSURANCE
A.
Perform testing, adjusting, and balancing, using the services of an independent Test
and Balance Agency regularly engaged in the testing and balancing of air and water
November 2013
Technical Specifications
15990-2
HVAC TESTING, ADJUSTING, AND BALANCING
systems and associated equipment and piping systems. The agency selected shall
be a certified member of the Associated Air Balance Council (AABC). The agency
shall be independent of the installing personnel or equipment supplier for this project.
1.06
B.
Work shall be accomplished in accordance with the agenda specified herein.
Procedures described herein shall be followed and, if not specifically described
herein, shall be in accordance with the AABC, "National Standards for Field
Measurements and Instrumentation - Total System Balance," NEBB, Procedural
Standards for Testing-Adjusting-Balancing of Environmental Systems," SMACNA,
HVAC Systems-"Testing, Adjusting, and Balancing," and ASHRAE, Systems and
Application Volume.
C.
Provide test results and final reports certified and signed by a Professional Engineer
registered in the State of New Jersey.
D.
Pre-Balancing Conference: Prior to beginning of the testing, adjusting, and balancing
procedures, schedule and conduct a conference with the representatives of installers
of the mechanical systems. The objective of the conference is final coordination and
verification of system operation and readiness for testing, adjusting, and balancing.
PROJECT CONDITIONS
A.
B.
System Operation:
1.
Testing and balancing shall not begin until each system has been completed
and is in full working order. The Contractor shall put all ventilating systems
and equipment including controls into full operation and shall continue the
operation of same during each working day of testing and balancing.
2.
Tests shall be performed and adjustments shall be made as necessary to
accomplish the design objectives.
3.
In systems with two or more operating modes, the system operation in the
primary mode shall be tested, balanced, and adjusted. After final adjustment
in the primary mode, the secondary modes shall be tested, and the system
data recorded. The Design Engineer will determine whether additional
balancing and adjusting are necessary to meet the requirements. In systems
with redundant equipment, each piece of equipment shall be tested and
adjusted independently to operate within the design criteria.
Readjustments:
1.
Should corrective measures caused by faulty installation require retesting,
adjusting, and balancing, such work shall be performed at no additional cost
to the NJ Transit.
PART 2 - PRODUCTS
2.01
INSTRUMENTATION
November 2013
Technical Specifications
15990-3
HVAC TESTING, ADJUSTING, AND BALANCING
A.
All systems and components thereof shall be adjusted to perform as required by the
contract drawings and specifications.
B.
Operating tests of fans and other equipment shall be of not less than four hours
duration after stabilized operating conditions have been established. Capacities shall
be based on temperature and air flow quantities measured during such tests.
C.
Method of application of instrumentation shall be in accordance with the approved
agenda.
1.
All instruments used for measurements shall be accurate, and calibration
histories for each instrument shall be available for examination. Each test
instrument shall be calibrated by an approved laboratory or by the
manufacturer. The Construction Manager has the right to request instrument
recalibration, or the use of other instruments and test methodology, where
accuracy of readings is questionable. Also refer to General Provisions for
Construction, for requirements.
2.
All instruments shall be applied in accordance with manufacturer's certified
instructions.
3.
All labor, instruments, and appliances required shall be furnished by the
Contractor. Permanently installed instruments used for the tests such as
gauges and thermometers shall not be installed until just prior to the tests to
avoid damage and changes in calibration.
4.
Accuracy of all thermometers shall be plus or minus 1 graduation at the
temperatures to be measured. Graduations shall conform to the following
schedule:
Design Temperature
o
Differential ( F)
10 or less
over 10
Maximum
o
Graduation ( F)
0.5
1
D.
Instruments which require calibration shall have unexpired calibration dates.
Instruments shall be calibrated against certified equipment having a known valid
relationship to nationally recognized standards. If no national standard exists, the
basis for calibration shall be documented and submitted in the final report.
E.
Certified documentation of all instrument calibrations shall be submitted in the final
report.
PART 3 - EXECUTION
3.01
APPLICABLE STANDARDS
A.
Perform testing and balancing in accordance with AABC National Standards for Field
Measurements and Instrumentation and the hereinbefore referenced NEBB,
ASHRAE, and SMACNA Standards and recommended practices, as applicable.
November 2013
Technical Specifications
15990-4
HVAC TESTING, ADJUSTING, AND BALANCING
3.02
PROCEDURES
A.
3.03
Air Systems: Perform the following minimum tests and balancing:
1.
Adjust all air handling systems to provide the required design air quantity to,
or through, each component. Adjusting and balancing of all systems shall be
conducted during periods of the year approximating maximum seasonal
operations, to the extent possible.
2.
Total air system quantities, generally, shall be varied by adjustment of fan
speeds or axial-flow fan wheel blade pitch. Adjustment of fans speed or fan
pitch, where required, shall be performed by the contractor at no cost to NJ
Transit.
3.
Adjustment of automatically operated dampers shall be set to operate as
indicated. Controls shall be checked for proper calibration. List of controls
requiring adjustment shall be submitted to the Construction Manager.
DOCUMENTATION
A.
Test Data Sheets: Test data sheets shall be provided in accordance with the
following requirements:
1.
Test data sheet forms shall be subject to approval and shall be provided for
recording measurement readings and data. These forms shall be supplied
by the Contractor, or may be reproduced from samples supplied by the
independent testing and balancing agent.
2.
Where computers are used for calculations and data printout is included,
standard forms may be used, provided that all information required by the
standard forms is included. These forms and an explanation of the computer
program shall be submitted for approval.
3.
For components not included in the test data sheet forms, the data shall be
recorded concisely and logically for submittal.
4.
Sheets shall be completed by the independent testing and balancing agent,
dated with test dates, and signed by the technician performing the work.
Prior to final submittal, the test data sheets shall be reviewed and approved
by the testing and balancing agent's Construction Manager. Test data
sheets shall be typed for final submittal.
5.
Spaces on the data sheet which are not applicable shall be indicated with an
N/A. Design data which is not known or not available shall be indicated with
an N/K.
6.
Readings or data which are applicable, but not provided for on the data
sheet, shall be included and shall be explained under the heading
"Remarks."
November 2013
Technical Specifications
15990-5
HVAC TESTING, ADJUSTING, AND BALANCING
B.
C.
Certified Reports: Three copies of the reports described herein, covering system
performance, air motion (fpm), and sound pressure levels, shall be submitted to the
Construction Manager prior to final tests and inspection.
1.
Instrument records including types, serial numbers, and dates of calibration
of all instruments shall accompany the final submittal data.
2.
Reports shall identify conspicuously items not conforming to contract
requirements, or obvious deficiencies in design and operation.
3.
Approved system flow diagram shall be submitted with the test data sheets
and report. Flow diagrams shall indicate measured flows, pressures, and
temperatures.
4.
The reports shall be certified by an independent Registered Professional
Engineer in the State of New Jersey, who is versed in the field of HVAC
balancing and who is not affiliated with any firm involved in the design or
installation phases of the project. Certification shall include checking of
adherence to agenda, of calculations, of procedures, and evaluation of final
summaries.
Air System Data: The certified report shall include for each air handling system the
data listed below:
1.
Equipment:
a.
b.
Installation data:
1)
Manufacturer and model
2)
Size
3)
Arrangement, discharge, and class
4)
Motor hp, voltage, phase, cycles, and full load amps
5)
Location and local identification data
Design data:
1)
c.
November 2013
Technical Specifications
Data listed in schedules on plans and specifications
Fan recorded test data:
1)
cfm
2)
Static pressure recorded only where total system delivery
cannot be checked by measuring velocity in main circuit
3)
rpm
4)
Motor operating amps
15990-6
HVAC TESTING, ADJUSTING, AND BALANCING
5)
D.
3.04
A.
3.05
Motor operating bhp
FINAL TESTS AND ACCEPTANCE
Test shall be made to demonstrate that capacities and general performance of the
tunnel ventilation system comply with contract requirements.
1.
At the time of final inspection, the Contractor shall recheck random
selections of data (air quantities, air motion, and sound levels) recorded in
the Certified Report.
2.
Points and areas for recheck shall be selected by the Construction Manager.
3.
Measurement and test procedures shall be the same as approved for work
forming basis of Certified Report.
4.
Selections for recheck (specific plus random), in general, will not exceed 25
percent of the total number tabulated in the report, except that special air
systems may require a complete recheck for safety reasons.
B.
If random tests elicit a measured flow deviation of 10 percent or more from that
recorded in the Certified Report listings, at 10 percent or more of the rechecked
selections, the report will be automatically rejected. In the event the report is rejected,
all systems shall be readjusted and tested, new data recorded, new Certified Reports
submitted, and new inspection tests made, all at no additional cost to the NJ Transit.
C.
Subsequent to any correctional construction work, such as acoustic corrections,
measurement shall be made to verify that associated airflow quantities, as previously
measured, have not been disrupted.
D.
Following final approval of Certified Reports by the Construction Manager, the settings
of all valves, splitters, dampers, and other adjustment devices shall be permanently
marked by the Contractor so that adjustment can be restored if disturbed at any time.
Devices shall not be marked until after final acceptance.
FIELD SERVICES
A.
Instruction of Maintenance Personnel: The Testing and Balancing Agency shall
instruct the maintenance personnel in the proper operation, setting, and adjustment of
the equipment.
B.
Re-inspection: The Testing and Balancing Agency shall make two return inspection
trips to the project, one during heating design conditions and one during airconditioning design conditions, for the purpose of checking out the entire system (or
group of systems). The Testing and Balancing Agency shall make additional
adjustments as required during the re-inspection.
November 2013
Technical Specifications
15990-7
HVAC TESTING, ADJUSTING, AND BALANCING
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be made at the Contact Lump Sum Price for
all the work, labor and materials necessary therefore and incidental thereto as shown
on the Contract drawings and described in these Specifications.
END OF SECTION 15990
November 2013
Technical Specifications
15990-8
SECTION 16010
ELECTRICAL GENERAL REQUIREMENTS
PART 1 - GENERAL
1.01
DESCRIPTION
A.
1.02
1.03
The work of this Section consists of the general requirements for Division 16 –
Electrical in accordance with the Contract Documents, unless specified otherwise
in the individual sections.
RELATED SECTIONS
A.
Section 13080 – Seismic Anchoring and Vibration Isolation for Mechanical and
Electrical Equipment.
B.
Not Used
C.
Not Used
D.
Section 16445 – Motor Control Centers and Motor Starters
E.
Section 16960 – Electrical Acceptance and Start-Up Testing and Training
QUALITY ASSURANCE
A.
Reference Standards:
1.
National Electrical Manufacturer's Association (NEMA)
a.
2.
ICS-6, Enclosures for Industrial Control and Systems.
National Fire Protection Association (NFPA):
a.
70, National Electrical Code (NEC)
b.
130, Standard for Fixed Guideway Transit Systems
B.
Regulatory Requirements: Equipment, materials, installation, and workmanship
shall be in accordance with the mandatory and advisory provision of the NEC.
C.
Service Support:
The equipment items shall be supported by service
organizations, which are reasonably convenient to the equipment installation in
order to render satisfactory service to the equipment on a regular and emergency
basis during the warranty period of the Contract. Where two or more items of the
same class of equipment are required, these items shall be products of a single
manufacturer, however, the component parts of the item need not be the
products of the same manufacturer unless stated in the technical section.
December 2013
Technical Specifications
16010-1
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
D.
1.04
Manufacturer's Nameplate:
Unless otherwise specified in the applicable
technical section, each item of equipment shall have a nameplate bearing the
manufacturer's name, address, model number, and serial number securely
affixed in a conspicuous place; the nameplate of the distributing agent will not be
acceptable.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Drawings:
Include complete wiring diagrams and installation details of
equipment indicating proposed location, dimensioned layouts and arrangements
(floor plans and elevations), control panels, anchorage, accessories, piping,
ductwork, and other items that must be shown to ensure a coordinated
installation. Wiring diagrams shall identify circuit terminals and indicate the
internal wiring for each item of equipment and interconnection between each item
of equipment. Drawings shall indicate adequate clearance for operation,
maintenance and replacement of operating equipment devices.
1.
Ventilation system instrumentation and control submittals shall include:
a. A complete interconnection diagram(s) for all ventilation
instrumentation and control (I&C) devices and enclosed
equipment. The diagram(s) shall be of the point-to-point type,
shall reflect the logical intent of the interconnection design
documentation, and shall show the external connections of all
devices and equipment. Computer-generated interconnection
lists will not be acceptable in lieu of a true interconnection
diagram.
b. Layout drawings and internal connection diagrams of the
instrumentation & control cabinets and other hardware.
c.
Material listing and specifications for programmable controllers,
including input/output units, programming terminal, and
equipment for interfacing.
d. Programmable controller program listed in logic program format.
Circuit functions shall be described; all contacts and outputs
shall be identified by word description and by number
designation. The logic diagrams shall be fully documented and
internal logic variables usage shall be identified, crossreferenced and listed. Inputs and outputs shall be referenced to
locations of signals on interconnection diagram. A full crossreference report shall be included.
e. Layout drawings and internal connection diagrams of the control
system major block components, control cabinets; relay cabinets
and vector drive panels.
f.
December 2013
Technical Specifications
A schedule of electrical apparatus for each panel which shall list
each I&C device by its designation as shown on the schematic
16010-2
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
wiring diagram and shall state for each device its rating, number
of poles or contacts, function, catalog number, and location. A
complete set of catalog cuts for materials furnished shall be
included for each piece of apparatus.
g. A complete interconnection diagram(s) for all I&C devices and
enclosed equipment. The diagram(s) shall be of the point-topoint type, shall reflect the logical intent of the interconnection
design documentation, and shall show the external connections
of
all
devices
and
equipment.
Computer-generated
interconnection lists will not be acceptable in lieu of a true
interconnection diagram.
h. All other active component software and hardware text
documentation and complete cross-referencing information.
C.
D.
i.
A set of descriptive leaflets, bulletins, and drawings covering all
I&C and BMS items. The catalog number of each component
shall be given in case it becomes necessary to order
replacement parts from the manufacturer.
j.
Manufacturer's Product Data: Submit manufacturer's product
data for each item listed in the Specifications and/or Contract
Drawings. Manufacturer's product data shall typically consist of
catalog cuts, manufacturing drawings, and/or specifications,
where applicable or as directed. All submissions of this type
shall be marked with references to the applicable Specification
Section or Contract Drawing number, the specific
k.
Test Reports, Certifications Ten sets. Submit such items where
specified in the Specifications or on the Contract Drawings, or as
directed.
Manufacturer's Instructions: Prior to installation, submit printed copies of
manufacturer's instructions. Installation of the item shall not proceed until
manufacturer's instructions are received.
1.
Modifications to manufacturer's preprinted data shall be submitted on the
manufacturer's letterhead giving the reason for the change and the
application section of the Specification.
2.
Certified Test Reports: Before delivery of materials and equipment,
certified copies of all test reports specified in the individual sections shall
be submitted for approval.
Operation and Maintenance Manuals:
1.
December 2013
Technical Specifications
Before acceptance of the work, the Contractor shall forward to the
Construction Manager six complete bound sets of instructions of each
equipment plant and its component parts, including manufacturers'
certificates, warranty slips, parts list, descriptive brochures, and
Contract No. 14-017X
16010-3
ELECTRICAL GENERAL REQUIREMENTS
maintenance and operating instructions, printed on bond white paper, for
all equipment and systems installed, properly tabbed and identified for
easy reference.
2.
Defects discovered on review will be indicated in the operations and
maintenance manual or otherwise communicated to the Contractor in
writing on return of the Operations and Maintenance Manual.
3.
After receipt of the Operations and Maintenance Manual marked
"Rejected, Revise and Resubmit", revise the Manual in accordance with
the directions for revision and resubmit six sets of the revised Manual for
review.
The Construction Manager will review and return the
resubmitted Operations Manual in the same manner and time as
specified above for the original submittal.
After receipt of the Operations and Maintenance Manual marked
"Approved" or "Approved as Noted", revise the Manual in accordance
with revisions noted, if any, and furnish 15 sets of the Operations and
Maintenance Manual in final form. The original six set submittal shall not
be considered included in the 15 sets of the Manual in final form.
4.
5.
If subsequent modifications to the equipment require revised operation
and maintenance procedures, revise the Operations and Maintenance
Manual to show the equipment as installed. Such revisions shall be by
issue of replacement pages to the final Operations and Maintenance
Manual to show the equipment as installed. Such revisions shall be by
issue of replacement pages to the final Operations and Maintenance
Manual, or by reissue of the Operations and Maintenance Manual, at the
Contractor's option. The revisions to the Operations and Maintenance
Manual shall be submitted not later than 60 days following delivery of the
equipment.
6.
Format:
December 2013
Technical Specifications
a.
The Operations and Maintenance Manual shall include title page,
contents page, frontispiece, and information covering
description, installation, operation, preventive maintenance,
corrective maintenance, overhaul, parts list, and list of
recommended spare parts, and an appendix.
b.
The title page shall include the name and function of the
equipment, manufacturer's identification number, and the
Contract Specifications number and title.
c.
The contents shall list all sections and subsection titles of the
Manual with reference to the page on which each starts and a list
of included drawings.
d.
The frontispiece shall be a recognition illustration of the
equipment described in the Manual.
16010-4
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
e.
7.
1.05
Pages shall be 8-1/2 inches by 11 inches in size or folded to that
size, and placed in a three-ring binder. Each binder shall not be
filled more than 2/3 of its capacity.
Contents:
a.
The descriptive information shall consist of drawings and
diagrams, and a physical and functional description of the
equipment, including major assemblies and subassemblies.
b.
The installation information shall cover pre-installation
inspection, installation, calibration, and preparation for operation,
both for initial installation and for installation after overhaul.
c.
The operation information shall include step-by-step procedures
for starting, restarting, operating, shutdown, and emergency
requirements. The information shall also include performance
specifications and operating limitations.
d.
The maintenance information shall include step-by-step
procedures for inspection, operation checks, cleaning,
lubrication, adjustments, repair, overhaul, disassembly, and
reassembly of the equipment for proper operation of the
equipment. A list of special tools, which are required for
maintenance, shall be included with the maintenance
information.
e.
The complete parts list and a list of recommended spare parts
shall provide all necessary information, including part numbers
and catalog item numbers if applicable, for identifying parts.
Parts or assemblies obtained from another manufacturer shall be
identified by the name of that manufacturer and its identifying
part number. The size, capacity, or other characteristics of the
part shall be supplied if required for identification.
f.
The appendix shall include safety precautions, a glossary, and, if
available at time of submittal, copies of test reports and other
relevant material not specified to be submitted.
g.
All information on material or equipment not used in the work
shall be deleted from the Operations and Maintenance Manual.
h.
One set of the Operations and Maintenance Manual in final form
shall be suitable for microfilming.
DELIVERY, STORAGE AND HANDLING
A.
Equipment and materials shall be properly stored and adequately protected and
carefully handled to prevent damage before and during installation. Equipment
and materials shall be handled, stored, and protected in accordance with the
manufacturer's recommendations and as approved by the Construction Manager.
December 2013
Technical Specifications
16010-5
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
Electrical conduit shall be stored to provide protection from the weather and
accidental damage. Cables shall be sealed, stored and handled carefully to
avoid damage to the outer covering or insulation and damage from moisture and
weather.
1.06
VENTILATION POWER
COORDINATION
A.
B.
C.
D.
E.
AND
CONTROL
SYSTEM
RESTORATION
AND
Electrical work shall be coordinated with other trades involved in the construction
work. All work shall be carefully laid out in advance coordinating electrical
features with architectural, structural, and mechanical features. Coordinate with
NJ Transit work in areas where other contracts are in progress.
The main objective of the electrical work is to replace previously damaged power
and control systems and components of the tunnel emergency / life safety
ventilation systems, and to reintegrate all restored and existing Newark Penn
ventilation controls, both hardwired
and SCADA, to the wider NLR tunnel
ventilation central command and control system.
A ventilation control system integrator that includes SCADA systems shall be
assigned on the Contractor’s side to ensure single-source responsibility of the
local Newark Penn ventilation control system integration to the NLR tunnel
ventilation system. The ventilation control system integrator shall be responsible
with coordinating all relevant subcontractor control system submittals including:
MCC internal wiring; terminations / markings / labeling; SCADA cabinets, PLC
racks, I/O’s; point-to-point wiring diagrams between MCC’s, control cabinets,
RTU’s and control panels, fan sensors and terminations; etc, to ensure a fully
functional system is ultimately delivered.
Note that the Contractor shall prepare and submit to the Engineer acceptance a
ventilation testing and commissioning plan (part of the overall emergency
ventilation acceptance plans) that shall include the new and restored electrical
power and control systems; for ventilation system operational and functional
details and requirements, please refer to the mechanical plans, specifications
and as-built reference documentation for additional information and details.
Removal And Relocation of Equipment
Remove existing electrical equipment, consisting of Motor Control Centers,
switches, conduits, boxes, fittings, wire and cable, etc. which are not to remain in
service, as indicated on the Contract Drawings. Remove electrical equipment
with the option of salvage by the Authority. Salvaged equipment will be picked
up by the Authority maintenance personnel. All other existing equipment
removed, in connection with the work under this Section and not reinstalled as
indicated on the Contract Drawings, shall become the property of the Contractor
and shall be disposed of by the Contractor.
Remove and relocate existing electrical equipment, consisting of Motor Control
Centers, switches, conduit, boxes, fittings, wire and cable, etc. as indicated on
the Contract Drawings, as specified herein or as directed. Maintain in service all
circuits disrupted by this relocation. Replace all service and distribution
equipment, determined unsuitable for further service as directed and supply all
conduit, boxes, wire and cable required for the relocations. All materials installed
for the relocations shall be of the same types and sizes as those removed. All
December 2013
Technical Specifications
16010-6
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
conduits installed in electrical distribution rooms, station platforms, enclosure
rooms and emergency exits, shall be painted to match adjacent surfaces.
Conduits installed in tunnels shall not be painted.
Where existing equipment is removed or abandoned, disconnect both the load
and line ends of conductors feeding said equipment and remove conductors.
Where fixtures or devices are removed, from an outlet that contains wiring that
must remain in service, tape the ends of the conductor or splice the wires that
are to remain in service and cap the outlet.
Wire and conduit, unless embedded in the structure, which will be abandoned
shall be disconnected at both ends and removed. Where abandoned wire and
conduits are embedded in the structure, wires shall be disconnected and
removed. Existing boxes which are embedded in the structure are to be provided
with blank, code gauge cover plates.
Cut and cap abandoned conduits 1/2 inch below the surface and patch after the
conductors have been removed.
F.
Point-to-Point Wiring
Contractor is advised to perform a thorough examination and full documentation
of the existing point-to-point wiring and terminations between damaged and
undamaged equipment, such between MCC’s, local Newark Penn fan control
panel (LCP), SCADA panels and damper panel, etc to ensure a smooth, fast
production of the necessary new point to point diagrams and panel layouts
The Contractor shall be solely responsible to generate without delay the required
correct, detailed shop drawings and final as-built point-to-point wiring
documentation for the new, restored ventilation control systems, and should
ensure this existing point to-point wiring survey work before removals in part of
the project requirements.
1.07
1.08
G.
Not Used
H.
Contractor is advised that the two utility services are not in phase, and may not
be paralleled.
MAINTENANCE DURING CONSTRUCTION
A.
The Contractor shall maintain the existing electrical systems to insure
continuance of operational features.
B.
Prior to removal of existing electrical equipment, the Contractor shall request and
receive approval two weeks before commencing operations.
POWER SYSTEM STUDIES AND TESTS
A.
General:
1.
December 2013
Technical Specifications
Protective device coordination studies shall be performed by the MCC
manufacturer. The studies shall be submitted to the Construction
16010-7
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
Manager prior to receiving final acceptance of the distribution equipment
shop drawings. If formal completion of the study calculations may cause
delay in equipment manufacture, the Construction Manager may choose
to accept a preliminary submittal of sufficient data to ensure that the
selection of device ratings and characteristics will be satisfactory.
2.
B.
The studies shall include all portions of the electrical distribution system,
from the 480 volt distribution system. Normal system connections and
those, which result in maximum fault conditions, shall be adequately
covered in the analysis.
Protective Device Coordination Study:
1.
A protective device coordination study shall be performed to provide the
necessary calculations and logic decisions required to select or to check
the selection of power fuse ratings, protective relay characteristics and
settings, rations and characteristics of associated current transformers,
and low voltage breaker trip characteristics and settings. The objective
of the study is to obtain optimum protective and coordination
performance from these devices.
2.
The coordination study shall include all low voltage classes of equipment
from the incoming line protective devices down to and including the rated
devices in the 480 volt distribution system. The phase and ground
overcurrent protection shall be included as settings of all other adjustable
protective devices.
3.
The time-current characteristics for the specified protective devices shall
be drawing on log-log paper. The plots shall include complete titles,
representative one-line diagram and legends, associated feeder fuse
characteristics, significant motor starting characteristics, complete
parameters of transformers, complete operating bands of low voltage
circuit breaker trip curves and fuses. The coordination plots shall
indicate the types of protective devices selected, proposed time and
instantaneous trip settings, transformer magnetizing in-rush and
transformer withstand parameters, cable thermal overcurrent withstand
limits and significant symmetrical and asymmetrical fault currents. All
restrictions of the NEC shall be adhered to and proper coordination
intervals and separation of characteristics curves shall be maintained.
The coordination plots for phase and ground protective devices shall be
provided on a system basis. Separate curves shall be used to clearly
indicate the coordinate achieved.
4.
The selection and settings of the protective devices shall be provided
separately in a tabulated form listing circuit identification, device number,
current transformer ratios and connection, manufacturer and type, range
of adjustment and recommended settings.
A tabulation of the
recommended power fuse selection shall be provided for the medium
voltage fuses where applied in the system.
December 2013
Technical Specifications
16010-8
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
C.
D.
Study Report:
1.
The results of the coordination system study shall be summarized in a
final report. Eight bound copies of the final report shall be submitted.
2.
The report shall include the following:
a.
Description, purpose, basis, and scope of the study, and a one
line diagram of that portion of the power system, which is
included within the scope of the study.
b.
Protective device time versus current coordination curves,
tabulation for rated versus calculated short circuit duties, and
commentary regarding same.
c.
Fault current calculations including a definitions of terms and
guide for interpretation of computer printout.
Protective Device Testing, Calibration and Adjustment:
The equipment
manufacturer shall provide the services of a qualified field engineer and
necessary tools and equipment to test, calibrate and adjust circuit breaker trip
devices based on the coordination study findings.
E.
1.09
After completion of the installation, the Contractor shall perform all operation
tests and calibrations on the protective relays. The Contractor shall test the
control and trip circuits, interlocks, the switchgear and grounding devices.
NAMEPLATES
A.
1.10
Unless otherwise specified, provide laminated plastic nameplates for each
panelboard, equipment enclosure, starter, relay switch, and device. Each
nameplate inscription shall identify the function and, when applicable, the
position. Nameplates shall be melamine plastic, 0.125 inch thick, black with
white letters. Surface shall be matte finish. Corners shall be square. Accurately
align lettering and engrave into the core. Minimum size of nameplates shall be 1
by 2.5 inches. Lettering shall be a minimum of 0.25 inch high normal block style.
Nameplates shall be secured with two stainless steel screws.
TRAINING OF NJ TRANSIT PERSONNEL
A.
Prior to final inspection or acceptance, instruct and demonstrate to designated
NJ Transit operating and maintenance personnel the operation, adjustment, and
maintenance of all equipment and systems. Training time shall be specified in
Section 16960.
B.
Explain to the NJ Transit operations and maintenance personnel, in full and to
their complete understanding, all procedures necessary to operate and maintain
all equipment and systems on a continuing basis.
C.
Review the contents of the Operations and Maintenance Manual with the
December 2013
Technical Specifications
16010-9
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
operations and maintenance personnel in full detail to explain all aspects of the
Manual and the operation and maintenance of all equipment and systems.
D.
1.11
POSTED OPERATING INSTRUCTIONS
A.
B.
1.12
Operating Instructions: Submit text of posted operating instructions for each
system and principal item of equipment as specified in the technical sections.
Provide for each system and principal item of equipment as specified in the
technical sections for use by operation and maintenance personnel. The
operating instructions shall include the following:
1.
Wiring diagrams, control diagrams and control sequence for each
principal system and item of equipment.
2.
Start-up, proper adjustment, operating, lubrication, and shutdown
procedures.
3.
Safety precautions.
4.
The procedure in the event of equipment failure.
5.
Other items of instruction as recommended by the manufacturer of each
system or item of equipment.
Print or engrave operating instructions and frame under glass or in approved
laminated plastic. Post instructions where directed. For operating instructions
exposed to the weather, provide weather-resistant materials or weatherproof
enclosures. Operating instructions shall not fade when exposed to sunlight and
shall be secured to prevent easy removal of peeling.
SEISMIC REQUIREMENTS
A.
All equipment shall be internally braced to withstand seismic forces as defined in
Section 13080, paragraph 1.03.F of the Contract Technical Provisions.
PART 2 - PRODUCTS
NOT USED
PART 3 – EXECUTION
3.01
PAINTING OF EQUIPMENT
A.
Factory Applied: Electrical equipment shall have factory applied painting
systems in accordance with NEMA ICS-6 corrosion-resistance test and the
additional requirements specified in the technical sections.
B.
Field Applied: Paint electrical equipment as required to match finish of adjacent
surfaces or to meet the indicated or specified safety criteria.
December 2013
Technical Specifications
16010-10
Contract No. 14-017X
ELECTRICAL GENERAL REQUIREMENTS
3.02
NAMEPLATE MOUNTING
A.
3.03
Provide number; location and letter designation of nameplates as indicated.
Fasten nameplates to the device with a minimum of two stainless steel screws.
EQUIPMENT INSTALLATION
A.
All equipment shall be installed in accordance with Section 13080 of the Contract
Technical Provisions.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in related items of work
shown on the Contract Drawings and described in the Specifications and
required for completion of work under this Contract.
END OF SECTION 16010
December 2013
Technical Specifications
16010-11
Contract No. 14-017X
SECTION 16050
BASIC ELECTRICAL MATERIALS AND METHODS
PART 1 - GENERAL
1.01
1.02
DESCRIPTION
A.
The work of this Section consists of providing basic materials and methods for
electrical work as necessary to support the sections in Division 16 – Electrical, which
specify particular categories of electrical work.
B.
The Contract Drawings show facilities diagrammatically and do not show offsets,
fittings, and accessories that may be required. Investigate carefully the structural and
finish conditions affecting the work, and provide such fittings and accessories as
required.
C.
The intent of this Section is to provide for all basic materials not elsewhere specified in
other sections of Division 16, but required to provide for completely operative
electrical systems in the designated structures from specified interfaces to and
including the last outlet and device.
D.
All work performed by the Contractor shall be done by skilled mechanics in a manner
satisfactory to the Construction Manager and in accordance with the requirements of
the NEC and any local authority having jurisdiction over this installation. If required,
certificates of approval shall be delivered to the Construction Manager before final
acceptance of the work.
E.
General requirements include those specified in Section 16010 and as specified
herein.
F.
Interface and Coordination:
1.
Interface and coordinate the work of this Section with the other Sections of
this Division 16, Electrical, as required to provide a complete and operable
electrical installation.
2.
Interface and coordinate with work completed or in progress or to be
performed under other sections of these Specifications or by other
contractors. Make indicated connections to previously completed work.
Where future connections to or extension of the work are indicated, make
safe and convenient provisions for such future connections and extensions.
3.
Take possession of and maintain electrical equipment left in place by others,
where applicable. Leave temporary electrical work, plant, and equipment in
place for maintenance and operation for the duration of the Contract.
RELATED SECTIONS
A.
Section 16010 – Electrical General Requirements
December 2013
Technical Specifications
16050-1
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
1.03
B.
Section 16061 – Grounding
C.
Section 16445 – Motor Control Centers and Motor Starters
D.
Section 16960 – Electrical Acceptance and Start-Up Testing and Training
QUALITY ASSURANCE
A.
Reference Standards:
1.
2.
December 2013
Technical Specifications
American National Standards Institute (ANSI):
a.
C37.35, Guide for the Application, Installation, Operation, and
Maintenance of High Voltage Air Disconnecting and Load Interrupter
Switches.
b.
C80.1, Rigid Steel Conduit, Zinc Coated.
American Society for Testing and Materials (ASTM):
a.
A 123, Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products.
b.
A 153, Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
c.
B8, Concentric Lay Stranded Copper Conductors, Hard, MediumHard, or Soft.
d.
D 149, Test Methods for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial
Power Frequencies.
e.
D 570, Test Method for Water Absorption of Plastics.
f.
D 638, Tensile Properties of Plastics.
g.
D 695, Test Method for Compressive Properties of Rigid Plastics.
h.
D 790, Test Methods for Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials.
i.
D 1000, Method of Testing Pressure Sensitive Adhesive Coated
Tapes Used for Electrical Insulation.
j.
D 1518, Test Method for Thermal Transmittance of Textile Material.
16050-2
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.
4.
k.
D 2240, Test Method for Rubber Property – Durometer Hardness.
l.
D 3005, Low Temperature Resistant Vinyl Chloride Plastic Pressure
Sensitive Electrical Insulating Tape.
m.
D 5034, Test Method for Breaking Force and Elongation of Textile
Fabrics (Grab Test).
n.
D 5035, Test Method for Breaking Force and Elongation of Textile
Fabrics (Strip Test).
o.
E 84, Test Method for Surface Burning Characteristics of Building
Materials.
p.
E 119, Method for Fire Tests of Building Construction and Materials.
q.
E 605, Test Methods for Thickness and Density of Sprayed FireResistive Material Applied to Structural Members.
r.
E 662, Test Method for Specific Optical Density of Smoke Generated
by Solid Materials.
s.
E 736, Test Method for Cohesion/Adhesion of Sprayed Fire-Resistive
Materials Applied to Structural Members – Modified Laboratory
Procedure.
t.
G 21, Test Method to Evaluate Resistance of Synthetic Polymer
Materials to Fungi.
Insulated Cable Engineers' Association (ICEA):
a.
S-68-516, Ethylene-Propylene Rubber Insulated Wire and Cable for
the Transmission and Distribution of Electrical Energy.
b.
T-33-655, Guide for Low Smoke, Halogen-Free (LSHF) Polymeric
Cable Jackets.
Institute of Electrical and Electronics Engineers (IEEE):
a.
5.
Military Specifications:
a.
December 2013
Technical Specifications
383, Standard for Type Test of Class 1E Electric Cables, Field
Splices, and Connections.
C-24643, Electrical Cable and Cord for Shipboard Use, Testing for
Low Smoke and Halogens.
16050-3
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
6.
National Electrical Manufacturer's Association (NEMA):
a.
250, Enclosures for Electrical Equipment (1,000 Volts Maximum).
b.
A-1, Molded Case Circuit Breakers.
c.
FB-1, Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit
and Cable Assemblies.
d.
OS-1, Sheet Steel Outlet Boxes, Device Boxes, Covers, and Box
Supports.
e.
ST-20, Dry Type Transformers for General Applications.
f.
WC-3, Rubber Insulated Wire and Cable for the Transmission and
Distribution of Electrical Energy.
g.
WD-1, General Requirements for Wiring Devices.
7.
National Electrical Safety Code (NESC).
8.
National Fire Protection Association (NFPA):
9.
10.
a.
70, National Electrical Code (NEC).
b.
130, Standard for Fixed Guideway Transit Systems
New Jersey Uniform Construction Code (NJUCC):
a.
Building Subcode.
b.
Electrical Subcode
Occupational Safety and Health Administration (OSHA):
a.
11.
December 2013
Technical Specifications
29 CFR 1926
Underwriters' Laboratories, Inc. (UL):
a.
1, Flexible Metal Electrical Conduits.
b.
6, Rigid Metal Electrical Conduits.
c.
20, General Use Snap Switches.
d.
44, Thermoset-Insulated Wires and Cables
e.
50, Cabinets and Boxes.
16050-4
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
1.04
f.
62, Flexible Cord and Fixture Wire
g.
67, Panelboards.
h.
98, Enclosed and Dead Front Switches
i.
198E, Class R Fuses.
j.
360, Liquid-Tight Flexible Steel Conduit, Electrical.
k.
489, Molded Case Circuit Breakers and Circuit Breaker Enclosures.
l.
510, Polyvinyl Chloride, Polyethylene and Rubber Insulating Auxiliary
Tape.
m.
514A, Metallic Outlet Boxes, Electrical.
n.
514B, Fittings for Conduit and Outlet Boxes.
o.
1072, Medium Voltage Power Cables.
p.
1561, Dry Type General Purpose and Power Transformers.
q.
1685, Safety Vertical Tray Fire Propagation and Smoke Release
Test for Electrical and Optical Fiber Cable.
r.
2196, Standard for Tests for Fire Resistive Cables.
s.
Fire Resistance Directory.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
List of Materials: At least 30 days before beginning the work of this Section, submit a
list of materials and equipment proposed for use together with applicable standards.
Give name of manufacturer, brand name, and catalog number of each item. Submit
the list complete at one time, with items arranged and identified in numerical
sequence by Specification Section and Paragraph number.
C.
Compliance with Applicable Standards: The label or listing of the specified agency
will be acceptable evidence.
D.
Factory Test and Inspection Certification:
1.
December 2013
Technical Specifications
Except as otherwise specified herein, where factory tests and inspections for
materials and equipment for which tests and inspections specified in
16050-5
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
referenced documents are waived, provide certified copies of reports for tests
performed on previously manufactured identical materials or equipment
within the previous 12 months.
2.
E.
Accompany test reports by signed statements from the manufacturer
certifying that the previously tested material or equipment is physically,
mechanically, and electrically identical to that proposed for the project.
Include wiring and control diagrams.
Shop Drawings:
1.
Submit shop drawings for review showing the exact location and
arrangement of conduits stubbed into equipment, cabinet, pull boxes and
assigned spaces, conduit sleeves for exposed conduits, and for fabricated
work being furnished and installed under these Specifications. Submit such
drawings before rough-in work, fabrication, and within ample time to prevent
delays in the Work. Include complete electrical wiring diagrams for
equipment and equipment installation.
2.
Submit catalog cuts and/or assembly drawings for all electrical materials
including:
December 2013
Technical Specifications
a.
Conduit and fittings (each type)
b.
Receptacles
c.
Circuit breakers
d.
Wiring devices (each type)
e.
Device plates
f.
Outlet, junction, pull and cast boxes, including fittings
g.
Panelboards (each type)
h.
Fire Alarm Control Panel and peripherals
i.
Fuses (each type)
j.
Wireways
k.
Supporting equipment
l.
Anchors and fasteners
m.
Disconnect (safety) switches
16050-6
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.
F.
1.05
n.
Transformers
o.
Wire and cable (each type)
p.
Interconnection control wiring diagrams.
Samples: Submit samples only when so requested by the Construction
Manager to permit confirmation of compliance with the Contract documents.
Samples will be returned to the Contractor. Approved samples may be
incorporated in the work provided the installation will comply with all
governing contract requirements.
Field Test Reports: Submit certified field test reports of field tests, verifying
performance of equipment and systems with Specification requirements.
DELIVERY, STORAGE AND HANDLING
A.
Each unit or component shall be shipped securely packaged and labeled for safe
handling in shipment and to avoid damage or distortion.
B.
Each item, unit or component shall be marked in accordance with applicable
reference standard.
C.
Materials shall be stored in a secure and dry facility and in original packaging in a
manner to prevent soiling, physical damage, wetting or corrosion prior to installation.
D.
Where possible protective coverings shall be maintained until installation is complete
and removed as part of final clean-up.
PART 2 - PRODUCTS
2.01
GENERAL REQUIREMENTS
A.
Furnish materials and equipment new and of design, sizes, and ratings as indicated.
All items shall be of the thicknesses shown on the Contract Drawings and herein
specified.
B.
Furnish materials and equipment bearing label or classification listing of a nationally
recognized testing laboratory where UL standards exist and such product labeling or
listing is available. Electrical materials shall comply with NFPA 70.
C.
Methods of fabrication, assembly, and installation are optional unless otherwise
indicated.
D.
Provide products that are free from defects, which may impair performance, durability
or appearance, and of the commercial quality best suited for the purpose indicated or
specified herein.
December 2013
Technical Specifications
16050-7
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
E.
2.02
Steel conduit and accessories shall be hot-dipped galvanized rigid steel (thick wall)
conduit.
CONDUIT
A.
Rigid Galvanized Steel (RGS) Conduit and Accessories:
1.
Provide conduit, couplings, elbows, bends, sealing fittings, and nipples
conforming to ANSI C80.1 and UL 6, with each length bearing
manufacturer's stamp and UL label. All conduits shall be threaded.
2.
The minimum nominal conduit size shall be ¾ inch.
3.
The male threads of conduit and fittings shall be hot-dip galvanized in such a
manner as to keep the threads clear of excess zinc. Female threads may be
electro-galvanized instead of hot-dipped. Conduit accessories such as lock
nuts, bushings, and connectors shall be zinc coated. All conduit fittings shall
be threaded and shall conform to NEMA FB-1. No set screw fittings shall be
used. No running threads will be permitted.
4.
Bushings for conduits 1-1/4 inches and larger shall have a nylon insulated
insert, and shall be concrete tight.
5.
Conduit bends shall be fabricated in a conduit bending machine. Conduit
shall not be bent utilizing a bending tool. The radius of the curve of the inner
edge of any bend shall be not less than six times the internal diameter of the
conduit. Factory bends shall be utilized wherever possible. All factory bends
shall be similar in construction to and of a type designed for use with the
conduit.
6.
Galvanized coating shall be touched up where the original galvanized coating
on conduit or on galvanized steel has been removed due to handling or for
other reasons. Replace galvanizing coating for male threads when conduit is
field cut. No cold galvanizing spray shall be used. Touch-up galvanizing
shall be applied with a brush. Galvanized coating shall be ZRC cold
galvanizing compound, or accepted equal.
7.
Conduit sleeves shall be galvanized rigid steel.
8.
Three piece couplings, Erikson fittings and split couplings shall be concretetight.
9.
All conduit fittings such as "T", "C", "L" and "E" fittings, shall be hot-dipped
galvanized malleable Spec 5 threaded body fittings as manufactured by O.Z.
Gedney, Appleton Electrical Products, and Killark or approved equal.
December 2013
Technical Specifications
16050-8
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
10.
Expansion/Deflection fittings shall be hot-dipped galvanized, watertight
(NEMA 4) and concrete tight. Fittings shall permit movement of conduit in
any direction for a total of one inch, from normal and angular misalignment of
the axes of coupled conduit runs in any direction up to 30 degrees. Fittings
shall be as manufactured by Appleton Electrical Products, O.Z. Gedney,
Spring City Electrical Manufacturing Company, or approved equal.
11.
Expansion fittings shall be hot-dipped galvanized, water-tight (NEMA 4) and
concrete-tight. Fittings shall permit expansion and contraction of conduit up
to four inches in the axial direction, two inches in either direction for a total of
four inches for expansion joints only. Fittings shall be as manufactured by
Appleton Electrical Products, O.Z. Gedney, Spring City Electrical
Manufacturing Company, or approved equal.
12.
Fittings and Accessories:
a.
Provide separable watertight hub fittings with a gasket, separate
nylon insulated throat, and a case-hardened locknut.
b.
Provide bushings of insulated metallic and grounding type.
c.
All conduits having a nominal diameter of 1-inch or larger shall be
equipped with insulated bushings meeting either of the following
requirements:
(1)
One piece threaded, hot-dip galvanized malleable iron type
with tin plated copper lay in lug with set screw and with
insulation molded into and securely locked into fitting.
Fitting shall have circular base and shall be O/Z Gedney
types “HBLG”, or approved equal.
(2)
Bushings of heat treated aluminum alloy with phenolic
treated fiber insulation.
13.
Through-wall seals shall be provided for all conduits entering the tunnel from
adjacent spaces. The seals shall be Type WSK as manufactured by O.Z.
Gedney, or other approved equal.
14.
Cleaning and Snaking of Conduits:
Existing and new conduits shall be carefully cleaned before installation of
new wiring. Ends shall be free from burrs and inside surfaces shall be free
from all imperfections likely to injure the wires or cables. Immediately before
the wires are pulled into any conduit run, such completed conduit run shall be
snaked with a steel band to which shall be attached an approved tube
cleaner equipped with an approved spherical mandrel of a diameter not less
than 85 percent of the nominal inside diameter of the conduit. Conduits
through which this mandrel does not pass shall be removed and replaced by
the Contractor at no additional expense to the Authority.
December 2013
Technical Specifications
16050-9
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
B.
C.
15.
Conduit and Duct Seals:
Conduits terminating in high humidity or prone to water infiltration areas such
as tunnel areas and in proximity to vent grates such as the areas adjacent to
the twelve V1 fans, and including spare conduits or ducts, shall be sealed at
both ends immediately after installation with conduit or duct sealing bushings
to provide a watertight seal. Reseal conduits or ducts immediately after the
installation of cables. The conduit sealing bushings shall be O-Z Gedney,
Type CSBI or approved equal. The duct sealing bushings shall be suitable for
ducts and shall be O-Z Gedney or approved equal.
16.
Conduit Connections with Exiting Conduit Systems:
Furnish all labor and material to furnish and install all additional conduits,
exposed and concealed, and all necessary pull, outlet and bottomless boxes,
and all supporting steel, to connect new conduits installed to an existing
conduit system as necessary. Restore the surface of the structure where it
has been damaged or removed to permit conduit connections necessary to
make a complete and finished installation as indicated on the Contract
Drawings, or specified herein, or as directed.
Liquidtight Flexible Metallic Conduit and Fittings:
1.
Provide conduit consisting of a core of flexible galvanized steel with an
extruded liquidtight plastic or neoprene jacket overall. Jacket shall be
moisture- and oil-proof, capable of conforming to the minimum radius bends
of flexible conduit without cracking.
2.
Provide conduits with a continuous copper bonding conductor spiral wound
between the convolutions, as required by NEC.
3.
Provide fittings conforming to UL 514B, zinc-coated.
4.
Furnish conduits of 1-1/4 inches diameter and smaller with a continuous
copper bonding conductor spiral wound between the convolutions.
5.
Liquid-tight flexible metallic conduit shall be Type UA flexible conduit.
6.
Liquid tight connectors for flexible metallic conduits shall be malleable firm
body, straight, 45 degrees and 90 degree as required for conduits up to one
inch in size and of malleable iron for conduits over one inch in size. All
connectors shall have insulated throats. The connectors shall be O.Z.
Gedney type 4Q series or approved equal.
Flexible Metal Conduit:
1.
December 2013
Technical Specifications
Flexible steel (galvanized) conduit (FSC) shall conform to UL 1.
16050-10
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
2.
2.03
Fittings shall be of a type specifically designed for use with conduit and shall
conform to UL 514B.
CONDUIT HANGERS AND SUPPORTS
A.
Provide trapeze type multiple pipe or conduit hangers and supports as indicated or
required.
B.
Fabricate hangers from two or more stainless steel hanger rods, a stainless steel
horizontal member, stainless steel U-bolts, clamps, and other attachments fabricated
from stainless steel materials as necessary for securing hanger rods, and conduits.
C.
Provide stainless steel hanger rods not smaller than 5/8-inch diameter, threaded
either full length or for a sufficient distance at each end to permit at least 1-1/2 inches
of adjustment.
D.
Provide horizontal member meeting the following requirements:
1.
E.
F.
G.
Standard structural steel shapes such as angles or channels, 3-1/4or 1-5/8
by 1-5/8 inches, 12 gauge, cold-formed, lipped channel, and designed to
accept special spring-held hardened stainless steel nuts for securing hanger
rods and other attachments. Nuts and clamps shall be compatible with the
channel. All nuts and clamps shall be stainless steel.
Design of conduit hangers shall meet the following requirements:
1.
Capable of supporting a load equal to the sum of the weights of the conduits
and wires, the weight of the hanger itself, plus 200 pounds.
2.
The stress at the root of the thread of the hanger rods shall be not more than
9,475 psi at design load.
3.
Size the horizontal member such that the maximum stress will be not more
than 12,650 psi at design load.
Provide one hole conduit straps for supporting up to one inch conduit. Straps shall be
stainless steel or malleable iron. Maximum spacing of straps shall be eight feet on
center.
Provide two heavy duty conduit straps for supporting conduit larger than one inch.
Heavy duty straps shall be stainless steel. Strap size shall be ¾ inch. Maximum
spacing shall be five feet on center.
H.
Provide clevis hangers for supporting horizontal conduit runs. Clevis hangers shall be
stainless steel with a hole for threaded steel rod.
I.
Provide riser clamps for supporting vertical conduit runs. Riser clamps shall be
stainless steel with two or three bolts and nuts and four inch ears.
December 2013
Technical Specifications
16050-11
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
2.04
J.
Provide "C" clamps for supporting conduit. "C" clamps shall be stainless steel with
hole for threaded steel rods. "C" clamps are not permitted for supporting vertical
conduit risers.
K.
All conduit hangers and supports installed in the tunnel shall be protected by spray-on
fireproofing as specified in paragraph 2.17 of this section.
INSERTS
A.
B.
2.05
1.
Stainless Steel
2.
Design for a maximum loading of 800 pounds with a safety factor of three.
3.
Knockout openings to accommodate either square or rectangular nuts.
Masonry Inserts:
1.
Insert, expansion or self-drilling type anchors and driving pins shall be used.
2.
Inserts shall be of the type to receive machine bolts after installation.
EQUIPMENT SUPPORTS
A.
2.06
Spot Inserts for Embedding in Concrete:
Provide prefabricated channels as indicated or required.
1.
Standard structural stainless steel channels, 1-1/2 by 1-1/2 or 1-5/8 by 1-5/8
inches, 12 gauge, cold formed, lipped channel, and designed to accept
special spring held hardened stainless steel nuts for securing anchor bolts or
hanger rods and other attachments. All securing equipment shall be
compatible with the channel and shall be stainless steel.
2.
Channel depth shall be as required to satisfy the load requirements and
safety factor.
3.
Two or more channels may be welded together to form members of greater
strength.
4.
All supports installed in the tunnel shall be protected by spray-on fireproofing
as specified in paragraph 2.17 of this section.
OUTLET, JUNCTION AND PULL BOXES
A.
Provide outlet boxes, junction, and pull boxes conforming to NFPA 70, Article 370.
B.
Electrical boxes shall conform to NEMA OS-1, NEMA 250, UL 50, UL 514A, UL 514B.
December 2013
Technical Specifications
16050-12
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
C.
Provide electrical boxes of the material, finish, type, and size indicated and as
required for the location, kind of service, number of wires, and function. Boxes shall
have mounting holes for No. 10-24 machine screws.
D.
Provide boxes complete with accessible covers designed for quick removal and
suitable for the purpose for which they will be used, except that boxes in which, or on
which, no devices or fixtures are to be installed shall be equipped with flat or raised
blank covers as required. Ceiling fixture outlet boxes shall be equipped with 3/8-inch
boltless fixture studs and shall be four inches square and 2-1/8 inch deep.
E.
Outlet Boxes (For Exposed Work in Non-Finished Areas)
1.
Boxes shall be corrosion-resistant cast, copper free aluminum Type FS or
FD.
2.
Provide cast metal faceplates with spring hinged waterproof caps suitably
configured for each application, including faceplates, gasket and stainless
steel or brass screws or fasteners. Faceplates materials shall match the type
of box.
F.
Covers shall be of same thickness as boxes and shall be secured in position by
means of No. 10-24 stainless steel machine screws. Arrange covers to be readily
and conveniently removed.
G.
Junction boxes installed in heated spaces shall be zinc-coated (galvanized) inside
and outside. Where outlet boxes are used as junction boxes, they shall not be
smaller than four inches square by 1-1/2 inches deep. Provide such boxes with flat
blank covers.
H.
Concealed switch boxes shall be not less than four inches square by 1-1/2 inches
deep for two devices, unless otherwise indicated. Provide covers with rectangular
openings of proper size and shape. Provide special boxes as required to suit the kind
of service and location requirements.
I.
Provide brackets, supports, hangers, fittings, bonding jumpers, and other accessories
as required.
J.
Provide neoprene gaskets 1/8-inch thick for boxes subjected to weather. Provide fire
resistant gaskets for pull boxes installed at the conduits for emergency equipment,
feeder cables and fire protection circuits.
K.
Junction and Pullboxes:
1.
December 2013
Technical Specifications
Provide galvanized, code gauge, sheet steel junction and pull boxes and
covers having interior dimensions over 100 cubic inches of types, shapes,
and sizes to suit each respective location and installation. Minimum junction
and pull box thickness shall be No. 10 USS gauge. Each box seam shall be
16050-13
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
continuously welded. Box flanges shall be turned inward unless otherwise
noted. All welds shall be made smooth and uniform. Excess welding
material shall be ground smooth
2.07
2.
All pull boxes shall be coated inside and outside to prevent oxidation and
shall be provided with blank cover or cover for the device being furnished.
3.
Boxes shall have knockouts suitable for the connecting of conduits as
indicated on the Contract Drawings.
4.
Junction and pull boxes subjected to weather or located in tunnels shall be
NEMA 4X, Type 316 stainless steel. All other junction and pull boxes shall
be galvanized steel-type.
5.
Junction boxes and pull boxes in the tunnel shall have spray applied
fireproofing and shall be equipped with fire-resistant board covers as
specified in Section 2.17.
WIRE AND CABLE (600
INSTALLATION IN TUNNEL
VOLTS
AND
BELOW)
LOW
SMOKE
A.
General: All cables shall be zero halogen, low smoke type.
B.
Conductors: Conform to requirements of the NEC.
requirements of ICEA.
C.
TYPE
FOR
Conform to applicable
1.
Materials: Soft-drawing copper.
2.
Conductor Sizes: Standard American Wire gauge sizes. Conductors No. 10
and smaller, solid copper; No. 8 and larger, stranded copper.
3.
Sizes shall be as indicated on the drawings.
Wire and Cables, 600 Volts and Below installed in Raceways:
1.
Single conductor cable shall be low smoke, non-halogen cross-linked
polyolfin protective covering over an insulation layer of silicone SR1001
meeting requirements of UL44.
2.
Cables shall be suitable for operation in an environment of 482 degrees
Fahrenheit for not less than one-hour, and 392 degrees Fahrenheit for not
less than two hours. The cable shall be RHH/RHW, low smoke, zero
halogen type for installation in rigid steel conduit, 2-hour fire rated system in
accordance with UL 2196. It shall meet the following performance
characteristics.
a.
December 2013
Technical Specifications
Cables shall pass the flame propagatory and smoke release criteria
according to the test method of UL 1685.
16050-14
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.
December 2013
Technical Specifications
b.
The halogen content of cable jackets shall not exceed 0.2 percent
according to the test method of MIL-C-24643. The Halogen content
of 0.2 percent or less shall be classified as "non-halogen".
c.
The toxicity index of cable jackets shall not exceed 4.0 according to
the test method of NES 713.
d.
The cable jackets shall comply with ICEA T-33-655 for smoke
generation.
e.
The acid gas content of cable jackets shall not exceed a maximum
of 3.0 percent according to the test method of MIL-C-24643.
f.
Pass flame test/gas burner in accordance with IEEE 383.
Use the additional performance characteristics for wires and cables for
stringent flame retardancy, low smoke, low toxicity, zero halogen and good
circuit integrity during a fire.
a.
Wires shall pass the flame propagatory criteria according to the test
method of VW-1.
b.
The halogen content of both the wire and cable insulation and cable
jacket(s) shall not exceed 0.2 percent according to the test method
of MIL-C-24643. Halogen content of 0.2 percent or less shall be
classified as "non-halogen."
c.
The toxicity index of both the wire and cable insulation and cable
jacket(s) shall not exceed 2.0 according to the test method of NES
713.
d.
The acid gas content of both wire and cable, insulation and cable
jacket(s) shall not exceed a maximum of 2.0 percent according to
the test method of MIL-C-24643.
e.
The wire and cable insulation materials shall pass the smoke
generation test in accordance with ASTM E 662. Wire and cable
insulation when tested on a specimen of 80 mils thick slab shall not
exceed the following values:
1)
Flaming Avg. Ds (4 minutes): 100
2)
Flaming Avg. Dm (20 Minutes): 200
3)
Non-Flaming Avg. Ds (4 minutes): 100
4)
Non-Flaming Avg. Dm (20 minutes): 350
16050-15
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
f.
4.
2.08
2.09
1)
Flaming Avg. Ds (4 minutes): 50
2)
Flaming Avg. Dm (20 minutes): 150
3)
Non-Flaming Avg. Ds (4 minutes): 50
4)
Non-Flaming Avg. Dm (20 minutes): 250
Cables shall be Type RHH/RHW, 2-hour rated as manufactured by
Rockbestos Suprenant Cable Corporation.
CABLE RATED 600 VOLTS AND BELOW FOR INSTALLATION RACEWAY INSIDE
EQUIPMENT ROOMS
A.
Size 14 AWG and Larger: NFPA 70, Type XHHW, cross-linked-thermosettingpolyethylene insulated in accordance with NEMA WC 7.
B.
Power, lighting, control, and branch circuit wiring shall be as follows:
1.
Size 14 AWG and larger: NFPA 70, heat, moisture and chemical resistant
ethylene-propylene co-vulcanized compound (EPCV) categorized by UL as
class XL, type XHHW, rated VW-1, meeting or exceeding all electrical, aging
and physical requirements of ANSI/UL 44 and ICEA S-68-516/NEMA WC8.
2.
Temperature Rating: Temperature rating of cables shall be not less than 90
degrees C.
3.
Flammability Requirements: Shall meet the requirement of UL1581.
FIXTURE WIRE
A.
B.
2.10
The cable jacket materials shall pass the smoke generation test in
accordance with ASTM E 662. Wire and cable jacket when tested
on a specimen of 80 mils thick slab shall not exceed the following
values:
Provide fixture wire conforming to UL 62 and the following additional requirements:
1.
Type SF-2 silicone rubber insulated.
2.
Conductor: Stranded copper conductor 16 AWG or larger as indicated.
Temperature Rating: Temperature rating of wire shall be not less than 90 degrees C.
SWITCHGEAR CONTROL WIRING
December 2013
Technical Specifications
16050-16
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
A.
B.
2.11
2.12
Provide switchgear control wiring conforming to UL 44, IEEE 383 and the following
additional requirements:
1.
Type: SIS tinned copper, cross-linked thermosetting-polyethylene insulation.
2.
Wire shall be single conductor, minimum Class B stranded, except that for
wires crossing hinged joints and swinging panels, and where “Extra Flexible”
wire is indicated, conductors shall be Class K stranded, conforming to ASTM
B-174.
3.
Conductors for potential transformers (PT’s) wiring shall be No. 12 AWG.
Conductors for current transformers (CT’s) wiring shall be No. 10 AWG
minimum.
Temperature Rating: Temperature Rating: Temperature rating of cables shall be not
less than 90 degrees C.
COLOR CODING OF CONDUCTORS
A.
Color code all supply cables and branch circuit conductors throughout the secondary
alternating current wiring system.
B.
Color code single conductor control wires for associated systems as follows:
1.
480/277 volt circuits, blue with yellow tracer.
2.
120/240 volt circuits, yellow with blue tracer.
C.
Solid color coatings and tracers: A strongly adherent paint or dye not injurious to the
insulation and which will not be obliterated by pulling into a conduit or raceway.
D.
On-site coloring of ends of conductor may be permitted by the Construction Manager
upon receipt of satisfactory evidence that the Contractor is unable to order color
coded wire and cable as specified. Provide certification from the cable manufacturer
that the paint or dye proposed for field application is non-injurious to the insulation.
Colored tape may be used to mark the ends of conductors in lieu of paint or dye.
IDENTIFICATION TAGS
A.
Provide waterproof identification tags of brass, aluminum, plastic, or pressuresensitive moisture-resistant labels designed for fastening to cables, feeders, and
power circuits in vaults, pull boxes, manholes, and switchboard rooms and at all
terminations of cable or wire.
B.
Stamp or print tags or labels to correspond with markings on the Contract Drawings or
accepted shop drawings, or mark so that feeder, cable, or conductor may be readily
identified. Tags on conductors at switches, receptacles, motor control panels,
wireways, and junction boxes shall bear the circuit number of the conductor as it
December 2013
Technical Specifications
16050-17
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
appears in the circuit directory. Mark conductors in motor control centers with the
terminal number.
C.
If suspended type tags are provided, design tie tags with slip-free plastic cable lacing
unit or design for attachment by nylon bundling straps.
2.13
CABLE SUPPORTS AND FASTENERS: Design for use with channel inserts.
2.14
CONDUCTOR BUILDING STRAPS
2.15
A.
Formed from self-extinguishing nylon having a temperature range of minus 65
degrees Fahrenheit to plus 250 degrees Fahrenheit.
B.
Equip each strap with a locking hub or head with a stainless steel locking barb on one
end and a taper on the other end.
C.
Make wire and cable ties for installation outdoors and in exposed locations of
ultraviolet resistant nylon material.
SPLICING AND TERMINATION FOR 600 VOLT RATED WIRES AND CABLES
A.
B.
Splice and Terminal Connectors:
1.
Design termination fittings for use with the cable furnished and UL listed.
2.
Termination and splice fittings for No. 10 and Smaller Conductors: Screw
on, spring pressure-type copper connectors with nonflammable, selfextinguishing insulation of temperature rating equal to that of cable being
connected. Terminals to provide a metal insulation grip on the conductor for
strain relief.
3.
Termination and splice fittings for No. 8 and larger conductors shall be
tool-applied compression connectors of material and design compatible with
the conductors for which they are used.
4.
Terminal connectors for conductors size No. 4/0 and larger shall be
long-barrel, double-compression type, and shall be furnished with two NEMA
standard bolting holes in the pad.
Splicing and Terminating Materials
1.
General:
a.
December 2013
Technical Specifications
All splicing and terminating materials shall be compatible so that no
one material will adversely affect the physical or electrical properties
of any other or of the wire or cable itself.
16050-18
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
b.
2.
3.
4.
5.
December 2013
Technical Specifications
All material for making splices and terminations shall be specifically
designed for use with the type of wire or cable, insulation and
installation and operating conditions of the specific application.
Connectors: Subject to compliance with requirements of this Section, provide
connectors of the following types:
a.
Solderless, uninsulated, high conductivity, corrosion resistant,
compression connectors conforming to UL 467 and IEEE 837;
b.
Insulated, identer type compression butt connectors;
c.
Insulated, integral self-locking flexible shell, expandable spring
connectors;
d.
Uninsulated indenter type compression pigtail connectors;
e.
Welded type connectors.
Terminals: Subject to compliance with requirements of Section, provide
terminals of the following types:
a.
Solderless, uninsulated, high conductivity, corrosion resistant,
compression terminals conforming to UL 467 and IEEE 837.
b.
Insulated, compression terminals,
c.
Solderless, high conductivity, corrosion resistant, hex screw type,
bolted terminals;
d.
Welded type terminals.
Shrinkable Tubing: Subject to compliance with requirements of this Section,
provide shrinkable tubing of the following types:
a.
Either irradiated modified polyvinyl chloride or irradiated modified
polyolefin heat shrinkable tubing;
b.
Cold shrinkable tubing.
c.
Insulation Resistance (Indirect Method of Electrolytic Corrosion): Ten
megohms.
Tapes and Sealers
16050-19
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
a.
6.
C.
Vinyl Tapes: Flame-retardant, cold and weather-resistant, ¾ inch or
1 ½ inches wide, as required, and conforming to UL 510 and ASTM
D 3005.
(1)
For interior, dry locations, provide seven mils, conforming to
ASTM D 3005 (Type I); Scotch (3M) No. 33, or approved
equal.
(2)
For exterior or damp and wet locations, provide 8.5 mils,
conforming to ASTM D 3005 (Type II); Scotch 3M) No. 88,
or approved equal.
b.
Rubber Tapes: Ethylene-propylene, rubber-based, 30-mil splicing
tape, rated for 130 degrees C operation; ¾ inch and wider (1, 1 ½, 2
inches) as shown on the Drawings or approved by the Engineer,
conforming to Federal Specifications HH-I-553 (Grade A); Scotch
(3M) No. 130C or approved equal.
c.
Insulating Putty: Rubber based, 125-mil elastic filler putty; 1 ½
inches wide; Scotch (3M) Scotchfil, or approved-equal.
d.
Silicon Rubber Tapes: Inorganic silicone rubber, 12-mil, 130
degrees C rated, anti-tracking, self-fusing tape; one inch wide;
Scotch (3M) No. 70, or approved equal.
e.
Sealer: Liquid applied, fast drying sealant; Scotch (3M) Scotchkote,
or approved equal.
Resin Filled Splices:
a.
Epoxy Molded Type: Two-piece, snap together molded bodies,
sized for wire or cable, with two-part low viscosity polyurethane
insulating and sealing compound, rated for 600 volts, using crimptype wire connector; Scotch (3M) No. 82-Al, 82-A2 or 82-A3
compound, or approved equal.
b.
Re-Enterable Type: Transparent, molded bodies clamped with
stainless steel strain-relief bar and shield continuity connectors,
sized for wire or cable, with loosely woven polyester spacer web and
jelly-like urethane formulation for permanent, re-entry capability;
Scotch (3M) No. 78-R1 through 78-R5, with No. 2114 compound, or
approved equal.
Grounding Wires and Cables: Unless otherwise shown on the Drawings, grounding
wires and cables shall be as follows:
1.
December 2013
Technical Specifications
Insulated
16050-20
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
2.
a.
Solid for sizes No. 8 AWG and smaller; ASTM B 8, Class B stranded
for sizes No. 6 AWG and larger; and of the same insulation type as
the power conductors.
b.
Covering shall be a continuous green color and conform to ASTM B
33 and UL 44.
Uninsulated
a.
General: Solid for sizes No. 8 AWG and smaller; ASTM B 8, Class
B stranded for sizes No. 6 AWG and larger.
b.
In Raceway: Soft-drawn and conforming to ASTM B3.
2.16
NOT USED
2.17
MECHANICAL/ELECTRICAL SUPERVISORY CONTROL AND DATA ACQUISITION
(SCADA) SYSTEM COPPER CABLE
2.18
A.
Ethernet Cable: 4 pair 24 AWG Fluoropolymer insulated unshielded twisted pair
cable comply with TIA/EIA 568A Category 5e suitable for 10 Mbps to 100 Mbps data
rate. Plenum rated.
B.
Telecommunication cable: Emergency telephone cables within tunnels and public
spaces shall be #18 AWG single twisted pair, insulated unshielded cable type CIC as
manufactured by Draka USA. The cable shall be classified as two-hour fire rated.
CABINETS
A.
Enclosures:
1.
Cabinets and covers, shall be fabricated from No. 10 USS gauge steel sheet.
Each cabinet seam shall be continuously welded. Box flanges shall be
turned inward. All welds shall be made smooth and uniform. Excess welding
materials shall be ground smooth.
2.
Cabinets and covers shall be galvanized after fabrication.
3.
Box covers shall be secured to boxes by captive stainless steel screws.
4.
Box covers shall be provided with continuous 1/8 inch thick neoprene gasket
continuous around the cover perimeter.
5.
Boxes shall be provided with mounting feet.
December 2013
Technical Specifications
16050-21
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
B.
2.19
All cabinets for installation in the tunnel shall be fabricated from 10 USS Gauge
stainless steel.
WIRING DEVICES
A.
Switches:
1.
Provide AC tumbler toggle switches conforming to minimum requirements of
NEMA WD-1 and as specified herein specified, of premium grade and heavy
duty type. Switches mounted outdoors shall be waterproof.
2.
Provide switches with large brown handles and neoprene bumpers that
operate in any position and are fully enclosed with entire body and cover of
molded phenolic, urea or melamine. Do not use fiber, paper, or similar
insulating material for body or cover.
3.
Switches shall have metal mounting yoke and plaster ears, insulated from
the mechanism and fastened to the switch body by bolts, screws, rivets or
other substantial means that meet test requirements.
4.
Provide a green colored equipment grounding screw on the yoke.
5.
Provide the section of the yoke normally intended to bear on the surface
outside the box with a minimum overall dimension of ¾ inch, measured at
right angles to the longitudinal axis of the yoke.
6.
Switch contacts shall be silver or silver alloys.
7.
Switches shall be back or side wired with terminals of screw or combination
screw clamp type.
8.
Terminal screws shall be No. 8 or larger, captive or terminal type.
9.
Provide wiring terminals capable of receiving and holding wire sizes as
follows:
Switch Rating
Wire Size, AWG No.
20 amperes
12
10.
Switches for use on lighting circuits shall be fully rated 20 amperes, 277 volts.
11.
Provide AC 120/277 volt snap switches capable of withstanding tests as
outlined in NEMA WD-1.
December 2013
Technical Specifications
16050-22
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
B.
C.
Receptacles:
1.
Standards: Connector and outlet receptacles shall conform to NEMA WD-1
for heavy duty general use type.
2.
Provide heavy duty, premium grade receptacles with fire-resistant nonabsorptive hot molded phenolic composition bodies and bases and with
metal plaster ears integral with supporting member. Receptacles shall be
flush type, except where otherwise indicated.
3.
Wall receptacles shall be NEMA 20R configuration single or duplex
receptacles as indicated.
4.
Provide receptacles and plugs (caps) with light colored terminal facilities for
neutral connections, amber or brass colored for phase conductor
connections, and green colored hexagonal machine screws for the
equipment grounding conductor or connections. Receptacle bodies shall be
brown.
5.
Contacts of the receptacles, including the grounding contact, shall be double
grip bronze type with spring steel backup clips so that both sides of each
male prong of the plug will be in firm contact.
6.
Provide receptacles with self-grounding clip or mounting strap screws.
Device Plates:
1.
Provide device plates for each switch, receptacle, and special purpose outlet.
2.
Provide multi-gang plates for multi-gang boxes.
3.
Provide device plates conforming to UL 514A.
4.
For special purpose outlets commercially produced using special material,
configuration and size, provide plates of brushed stainless steel and of a
design for the particular application.
5.
Provide device plates in public areas of die cast copper free aluminum, UL
listed for wet locations and self closing spring door.
2.20
NOT USED
2.21
DISCONNECT (SAFETY) SWITCHES:
A.
Safety Switch Type Disconnecting Devices: Provide safety switch disconnecting
devices, enclosed, conforming to ANSI C37.35.
December 2013
Technical Specifications
16050-23
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
B.
2.22
Heavy-duty Safety Switches (600 Volts AC):
1.
Provide heavy-duty safety switches having electrical characteristics, ratings,
and accessories as indicated.
2.
Provide switches with NEMA 12 industrial duty enclosures indoors, NEMA 4 in
unheated spaces, NEMA 4X stainless steel for outdoors and in tunnel, with
metal nameplates, front cover mounted, containing a permanent record of
switch type, catalog number, and horsepower ratings.
3.
Provide handle with visible blades; reinforced fuse clips; non-teasible,
positive, quick-make quick-break mechanism; and padlockable in the OFF
and ON positions. Provisions for at least three locks in the "OFF" position
shall be provided.
4.
Provide switches meeting UL 98 requirements.
5.
Switches shall have a dual cover interlock to prevent unauthorized opening of
the switch door when the handle is in the "ON" position, and to prevent
closing of the switch mechanism when the door is open. Means shall be
provided to permit authorized personnel to release the interlock for inspection
purposes. Fused switches shall utilize Class R fuse holders.
6.
Switches shall be six pole, three pole, double pole or single pole, single
throw, 240 or 600 volts. Voltage, ampere and phase ratings as shown on the
Contract Drawings. Where ratings is not shown on the Contract Drawings,
size the switch and fuse in accordance with equipment nameplate data and
NEC requirements. The UL listed short circuit rating of the switch shall be
200,000 RMS symmetrical amperes when Class R or Class J fuses are used
with the appropriate rejection scheme.
PANELBOARDS (POWER, LIGHTING)
A.
Interiors:
1.
Panelboards shall have main bus, neutral bus, ground bus and main circuit
breaker unless otherwise noted.
2.
Interiors shall be completely factory assembled with bolt-on devices. They
shall be designed such that switching and circuit protective devices can be
replaced without disturbing adjacent unit and without removing the main bus
connectors. Where "space only" is indicated, provisions shall be made for
the future installation of a protective device sized as indicated.
3.
Full size insulated copper neutral bars shall be provided. Bus bar taps for
panels with single pole branches shall be arranged for sequence phasing of
the branch circuit protective devices. Neutral bus shall be provided with
December 2013
Technical Specifications
16050-24
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
suitable lugs for each outgoing feeder requiring a neutral conductor
connection.
4.
Main bus bars shall be copper sized in accordance with UL standards to limit
temperature rise on any current carrying part to a maximum of 50 degrees
Centigrade above an ambient of 40 degrees Centigrade.
5.
Panelboards enclosure shall be NEMA 12.
6.
A separate copper ground bus shall be provided and marked with a green
stripe along its front and bonded to the enclosure. The ground bus shall be
provided with suitable lugs for each incoming and outgoing feeder requiring
grounding conductor connection.
B.
Boxes: Boxes shall be constructed of code gauge, galvanized sheet steel with lapped
and welded joints and with a continuous perimeter flange on the face of the box for
trim mounting. Minimum gutter space shall be provided in accordance with the NEC.
Where feeder cables supplying the mains of a panel are carried through its box to
supply other panels or equipment, the box shall be sized to include the additional
required gutter space. Boxes for two section panels shall be fabricated as a single
box with a barrier between sections or two separate boxes bolted together to form a
single unit. Boxes shall be furnished without knockouts.
C.
Trims:
D.
1.
Shall be constructed of code gauge steel, single door construction and
fastened to the box by means of stainless steel machine screws or other
approved means.
2.
Doors shall be fastened to the trim with flush butt hinges or other approved
method. The door shall be equipped with a flush, cylinder tumbler type lock
with a catch and spring loaded stainless steel door pull. All panelboard locks
included in the project shall be keyed alike.
3.
A directory frame with a clear plastic cover, in which shall be mounted a
typewritten directory identifying each circuit within the panel, shall be
furnished and installed on the inside of each door.
4.
Nameplates shall be furnished and installed on the front of each panelboard.
Nameplates shall indicate panel designations shown on the Contract
Drawings. Approved nameplates showing the panel voltage, phases,
number of wires and the ampacity of mains shall be installed on all cabinets,
and shall be visible without removing panel cover.
5.
Surface of the trim assembly shall be properly cleaned, primed and a finish
coat of gray paint applied.
Circuit Breakers:
December 2013
Technical Specifications
16050-25
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
2.23
1.
General: Shall be bolt-on, thermal magnetic type built in accordance with
NEMA AB-1. Circuit breakers shall have a minimum interrupting capacity of
10,000 symmetrical amperes when applied to 120/240 volts, 14,000
symmetrical amperes when applied to 277/480 volts.
2.
Multiple Pole Breakers: Shall be common trip type with a single operating
handle. Breaker design shall be such that an overload in one pole will
automatically cause all poles to open. Single pole circuit breakers grouped
with handle clampers or ties will not be accepted as multiple pole breakers.
E.
Integrated Equipment Short Circuit Rating: Each panelboard, as a complete unit,
shall be labeled with a UL short circuit rating not less than 10,000 symmetrical
amperes for 120/240 volt and 120/208 volt panels, 14,000 symmetrical amperes for
277/480 volt panels.
F.
Panelboard Ratings:
1.
Panelboards shall be 120/240 volt, single phase, three wire, or 120/208 volt,
480/277 volt, three phase, four wire, with circuit breakers in the quantities and
sizes indicated on the panel schedule.
2.
Panelboards shall conform to UL 50, UL 67 and shall be UL listed.
Panelboards shall bear the UL label.
TRANSFORMERS
A.
General Purpose Transformers (600 Volts and Below):
1.
Standards: Conform to NEMA ST-20, UL listed.
2.
Application: Shall be suitable for indoor application and transformation of
the incoming 480 volt to 120/208 or 120/240 volt utilization level.
3.
Type: Two winding, low voltage, dry type.
4.
Cooling: Self-cooled.
5.
Core and Coil Assembly: Coils shall be of the continuous wound
construction. Cores shall be constructed of high grade, non-aging grain
oriented silicon steel with high magnetic permeability, and low hysteresis and
eddy current losses. Magnetic flux densities shall be kept well below the
saturation point. The core and coil assembly shall be completely
encapsulated in a proportional mixture of resin and aggregate to provide a
moisture-proof, shock resistant seal.
6.
Insulation System:
December 2013
Technical Specifications
16050-26
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
7.
2.24
KVA Rating
Insulation
2 and below
105 degrees Centigrade, based on 80 degrees
Centigrade rise by resistance.
3 through 75
185 degrees Centigrade based on 115 degrees
Centigrade rise by resistance.
Enclosure: Shall be constructed of heavy gauge, sheet steel, totally
enclosed, non-ventilated. 45 kVA transformer located in Warrant Street A.C.
Switch Room shall have enclosure constructed from Type 316 stainless
steel.
FUSES
A.
General: A complete set of fuses shall be provided for each fusible switch. Time
current characteristics curves for fuses servicing motors or connected in series
with circuit breakers or other circuit protective devices shall be coordinated for
proper operation. Coordination data shall be submitted for approval. Fuses shall
have a voltage rating not less than the circuit voltage.
B.
Cartridge Fuses, Current Limiting Type (Class R): Shall conform to UL 198E,
Class RK-5, time delay type. Associated fuse holders shall be Class R only.
PART 3 - EXECUTION
3.01
INSTALLATION - GENERAL
A.
Install electrical materials, equipment, and accessories in locations as indicated, rigid
and secure, plumb and level, and in alignment with related and adjoining work to
provide a complete and operable system. Do not weld electrical materials for
attachment or support.
B.
Provide anchor bolts and anchorage items as required, and field check to ensure
proper alignment and location. Provide templates, layout drawings, and supervision at
the jobsite to ensure correct placing of anchorage items in concrete. Check
embedded items for correctness of location and detail before concrete is placed.
C.
Install supporting members, fastenings, framing, hangers, bracing, brackets, straps,
bolts, and angles as required to set and connect the work rigidly.
D.
Control erection tolerance requirements so as to not impair the strength, safety,
serviceability, or appearance of the installations. Determine exact locations of
conduit. Route conduit parallel to building lines unless otherwise indicated.
E.
The trade size, type, and general routing and location of conduits, raceways, and
boxes shall be as indicated or specified.
December 2013
Technical Specifications
16050-27
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.02
F.
Install exposed conduit so as to avoid conflicts with other work. Install horizontal
raceways close to the ceiling or ceiling beams, and above water or other piping
wherever possible.
G.
The Contract Drawings shall be considered as diagrammatic showing general
arrangement and location of boxes and conduits. The Contract Drawings shall be
followed as closely as practical, however final location may be adjusted slightly in the
field to avoid interference after prior approval in writing is obtained from the
Construction Manager.
H.
Install switches, receptacles, special purpose outlets, and cover plates complete in a
neat manner in accordance with the NFPA 70 and local electrical codes. Plug
unused openings in boxes, cabinets, and equipment.
I.
Use of explosive fasteners is prohibited.
CONDUIT AND FITTINGS
A.
Electrical Conduit - Installation Requirements:
1.
Install conduit in accordance with NFPA 70 and as indicated. At the end of
each work day cap installed conduits to prevent concrete, dirt and other
foreign materials from entering and obstructing the conduit, outlets, and pull
and junction boxes. Do not use conduit smaller than 3/4-inch. All conduit
fittings shall be threaded.
2.
Unless otherwise indicated, make conduit bends in accordance with NEC,
with not more than three 90 degree bends, 270 degrees total, per run of
conduit. Where more bends are required in a particular run, install pull boxes
as required to facilitate pulling conductors even if not indicated. Install pull
boxes every 100 feet in a straight low voltage conduit run.
3.
Provide and install metallic numbering tags indicating the conduit number on
both ends of all conduit.
4.
Properly support and anchor conduit to be embedded to maintain correct
location and spacing and to prevent flotation during concreting operations. If
necessary, provide suitable metal supports.
5.
Install conduit so that moisture collecting in the conduit will be drained to the
nearest outlet or pull box.
6.
Whenever exposed or buried conduit passes through an expansion or
contraction joint in the structure, install the conduit at right angles to the joint,
and provide an approved conduit expansion fitting at the joint. Paint the
conduit with an approved bituminous compound for one foot on each side of
the expansion couplings.
December 2013
Technical Specifications
16050-28
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
7.
Provide expansion fittings in conduit runs where required to compensate for
thermal expansion.
8.
Rod and swab embedded conduit after installation to remove foreign matter.
If obstructions are encountered which cannot be removed, or if conditions
exist which may result in damage to wires and cables pulled through the
conduit, install new conduit at no additional cost to the NJ Transit.
9.
After the conduit has been rodded and swabbed, install covers on boxes and
protect conduit ends to prevent foreign material from entering the conduit.
Cap conduit ends at end of day's installation to prevent entry of water or
foreign matter prior to next day's work.
10.
Where conduit is exposed to different temperatures, seal the conduit to
prevent condensation and passage of air from one area to the other.
11.
Metallic conduits shall be electrically and mechanically continuous and
connected to ground by bonding to the grounding system where required.
12.
Apply conductive compound to the threads of threaded rigid conduit joints.
Do not use compounds containing lead. Terminate the conduit in appropriate
boxes at motors, switches, outlets, and junction points.
13.
When field cutting of conduit is required, thread and ream the conduit to
remove rough edges. Where a conduit enters a box or other fitting, provide a
bushing to protect the wire from abrasion. Provide insulation type bushings
and double locknuts on ends of rigid conduits terminating at steel boxes,
panelboards, cabinets, motor starting equipment, and similar enclosures.
Running thread are not permitted. Replace galvanizing on all field threads
with approved brush-on galvanizing touch up paint. Spray cold galvanizing
compounds shall not be used.
14.
Support individual horizontal conduits not larger than 1-1/2 inches in diameter
by means of one hole conduit straps with back spacers or individual conduit
hangers.
15.
Space conduits installed against concrete surfaces 1/4 inch away from the
surface by clamp backs or other approved means.
16.
Support individual horizontal conduits larger than 1-1/2 inches in diameter by
individual hangers and forged steel conduit strap for vertical runs.
17.
Hanger rods used in connection with spring-steel fasteners, clips and clamps
shall be either 3/8-inch diameter galvanized steel rods or, if concealed above
a suspended ceiling, galvanized perforated steel strapping. Do not use wire
for support of conduit.
December 2013
Technical Specifications
16050-29
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
B.
18.
Support parallel conduits at the same elevation on multiple conduit hangers
or channel inserts. Secure each conduit to the pipe hanger or channel insert
member by a U-bolt, one-hole strap or other specially designed and
approved fastener suitable for use with the pipe hangers or channel inserts.
Install conduits at least six inches away from parallel runs of flues and steam
or hot water pipes.
19.
Space supports not over ten feet on centers for vertical conduits spanning
open areas. Securely anchor conduit at each end, and run so as not to
interfere with the installation and operation of equipment at the location.
20.
Install liquidtight flexible metal conduit at structural construction joints, at
motor connections and where required so that liquids tend to run off the
surface and not drain toward fittings. Provide sufficient slack to reduce the
effects of vibration. Running threads are not acceptable. Where necessary
for connecting to rigid conduits, use right and left hand couplings.
21.
Changes in direction shall be made with symmetrical bends or cast metal
fittings. Field made bends and offsets shall be made with a conduit bending
machine. Crushed or deformed conduits shall not be installed. Trapped
conduits shall be avoided. Plaster, dirt, or trash shall be prevented from
lodging in conduits, boxes, fittings and equipment during construction.
Conduits shall be cleaned of all obstructions.
22.
For conduits passing through mechanical and electrical equipment room
walls, fireproof walls, floor, caulk space between conduit and enclosing
sleeve with fireproof, inorganic acoustical fiber or other suitable approved
compound to prevent the spread of fire, smoke, hot gases, and to prevent
sound transmission.
23.
Conduits shall be of such size and so installed that the required conductors
may be drawn in without injuring or excessive strain.
24.
Examine carefully all conduits and fittings before installing and all pieces
having splits, breaks, blisters, or defects shall be set aside and removed from
the site.
25.
Where conduits are installed in existing concrete slabs, saw cut the slab, chip
concrete, install conduits and pack the trench with concrete to match existing.
Finish the surface smooth and level with the adjoining surfaces. Spacing of
conduits shall be as shown on the Contract Drawings.
Liquid-Tight and Metallic Flexible Conduit:
1.
December 2013
Technical Specifications
Install flexible metal conduit so that liquids tend to run off the surface and not
drain toward fittings. Provide sufficient slack to reduce the effects of
vibration.
16050-30
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
C.
D.
3.03
3.05
Provide suitable flexible conduit connections at all motors with the minimum
length practicable.
3.
Flexible conduit shall be extended into the termination fitting as far as
practicable.
4.
Flexible conduit between three and six feet in length shall be provided for
equipment subject to vibration, noise transmission, or movement; and for all
motors. Flexible conduit shall be installed to allow 20 percent slack.
Minimum size shall be ¾ inch diameter. Liquid-tight flexible conduit shall be
used in wet locations.
Pull Cords:
1.
Provide nylon pull cords of tensile strength not less than 240 pounds in each
conduit and duct. Leave pull cords in ducts and conduit.
2.
Splices in pull cords will not be permitted.
3.
Leave ample slack length at each end of pull cords.
Filling of Openings: Wherever slots, sleeves, or other openings are provided in floors
and walls for the passage of raceways, conduits, and bus ducts, fill such openings as
follows:
1.
Provide fire-resistive filling material and installation for openings.
2.
Where conduits passing through openings are exposed in finished rooms,
use surface filling material that matches, and is flush with, the adjoining
finished floor, ceiling, or wall.
INSERTS
A.
3.04
2.
Spot Inserts: Install with the insert face flush with the finished concrete surface, firmly
embedded, with no evidence of movement.
CABLE AND WIRE
A.
Not Used
B.
All wiring shall be rated 90 degrees Centigrade for wet or dry locations.
OUTLET, JUNCTION, AND PULL BOXES
A.
Outlet Boxes:
1.
December 2013
Technical Specifications
Unless otherwise indicated, flush mount outlet boxes with the front edges of
the boxes or tile covers attached thereto flush with the finished wall or ceiling.
16050-31
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.06
3.07
Mount boxes so that the long axis of the devices will be vertical, unless
otherwise indicated.
3.
Locate boxes and box knockouts in concrete so as not to interfere with the
reinforcing steel.
4.
The mounting height indicated for a wall-mounted outlet box shall be
construed to mean the height from the finished floor to the horizontal
centerline of the cover plate.
B.
Junction and Pull Boxes: Install so that covers are readily accessible after completion
of the installation.
C.
Boxes Set in Concrete:
1.
Support boxes to prevent movement during placement of concrete.
2.
Unused nailing holes or other holes in the side or bottom of the boxes shall
be plugged or masked.
3.
After installation, clean boxes placed in concrete and provide covers to
prevent entry of dirt and debris.
WIRING DEVICES
A.
Attach receptacles rigidly to outlet box by means of two stainless steel screws.
B.
For exterior and damp locations, surface or embedded, mount receptacles in
watertight cast metal outlet boxes with threaded hubs or bosses and equipped with
gasketed spring cover.
DISCONNECT (SAFETY SWITCHES)
A.
3.08
2.
Perform all work in accordance with the applicable requirements of the NEC and
authorities having jurisdiction. Install disconnect switches where shown on the plans.
Enclosures shall be mounted so that front and sides are vertical.
PANELBOARDS – POWER, LIGHTING
A.
General: Prior to commencing installation:
1.
Verify that all surfaces upon or in which enclosures are to be mounted are
properly prepared and that all pre-mounting wire pulling has been completed
and properly tagged. Take corrective action if necessary.
2.
Verify that enclosure mounting provisions are suitable for intended mounting.
Make corrective adjustments, if necessary.
December 2013
Technical Specifications
16050-32
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.09
3.10
3.
Verify that all factory installed circuit breakers are correct rating for the
applicable circuit applications as indicated. Take corrective action if
necessary.
4.
Install panelboards in enclosures in accordance with manufacturer's
instruction before mounting enclosure.
5.
Complete all directory cards with the information indicated above. Typewrite
information on directory cards.
6.
Adjust straight and plumb fasten securely in place. Align and securely and
independently fasten each section of multi-section enclosures. Mount all
panelboard cabinets with top of cabinet 6 feet-6 inches and bottom not less
than twelve inches above finished floor unless otherwise indicated.
7.
Neatly route, harness and support conductors in gutters, wiring spaces and
compartments. Bending radii not less than recommend by conductor
manufacturer.
B.
Install bonding jumpers from conduits entering cabinets to ground bus.
C.
Identify each circuit in cabinet. Attach identification tags bearing the number of the
circuit to all wires in panelboard gutters.
D.
Make all electrical connections for all wiring entering cabinets.
TRANSFORMERS
A.
Perform all work in accordance with the applicable requirements of NEC and
authorities having jurisdiction.
B.
Install transformers as indicated and in accordance with manufacturer's instruction.
C.
Conduit Connections: Use flexible conduit not less than 18 inches or more than 36
inches in length unless otherwise indicated.
D.
Comply with NEC and NESC.
E.
Mount five kVA and larger transformers on vibration damping and noise reducing
supports or devices to further reduce the noise level below that above specified, and
prevent transmissions of vibration to structural members.
DEVICES SUBJECT TO MANUAL OPERATION
A.
Each device subject to manual operation shall be operated at least five times,
demonstrating satisfactory operation each time.
December 2013
Technical Specifications
16050-33
Contract No. 14-017X
BASIC ELECTRICAL MATERIALS AND METHODS
3.11
FIRE-RESISTANT BOARD FOR MEDIUM VOLTAGE PULL BOXES
A.
3.12
All materials shall be inspected prior to construction to insure that they are free of
defects. Boards shall be cut with edges straight and square to maintain flush edges.
FIELD QUALITY CONTROL
A.
For testing requirements, refer to Section 16960 of the Technical Provisions.
B.
The Engineer reserves the right to require such tests, after installation, as in his
opinion may seem adequate and reasonable to demonstrate that the work has been
properly performed. All apparatus, labor and other facilities necessary to perform the
tests shall be provided. Any work which, in the opinion of the Engineer, is found to be
defective, shall be replaced.
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in the related items of work
shown on the Contract Drawings described in the Specifications and required for
completion of work under this Contract.
END OF SECTION 16050
December 2013
Technical Specifications
16050-34
Contract No. 14-017X
SECTION 16051
MOTORS
PART 1 - GENERAL
1.01
DESCRIPTION
A.
1.02
1.03
This Section includes technical provisions for installing, connecting, and testing
electric motors as indicated.
RELATED SECTIONS
A.
Section 16050 – Basic Materials and Methods
B.
Section 16061 – Grounding
C.
Section 16960 – Electrical Acceptance and Start-Up Testing and Training
REFERENCE STANDARDS
A.
B.
American National Standards Institute (ANSI):
ANSI C33.123
Electric Motors
ANSI Z55.1 - 1967
Gray Finishes for Industrial Apparatus and Equipment
American Society for Testing and Materials (ASTM):
ASTM A582
C.
Institute of Electrical and Electronics Engineers (IEEE):
IEEE 85
IEEE 112A
D.
E.
Airborne Sound Measurements on Rotating Electrical Machinery
Test Procedure for Polyphase Induction Motors and
Generators
National Electrical Manufacturers Association (NEMA):
NEMA MG1
Motors and Generators
NEMA MG2
Safety Standard for Construction and Guide for Selection
Installation and Use of Electric Motors and Generators
National Fire Protection Association (NFPA):
NFPA 70
F.
Free-Machining Stainless and Heat-Resisting Steel Bars,
Hot-Rolled or Cold-Finished
National Electrical Code
Underwriters Laboratories (UL):
December 2013
Technical Specifications
16051-1
Contract No. 14-017X
MOTORS
UL 674
1.04
SUBMITTALS
A.
General: General Provisions for Construction, for submittal requirements and
procedures.
B.
Shop Drawings: Submit electrical diagrams of wiring, circuits, switches, Motor Control
Centers connected to the fan motors, and the associated fan control panels.
C.
Product Data: Submit manufacturer's literature and descriptions of fan electrical
motors.
D.
Test Reports: Submit certified test reports of factory tests performed on each motor,
in accordance with NEMA MG1 and other standards.
E.
Operation and Maintenance Data: Submit in accordance with Section 01730,
Operation and Maintenance Data. Submittal shall include the following:
F.
1.05
Electric Motors and Generators for Use in Hazardous Locations,
Class I, Groups C and D, Class II, Groups E, F and G
1.
Description of motor and its components.
2.
Manufacturer's operating and maintenance instructions, parts list,
illustrations, and diagram for components.
3.
Recommended list of spare parts.
4.
Wiring diagram.
5.
Speed-torque curve.
6.
Outline and base dimensions.
Field Test Reports: Submit test results of field performance tests.
DELIVERY, STORAGE AND HANDLING
A.
Contractor shall make all necessary arrangements to pick up the motors or fan
assemblies with pre-installed motors and appurtenances, from the NJ TRANSIT
storage facilities, including all necessary transportation means and appropriate
staffing.
B.
Store motors or fan assemblies with pre-installed motors and appurtenances in
secure and dry storage facility. Coordinate with the fan manufacturer and NJ
TRANSIT to ensure the new fan motors and assemblies are properly stored and
maintained in accordance with the fan and motor manufacturer’s requirements.
PART 2 - PRODUCTS
December 2013
Technical Specifications
16051-2
Contract No. 14-017X
MOTORS
2.01
Motors are part of the ventilation fan units that are provided by NJ TRANSIT and picked
up by the Contractor, no motors are provided under this contract.
PART 3 - EXECUTION
3.01
3.02
INSTALLATION
A.
Wire and connect motors in accordance with the manufacturer's recommendations
and as indicated.
B.
Install conduit in accordance with Section 16050.
C.
Connect power cable as indicated, in accordance with Section 16050.
D.
Ground motor enclosure in accordance with Section 16061.
E.
Provide liquid tight flexible metal conduit connection at motor.
FIELD QUALITY CONTROL
A.
Perform the following tests. Furnish equipment, instruments, and measuring devices
as required to perform the tests.
1.
Test circuits for connections in accordance with the wiring diagram. Test
motors for correct rotation. Disconnect motor shaft from driven machine if
damage may be caused by incorrect rotation.
2.
Test that insulation resistance to ground of non-grounded conductor is a
minimum of ten meg-ohms.
3.
Test motor enclosure for continuity to the grounding system.
4.
Test operation of circuits and controls for motors. When testing, operate
each control a minimum of ten times and each circuit continuously for a
minimum of 1/2-hour.
5.
Perform all other required tests as described elsewhere and under other
specification sections including mechanical division 15, electrical division 16,
and under other sections. For additional electrical testing requirements, refer
to Section 16960 of the Technical Provisions.
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
December 2013
Technical Specifications
16051-3
Contract No. 14-017X
MOTORS
A.
Payment for the work of this Section will be made at the Contract Lump Sum Price for
all the work, labor and materials necessary therefore and incidental thereto as shown
on the Contract Drawings and described in these Specifications.
END OF SECTION 16051
December 2013
Technical Specifications
16051-4
Contract No. 14-017X
GROUNDING
SECTION 16061
GROUNDING
PART 1 - GENERAL
1.01
DESCRIPTION
A.
1.02
1.03
The work of this Section consists of providing complete system neutral
grounding, equipment grounding, and building structural grounding.
RELATED SECTIONS
A.
Section 16050 – Basic Electrical Materials and Methods
B.
Section 16051 – Motors
C.
Section 16445 – Motor Control Centers and Motor Starters
D.
Section 16960 – Electrical Acceptance and Start-Up Testing and Training
QUALITY ASSURANCE
A.
Reference Standards:
1.
American Association of Railroads (AAR) Manual.
2.
American Society for Testing and Materials (ASTM):
3.
a.
B 8, Concentric Lay Stranded Copper Conductors, Hard,
Medium-Hard or Soft.
b.
B 187, Copper Bus Bar, Rod and Shapes.
c.
C 653, Guide for Determination of the Thermal Resistance of
Low Density Blanket Type Mineral Fiber Insulation.
d.
D 5, Test Method for Penetration of Bituminous Materials.
e.
D 149, Test Methods for Dielectric Breakdown Voltage and
Dielectric Strength of Solid Electrical Insulating Materials.
f.
D 257, Test Methods for D-C Resistance or Conductance of
Insulating Materials.
g.
D 570, Test Method for Water Absorption of Plastics.
National Fire Protection Association (NFPA):
a.
4.
70, National Electrical Code (NEC).
Underwriters' Laboratories, Inc. (UL).
GROUNDING
1.04
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
As-Built Drawings: Submit prior to final acceptance of the Work, drawings
showing complete layout of systems installed including physical location of
ground rods to which connections were made.
C.
Field Quality Control Test Report: Submit reports complying with requirements
hereinafter.
PART 2 - PRODUCTS
2.01
BARE GROUND WIRES
A.
2.02
INSULATED GROUND WIRE
A.
2.03
Soft draw copper, Class A or Class B stranded, meeting the requirements of
ASTM B 8; size in accordance with the NEC except where sizes specified herein
or shown on the Contract Drawings are larger than those required by NEC.
Grounding cable shall be continuous without joints or splices throughout its
length.
Copper, Class B stranded, 600 volts, 90 degrees Centigrade, NEC Type THWN;
meeting requirements of AAR Specification No. 535.2; sized as described in
Article 2.01 herein; and UL listed.
PRODUCTS USED FOR COPPER THERMIT WELDED CONNECTIONS
A.
Use products for copper thermit welded connections which are the products of
one manufacture and are produced for the specific application for which they are
used.
B.
Use materials and equipment which meet or exceed the applicable requirements
of the AAR Manual, Electrical Section, Section 13, Chapter 3, Part 6.
C.
Coating Materials for Thermit Welded Connections: Use black, rubber based
compound coating materials, which are soft, permanently pliable, moldable, and
unbacked, not less than 1/8 inch thick, with properties as follows:
1.
Solids: 100 percent
2.
Density: 12.0 pounds per gallon minimum.
3.
Penetration: 90-130, ASTM D 5.
4.
Water Absorption: 0.10 percent maximum, ASTM D 570.
5.
Dielectric Strength: 500 volts per mil, ASTM D 149.
6.
Volume Resistivity:
2,000 megohms-inches, ASTM D 257, 5,000
GROUNDING
megohms-cm, ASTM D 257.
2.04
8.
Chemical Resistance: Melting point, non-flammability, slow burning
(ASTM C 653); resists alcohol, water, aqueous hydrochloride and
sodium hydroxide; dissolved by carbon tetrachloride, naptha, gasoline,
mineral spirits, ketones, and benzene.
9.
Highly Cohesive and Adhesive: Adheres strongly to metals and concrete
and to itself.
For solderless type made of high strength electrical bronze with silicon bronze
clamping bolts and hardware; designed such that bolts, nuts, lock washers and
similar hardware which might nick or otherwise damage the ground wire will not
directly contact the ground wire.
GROUND BUS
A.
2.06
Service Temperature: Minus 40 degrees Fahrenheit to plus 160 degrees
Fahrenheit.
BOLTED GROUNDING CONNECTORS
A.
2.05
7.
One-quarter inch by two inch copper bus bar mounted as shown on the Contract
Drawings; drilled and tapped to receive ground cable connections from the
ground rod assembly and ground connections for equipment as required. Bar
shall have 98 percent conductivity, conforming to ASTM B 187.
GROUND RODS
A.
Ground rods shall be copper-clad, sectional type, ¾ inch in diameter with each
section ten feet long. The lower rod shall be tapered at one end.
PART 3 – EXECUTION
3.01
PREPARATION
A.
3.02
Perform testing as specified hereinafter.
GENERAL GROUNDING REQUIREMENTS
A.
Provide electrical grounding complying with procedures of NEC and as indicated.
B.
Equipment Ground Conductors:
1.
Provide insulated ground conductor as shown on the Contract Drawings,
terminating in a ground grid consisting of grounding conductors and
ground rods buried in earth.
2.
Provide insulated ground conductor (green) sized in accordance with
NEC for each feeder, branch circuit, lighting circuit raceway. Terminate
ground conductors on ground buses, equipment ground pads or ground
grids only, and in no case to neutral buses.
GROUNDING
C.
Neutral Conductor (White): Neutral conductor shall be provided for each feeder
and branch circuit serving 277 volt lighting or equipment load independently of
the required equipment ground (green) conductor.
D.
Unit Substation:
E.
3.03
Provide ground bus in both primary switchgear section and secondary
terminal compartment.
2.
Connect both ground buses to system ground bus as shown on the
Contract Drawings.
Provide convenience outlets having ground fault circuit breakers, complying with
Section 16050.
SYSTEM NEUTRAL GROUNDING
A.
3.04
1.
Provide three phase alternating current secondary distribution systems wye
connected with neutral grounding as the source.
1.
Run throughout as indicated, system neutral and ground bus and
equipment ground conductor or both as indicated. Neutral buses shall
be connected to the system ground at a single point only, with
connecting made via a suitable link to permit isolation of system neutral
wiring for testing.
2.
Solidly ground neutral deriving equipment.
3.
Connection Secondary Wye Neutral Points:
a.
At Power Transformers and Load Centers: Provide copper
conductors, sized, as indicated, but in no case smaller than that
required by NEC.
b.
At Dry Type Transformers: Use equipment ground conductor for
connection of equipment and neutral to ground system.
EQUIPMENT GROUNDING
A.
General: All non-current carrying enclosures of electrical equipment and all
permanently installed exposed metallic equipment and piping shall be
permanently and effectively grounded as shown, specified, and in accordance
with the NEC.
B.
Alternating Current Switchgear:
1.
Connect continuous equipment ground bus at each end by copper
ground wire to building or facility ground bus.
2.
Provide ground wire equal in size to largest conductor in line feeding
equipment, but not less than No. 6 AWG, nor larger than No. 4/0 AWG.
GROUNDING
3.
C.
Wire Channels, Metallic Conduit, Flexible Conduits, Metallic Boxes, Panelboards
and Transformer Enclosures: Ground to ground bus with copper ground
conductors sized as shown on the Contract Drawings.
D.
Motors, Lighting Fixtures and Equipment:
E.
3.05
1.
Accomplish grounding with equipment ground.
2.
Provide equipment ground conductor sized by NEC electrically and
mechanically continuous from system equipment and neutral ground
connection at source of supply to equipment to be grounded.
Building Type Conductors:
1.
Where conductors are provided in raceways, run equipment ground
conductor for alternating current systems within raceways with circuit
conductors.
2.
Provide copper equipment ground conductor minimum one size smaller
than phase conductors, except having minimum size of No. 12 and
maximum size No. 4/0 AWG.
3.
Identify equipment ground conductors with colored green Type THW
insulation, except where green insulation is not available on larger sizes,
black colored insulation shall be used and suitably identified with green
tape at each junction box or device enclosure.
F.
Junction Boxes, Pull Boxes and Other Enclosures Sized Above Five Square
Inches: Securely bond equipment ground conductors to enclosures utilizing
equipment ground bus or lug.
G.
Ground all manhole hardware including cable racks and frames.
CONVENIENCE OUTLETS
A.
3.06
Provide ground wire in rigid steel conduit bonded at both ends.
Ground all convenience outlets in accordance with the NEC.
THERMIT WELDING CONNECTIONS
A.
Connect electrical wires together, to reinforcing steel as indicated, by thermit
welding using the manufacturer's recommended molds and size of charges for
the application.
B.
Prepare the material to be welded and perform thermit welding in accordance
with manufacturer's instructions.
C.
Test completed thermit welds before coating by striking with two pound hammer.
If cracks develop, replace welds at no additional expense to NJ Transit. When
required by the Construction Manager, test the electrical continuity of bonds.
D.
Apply coating so that it extends one inch beyond point of attachment to steel
GROUNDING
member, overlaps wire coating one inch, and provides insulation thickness
equivalent to wire insulation, but not less than 1/8 inch in thickness. Do not apply
coating material at ambient temperatures below 20 degrees Fahrenheit or above
125 degrees Fahrenheit. Maintain, by an accepted method, curing temperature
within above temperature range for at least four hours after application of
coating. Protect coating by accepted means until embedment.
3.07
FIELD QUALITY COTNROL
A.
B.
Testing Building Structural Grounding:
1.
General: After construction of ground loop and ground electrodes, and
prior to interconnection of other ground systems at southbound turnout,
perform ground resistance testing.
2.
Test Report: Submit report giving results of testing procedures, which
shall also include temperature, humidity, and condition of soil at time of
tests.
For additional testing requirements, refer to Section 16960 of the Technical
Provisions.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be included in the related items of work
shown on the Contract Drawings, described in the Specifications and required for
completion of work under this Contract.
END OF SECTION 16061
SECTION 16445
MOTOR CONTROL CENTERS AND MOTOR STARTERS
PART 1 - GENERAL
1.01
1.02
1.03
DESCRIPTION
A.
The work of this Section consists of furnishing, installing, connecting and testing
motor control centers (MCC) and motor starters, complete in place, as shown on
the Contract Drawings and as specified herein.
B.
General requirements include those specified in Section 16010 of these
Specifications and herein. Materials not normally furnished by the manufacturer
with this equipment are specified in Section 16050 of these Specifications.
C.
Motor Control Center (MCC) starter contacts, auxiliary devices, pilot lights,
monitoring, alarm, control and interlocking requirements for Heating, Ventilating,
and Air Conditioning Systems (HVAC), including sequence of operation, are
described in Section 15951.
D.
Remote I/O and communication components for integrating MCCs with
Ventilation SCADA are described in Section 13450.
RELATED SECTIONS
A.
Section 13450 – Supervisory Control and Data Acquisition (SCADA) System
B.
Section 13080 – Seismic Anchoring and Vibration Isolation for Mechanical and
Electrical Equipment
C.
Section 16010 – Electrical General Requirements
D.
Section 16050 – Basic Electrical Materials and Methods
E.
Section 16051 – Motors
F.
Section 16061 –Grounding
G.
Section 16960 – Electrical Acceptance and Start-Up Testing and Training
QUALITY ASSURANCE
A.
Reference Standards:
1.
December 2013
Technical Specifications
American Society for Testing and Materials (ASTM):
a.
A 525, General Requirements for Steel Sheet, Zinc Coated
(Galvanized) by the Hot-Dip Process.
b.
B 187, Copper Bus Bar, Rod, and Shapes.
16445-1
Contract No. 14-017X
MOTOR CONTROL CENTERS AND MOTOR STARTERS
c.
2.
Federal Specifications (FS):
a.
3.
4.
TT-C-490D, Cleaning Methods for Ferrous Surfaces and
Pretreatments for Organic Coatings.
National Electrical Manufacturers Association (NEMA):
a.
AB-1, Molded Case Circuit Breakers
b.
ICS-1, general Standards for Industrial Control
c.
ICS-2, Standards for Industrial Control Devices, Controllers and
Assemblies.
National Fire Protection Association (NFPA):
a.
5.
D 2092, Practices for Preparation of Zinc Coated Galvanized
Steel Surfaces for Paint
70, National Electrical Code (NEC).
Underwriters Laboratories, Inc. (UL):
a.
94, Tests for Flammability of Plastic Materials for Parts, Devices,
and Appliances.
b.
489, Molded Case Circuit Breakers and Circuit Breaker
Enclosures
c.
508, Industrial Control Equipment
d.
845, Motor Control Centers.
e.
991, Tests for Safety Related Controls Employing Solid State
Devices
B.
Conform to applicable requirements of the NEC.
C.
Components of the same type, size, rating, functional characteristics and make
shall be interchangeable.
D.
Test and certify controls and auxiliary devices in accordance with NEMA ICS-2.
Furnish certificate of conformance to the Construction Manager before the
assembled equipment is shipped.
E.
Furnish UL label for all electrical components and materials, when available.
F.
Source Quality Control:
December 2013
Technical Specifications
16445-2
MOTOR CONTROL CENTERS AND MOTOR STARTERS
1.03
1.
Perform factory tests as required to verify proper performance of the
equipment. The Construction Manager may witness the tests.
2.
Motor control center section assigned for emergency fans, underplatform
exhaust fans, and station ventilation fans shall perform a partial seismic
test (circuit continuity relay) conforming to NEMA ICS-2.
SUBMITTALS
A.
In accordance with the General Provisions for Construction.
B.
Submit shop drawings and electrical diagrams of equipment and layouts.
C.
1.
Submit shop drawings, showing materials and methods of construction,
door arrangement, conduit hub and knockout locations, complete internal
wiring diagrams, mounting locations and supports for equipment
mounted in the panels and cabinets, terminal strip designations and wire
numbers.
2.
Shop drawings shall include, but not be limited to the following:
a.
Floor plan with all overall dimensions, front view and mounting
arrangement.
b.
Maximum short circuit bracing.
c.
Circuit breaker type, size and interrupting rating.
d.
Motor Circuit Protector type, size and interrupting rating.
e.
Starter and overload relay data.
f.
Elementary diagrams.
g.
Power and control cable entries.
h.
A bill of material listing equipment type, ratings, manufacturer
and catalog numbers.
Submit manufacturer's product data of specified materials and equipment for the
following, including model number or item identification, UL listing and rating.
1.
Motor control center(s).
2.
Motor starters (each type).
3.
Circuit breakers.
December 2013
Technical Specifications
16445-3
MOTOR CONTROL CENTERS AND MOTOR STARTERS
D.
E.
1.04
4.
Control devices (control logic relays, and remote I/O processing and
communication components).
5.
Control transformers.
6.
Motor circuit protectors.
7.
Fuses, Compartment Thermostats.
8.
Ground Bus and associated supports.
Submit maintenance data and operating instructions including the following:
1.
Description of the equipment and its components.
2.
Manufacturer's operating and maintenance instructions, parts list,
illustrations, and diagram of components.
3.
Recommended list of spare parts.
4.
Wiring diagram.
Submit certified test reports of factory and field tests performed verifying that
performance of equipment meets Specification requirements.'
DELIVERY, STORAGE AND HANDLING
A.
Ship each unit securely wrapped, packaged, and labeled for safe handling of
shipment and to avoid damage or distortion.
B.
Store motor control centers, motor starters, control stations and contactors in
secure and dry storage facility.
C.
Coordinate maximum dimensions of shipping sections with the dimensions of
access corridors and door to ensure shipping dimensions will allow movement of
equipment through structure without damage to equipment or structure.
PART 2 - PRODUCTS
2.01
MOTOR CONTROL CENTERS
A.
Provide motor control centers conforming to UL 845 and NEMA ICS-2, Class II,
Type B, rated 480 volts, three phase, four wire, 60 Hertz, totally enclosed, rigid,
self-supporting, dead-front, freestanding modular assembly having vertical and
horizontal buses, wireways, compartments equipped with circuit breakers,
starters and space heaters as indicated.
December 2013
Technical Specifications
16445-4
MOTOR CONTROL CENTERS AND MOTOR STARTERS
B.
Provide nameplate on each motor starter and control center in accordance with
NEMA ICS-2, showing manufacturer's name and brand designation, the
referenced standard, type, class, and rating as applicable.
C.
Motor control centers shall include the following appurtenances and accessories:
1.
December 2013
Technical Specifications
Enclosure: NEMA 12 steel enclosure with drip shield, gasketed doors,
modular assembly allowing a maximum of six Size 1 compartment units
in one vertical assembly, without structural interference. Enclosure
heights shall conform to the dimensions shown on the Contract Drawings
(in the referenced as-build set). Include the following:
a.
Provide each unit compartment with individual door having
concealed hinges and unit door mechanically interlocked with
unit circuit breaker to prevent opening or closing of door when
the circuit breaker is in the "ON" position. Provide defeater to
bypass the interlock.
b.
Equip circuit breaker in each compartment with mechanism and
operating handle for operation at front door. Handle shall be
lockable at both "ON" and "OFF" positions. Provide method so
each unit can be padlocked in the test position with the stabs
completely withdrawn from the vertical buses.
c.
The top of each vertical section shall be provided with sufficient
space for entering armor jacketed, multi-conductor cables and
rigid steel conduit.
d.
Provide horizontal wireway with removable coverplate at the top
and bottom for wiring between sections, incoming conduit and
cable, motors and control wiring. Provide top trough separated
by a barrier from the main horizontal bus.
e.
Provide vertical wireway, (minimum 40 square inches) with its
own door, adjacent to each vertical section and front accessible
for the full height of section. Provide wire hangers.
f.
Provide individual vertical sections fabricated from 12 gauge
steel, continuous top and bottom frames. Steel frames shall be
connected by vertical members consisting of cold rolled steel box
sills at each corner and 12 gauge vertical C-channels.
g.
Provide enclosure fabricated from zinc coated steel sheet
conforming to ASTM A 525, coating designation G90, minimum
thickness of 12 gauge.
h.
Provide painted finish for all ferrous and galvanized metal
surfaces as follows: ferrous metal surfaces shall be prepared for
painting in accordance with FS TT-C-409. Galvanized metal
16445-5
MOTOR CONTROL CENTERS AND MOTOR STARTERS
surfaces shall be prepared for painting in accordance with ASTM
D 2092. After pretreatment, prime paint surfaces with an
approved corrosion-inhibitive metal primer for ferrous or
galvanized surfaces, as applicable. Finish coat shall be a heavy
duty gray enamel.
i.
j.
2.
3.
December 2013
Technical Specifications
Provide removable lifting angles on the top of each motor control
center shipping section. Mount each shipping section on steel
channel sills. Verify room openings for size of shipping sections.
Provide a separate compartment to house Remote I/O process
control unit and associated redundant communication
components.
Horizontal and Vertical Buses: Provide main horizontal buses at the top
or center of the structure for the entire length of the MCC. Provide
vertical buses for feeding power to each compartment in each vertical
assembly and securely bolted to the main buses. Provide a neutral
landing pad in each incoming line compartment. Buses shall meet the
following requirements:
a.
Bus bar shall conform to ASTM B 187, 98 percent conductivity
copper, tin plates, fully insulated by extruded sleeve or wound
tape.
b.
Each horizontal and vertical bus shall be rated for a minimum of
1,600 and 300 amperes respectively, unless the particular
section requires higher rating at vertical buses due to the
arrangement of the horizontal buses.
Both vertical and
horizontal buses shall have current density not to exceed 1,000
amperes per square inch unless otherwise indicated. Provide
tubular vertical bus to enhance mechanical and thermal
characteristics.
c.
Each bus shall be rigidly held by bus supports, which have high
dielectric qualities, are moisture-resistant, non-carbonizing,
nontracking, and have vertical creepage surfaces to prevent
faults due to build-up of conductive dirt.
d.
Completely isolate both horizontal and vertical buses with bus
support molding, both between phase-to-phase and phase-toground. Cutouts at the molding for plug-in unit stabs shall be
equipped with shutter cover when the unit is in the drawout
position, to avoid accidental contact with the vertical buses.
e.
Brace bus assembly to withstand short circuit rating as indicated
but not less than 65,000 symmetrical amperes (RMS).
Ground Bus: Provide continuous bare copper ground bus, ¼ inch by two
inches in cross-section, provided throughout the length of the control
16445-6
MOTOR CONTROL CENTERS AND MOTOR STARTERS
center. Provide cable lugs at each of the line-up. A copper vertical
ground bus, which make contact with the plug-in units before the bus
stabs engage the vertical bus.
4.
5.
Compartments: Compartment arrangement shall be in accordance with
the MCC schedules and configurations indicated. Provide spaces, if any,
at the lowest portion of each section and assign a continued
compartment number from the schedule.
a.
Design each section such that each compartment can be easily
modified to accommodate any standardized drawout unit.
Provide steel isolation barrier between units with rigid connection
to form an effective grounding path to the steel structure.
b.
Provide unit guides in unit compartment for aligning starter stabs.
Drawout Units:
Components in each drawout unit shall be the
manufacturer's standard products and readily available for repair and
maintenance.
a.
b.
Circuit Breaker:
(1)
Provide a 480-volt, three-pole circuit breaker for each
unit compartment in accordance with the requirements
indicated. Line side of circuit breaker shall have tin
plated stab assembly for connecting to the vertical buses
in unit compartment.
(2)
In general, circuit branch circuit breaker compartment
shall be a molded case, thermal magnetic current
limiting type, with an interrupting capacity of 22,000
amperes at 480 volts AC. Provide shunt trip attachment
where indicated in the MCC schedules. Each breaker
shall be equipped with auxiliary contacts for remote
monitoring.
(3)
Breakers for combination starters shall be a motor circuit
protector (MCP) type, equipped with current limiter.
Combination starter shall conform to the requirements
specified herein.
Motor Starter:
(1)
December 2013
Technical Specifications
Provide NEMA ICS-2 motor starter. Motor starters shall
be a combination type, full voltage, single speed or two
speed with non-reversible or reversible operations as
indicated on the Contract Drawings. Contact rating shall
be 480 volts AC as indicated on the Contract Drawings.
Motor starter size shall be as indicated, not smaller than
16445-7
MOTOR CONTROL CENTERS AND MOTOR STARTERS
Size 1. Provide a disconnect switch for each starter
control circuit. Disconnect switch shall be open when
motor circuit breaker is opened.
December 2013
Technical Specifications
(2)
Provide solid-state overload relays with current sensors
for tunnel ventilation fans. Relays shall be Siemens
Type 34B overload relay, or approved equal.
(3)
Tunnel ventilation fan motor overloads shall be sized
140 percent of full load current.
(4)
Provide two NO and two NC auxiliary contacts with
provision for future addition of two NC or NO contacts.
Auxiliary contacts shall be convertible.
c.
Unit Device Panel: Provide a device panel assembly, visible
from the front of unit door, with switches and pilot lights as
indicated in the wiring diagrams. The device panel may be
hinged to the unit allowing the door to dispense with hinged
wiring. Devices shall conform to the requirements specified
herein.
d.
Terminal Blocks: Equip each unit with a pull apart type terminal
block and arranged such that control wiring shall be deenergized when the unit is drawn out from the compartment.
e.
Control Wiring:
(1)
Factory wire each compartment to the terminal block
and/or to other compartments in the same line-up.
Control wires shall be a minimum of No. 14 AWG,
stranded, thermoplastic insulated wire, rated 105
degrees Centigrade.
(2)
Interconnection wiring between compartments shall be a
minimum of No. 14 AWG, Type SIS. Interconnection
wiring means cables interconnected to any compartment
in the same line-up, even though such compartment may
not be connected to the horizontal or vertical bus.
(3)
Power cable shall be of the same type and rating, black
color, and with capacity compatible with the starter or
breaker rating.
(4)
Provide motor controllers built in interlocking logic per
contract drawings and remote I/O and redundant
communication components housed within MCC to
communicate with the Supervisory Control and Data
16445-8
MOTOR CONTROL CENTERS AND MOTOR STARTERS
Acquisition System (SCADA) as specified in Section
13450.
f.
Relay Compartment: Provide drawout type relay compartment
without stabs. Relays and wiring devices shall be as indicated.
Clearly label each relay compartment and 120 volts AC circuit
breaker compartment at the drawout unit and indicate location of
power supply.
g.
Nameplates:
requirements:
h.
2.02
with
the
following
Label each motor control center with a four inch wide
nameplate showing its function in 2-1/2 inches high.
(2)
Label each compartment with a two inch wide name
plate showing function and number of the motor
controlled in ½ inch high with a maximum of three lines.
Space Heaters:
(1)
Furnish unit space heaters of required rating in each
vertical section of the motor control center. Suitably
locate the space heater such that all compartments in
the same vertical sections are uniformly heated.
(2)
Space heater bus shall have 120 volts, 60 Hertz supply
from step-down transformer fed from motor control
center bus.
Do not load each space heater circuit more than ten
amperes. Each vertical section shall have one common
fused disconnect switch, and bypass switch. Provide
one thermostat.
Control Transformer:
(1)
Each motor control center shall have a control
transformer sized to handle all starter coils, relays,
indicating lights, and miscellaneous auxiliary devices
shown on the wiring diagrams. In addition the control
transformer shall be sized to carry 150 VA more capacity
than required.
(2)
Control transformers shall have a single secondary dual
element fuse sized to protect against transformer
overload. The coil side of the transformer secondary
shall be grounded to the unit support or back pan.
MOTOR STARTERS
December 2013
Technical Specifications
nameplates
(1)
(3)
i.
Provide
16445-9
MOTOR CONTROL CENTERS AND MOTOR STARTERS
A.
Provide motor starters meeting requirements of NEMA ICS-2, general purpose
Class A, and the following additional requirements.
1.
Rating: Continuous current rating suitable for associated motor as
indicated.
Provide heater sized for motor running protection in
accordance with the NEC.
2.
Type:
3.
a.
Less Than ½ Horsepower Motor: Magnetic or manual starter
operable on 120 volts, single phase, 60 Hertz supply unless
otherwise indicated.
b.
½ Horsepower and Up to 250 Horsepower Motor: Across-theline magnetic starter operable on 480 volts, three phase, 60
Hertz supply.
Enclosure:
a.
B.
Type:
(1)
For dry, dust-free, and heated indoor location use NEMA
12.
(2)
For damp dusty and unheated indoor location use NEMA
13 gasketed.
(3)
For outdoor and tunnel location use NEMA 4X (stainless
steel).
b.
Materials: Provide enclosure fabricated from zinc coated steel
sheet conforming to ASTM A 525, coating designation G90,
minimum thickness of 14 gauge.
c.
Finish: Provide painted finish for all ferrous and galvanized
metal surfaces as follows: ferrous metal surfaces shall be
prepared for painting in accordance with FS TT-C-490D.
Galvanized metal surfaces shall be prepared for painting in
accordance with ASTM D 2092. After pretreatment prime paint
surfaces with an approved corrosion-inhibitive metal primer for
ferrous or galvanized surfaces, as applicable. Finish coat shall
be a heavy duty gray enamel.
Combination Starters: provide combination starter meeting requirements of
NEMA ICS 2, rated 480 volts, three or single phase, 60 Hertz, and the following
additional requirements.
December 2013
Technical Specifications
16445-10
MOTOR CONTROL CENTERS AND MOTOR STARTERS
1.
Provide one 480 volt, three pole motor circuit protector type circuit
breaker with current limiter, as indicated.
2.
Provide externally mounted operating handle with position indicator
showing "ON", "OFF", "TRIPPED" condition of the circuit breaker or
disconnect switch as applicable. Operating handle shall be interlocked
for preventing opening and closing of the door when the circuit breaker
or disconnect switch is in the "ON" position. Provide defeater to bypass
the interlock and provisions for padlocking in any position.
3.
Provide indicating lights on each unite enclosure as indicated on
approved wiring diagrams.
Indicating lights shall be NEMA 13,
transformer push-to-test type.
4.
Provide the MCP with adjustable magnetic protection and a means to
stop the magnetic adjustment at 1,300 percent motor nameplate full load
current to comply with NEC requirements, and transient override feature
for motor inrush current.
5.
Combination starters Size 1 through Size 4 shall be drawout type
construction. Combination starters Size 5 and larger shall be bolt-on
construction.
C.
Reversible Motor Starter:
Starters shall be magnetic, full voltage type,
mechanically and electrically interlocked having similar characteristics,
components and requirements as specified elsewhere herein.
D.
Multi-Speed Motor Starters: Multi-speed motor starters shall be of the magnetic,
full voltage type, mechanically and electrically interlocked having similar
characteristics, components and requirements as specified herein.
E.
Provide nameplate on each motor starter in accordance with NEMA ICS 2,
showing manufacturer's name and brand designation, the referenced standard,
type, class and rating as applicable.
F.
Control Transformer:
1.
Each combination magnetic motor starter unit shall have a control
transformer sized to handle the starter coil burden plus two pilot lights
and two relays. In addition, each control transformer shall be sized to
carry 150 VA more capacity than required.
2.
Control transformers shall have a single secondary dual element fuse
sized to protect against transformer overload. The coil side of the
transformer secondary shall be grounded to the unit support or back pan.
December 2013
Technical Specifications
16445-11
MOTOR CONTROL CENTERS AND MOTOR STARTERS
G.
Provide all starter enclosures with padlock ears, and frames and supports for
wall, floor, or panel mounting as indicated. Provide the enclosure with both the
starter and the circuit breaker/disconnect with adequate space for wiring and
service to all internal parts. Attach a complete wiring diagram to the cover.
H.
Contact and Coils:
I.
J.
1.
Three poles with replaceable contacts with arc hood front cover. Rate
contacts at 600 volts AC, ampere rated, designed for minimum arcing on
both opening and closing. Both moving and stationary contacts shall be
accessible from the front for inspection and maintenance.
2.
Auxiliary contacts, field convertible to N.O. or N.C., as required to meet
the control and interlock requirements of the project. Provide at least
one set of auxiliary contacts for each starter.
3.
Provide clamping type wire lugs for power connections designed for use
with copper wire.
Overload Relays and Thermal Limits.
1.
Provide thermal overloads that release all phases upon a motor
overload.
2.
Provide overload relays with the melting eutectic alloy type with heater
elements sized for motor nameplate full load current (FLA). Other types
of overload relays with field adjustable trip currents may be used in lieu
of the melting alloy type provided they protect the motor equally.
3.
Provide overload relay with require manual reset in the event of a trip.
Extend reset button through the cover on all NEMA types.
Cover Controls: Unless indicated otherwise elsewhere, provide the following as
a minimum:
1.
Selector Switch: Three position operator and spring loaded contact
block, to facilitate switching between two circuits with an "OFF" position
between.
Provide large legend plate marked "HAND-OFFAUTOMATIC". Use this type of cover control on all motors requiring
remote or automatic control.
2.
Pushbutton Station: Provide pushbutton type control of motors when
remote switching or automatic control is not required. Provide raised
head "STOP" button. Provide large legend plates marked "START" and
"STOP".
3.
Indicating Lights: Provide pilot light to indicate that the motor is
operating. Provide large legend plate marked "MOTOR RUNNING" or
other designated title. Provide transformer type pilot lights with a
December 2013
Technical Specifications
16445-12
MOTOR CONTROL CENTERS AND MOTOR STARTERS
"PRESS-TO'TEST" feature. Pilot bulbs shall be 6.3 volt incandescent
type. Provide red acrylic lens, removable for bulb replacement.
4.
2.03
Quality: Provide NEMA 13 oil-tight cover controls as a minimum,
supplied with contact blocks, operators, lights, gaskets, legends, etc.
required for a complete array of controls. Provide internal wiring to
accomplish the intended control action.
K.
Sizing: Size starters in accordance with manufacturer's procedures using actual
motor nameplate ratings for full load current (FLA).
L.
Spare Parts: Provide one box of six – 6.3 volt AC incandescent pilot light lamps
per starter. Store lamps inside the starter cabinet.
CONTROL STATIONS
A.
B.
Enclosure:
1.
For dry, dust-free, and heated indoor location, NEMA 12 with drip shield.
2.
For damp, dusty, and unheated indoor location, NEMA 13 gasketed.
3.
For outdoor and tunnel locations, NEMA 4X (stainless steel).
Auxiliary Devices:
1.
Provide devices of heavy duty oil-tight construction. Indicating lights
shall be NEMA 13, push-to-test transformer type, 120 volts AC, 60 Hertz,
with 50,000 hour lamp life. Provide all starters with "HAND-OFFAUTOMATIC" switches.
2.
C.
D.
2.04
Install auxiliary devices at each unit that are standard products and wired
in accordance with control diagrams as indicated. Provide heavy duty
type relay extended operating duty, with a contact rating of 20 amperes
at 120 volts AC, operating satisfactorily at a temperature of 120 degrees
Fahrenheit. Identify relay characteristics, including inrush current rating
on the shop drawings.
Fabrication: Fabricate and wire local control stations complete as indicated.
Terminal Strips: Channel mounted, snap fit terminal blocks for 600 volt service,
molded, high impact strength, strap screw type for No. 22 through No. 10 AWG.
Terminals shall be at 3/8 inch centers.
MANUAL STARTERS
A.
Provide manual starters for fractional hp loads rated at 120 volts AC single
phase. Manual starters shall have quick-make quick-break toggle mechanism,
trip-free manual reset thermal overload relay, position indicator showing "ON",
December 2013
Technical Specifications
16445-13
MOTOR CONTROL CENTERS AND MOTOR STARTERS
"OFF", and "TRIPPED" positions, and red indicating light showing the closed
position.
2.05
NAMEPLATES
A.
2.06
INDIVIDUAL CONTROL RELAYS
A.
2.07
Control relays shall have convertible contacts rated a minimum of ten amperes,
600 volts. Verify coil voltage, and number and type of contacts. Furnish in
NEMA 12 enclosures, unless otherwise noted.
SCADA CONNECTIONS
A.
2.08
Nameplates shall be two inches wide, maximum of three lines, for each motor
starter, control station and contactor, showing function and number of the motor
controlled.
All control inputs shall be factory wired to terminal blocks mounted within the
MCC enclosure as shown on the drawings and as required. Space shall be
allowed for distributed input/output units adjacent to the terminal blocks.
POWER MONITORING
A.
Power transducers with associated current and voltage transformers (CT and VT)
shall be installed within the MCC enclosure.
PART 3 - EXECUTION
3.01
INSTALLATION
A.
Motor control centers, motor controllers, motor starters, control stations,
contactors, remote I/O, communication modules.
1.
Embed structural steel or cast iron sills for anchoring motor control
centers flush with raised concrete pad as indicated.
2.
Install motor control centers motor starters, control stations, contactors,
and remote I/O and communication components as indicated and as
recommended by the equipment manufacturer. Bolt vertical sections of
MCC together.
3.
Energize all heaters in motor control center sections within 24 hours after
being delivered to the site.
4.
After the motor control center and motor controllers have been leveled
on the foundation, place non-shrink cement mortar grout between
cabinet based and the foundation.
December 2013
Technical Specifications
16445-14
MOTOR CONTROL CENTERS AND MOTOR STARTERS
3.02
5.
If the heating elements of motor starters, remote I/O, and/or
communication components are shipped separately from the starters,
install them under the work of this Section.
6.
Provide embedded or surface mounted structural steel or cast iron sills
for anchoring control stations.
FIELD QUALITY CONTROL
A.
Perform the following tests and submit a certified report to the Construction
Manager for review. Provide all equipment and instruments required to perform
the tests.
1.
Test circuits for connections in accordance with accepted wiring
diagrams.
2.
Test that insulation resistance to ground of non-grounded conductor is a
minimum of ten megohms.
Test equipment enclosures for continuity to the grounding system.
3.
4.
B.
Test operation of circuits and controls. When testing, operate each
control a minimum of ten times and each circuit continuously for a
minimum of ½ hour.
For additional testing requirements, refer to Section 16960 of the Technical
Provisions.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will be measured for payment as follows.
Pay Item
Description
16445.1
Motor Control Centers and other equipment
16445.2
Installation and Testing
PAYMENT
A.
Payment for the work of this Section will be included in related items of work
shown on the Contract Drawings and described in the Specifications and
required for completion of work under this Contract.
END OF SECTION 16445
December 2013
Technical Specifications
16445-15
SECTION 16960
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND TRAINING
PART 1 - GENERAL
1.01
DESCRIPTION
A.
Work Included: The work of this Section consists of furnishing all labor,
materials, test equipment, and technical supervision to perform and record the
electrical field tests as specified, and perform and record all electrical tests as
required, including tests on 600 volt wire and cable, distribution transformers,
rotating equipment, grounding, special service systems, including fire alarm, and
relays, unless otherwise specified.
B.
This Section also includes requirements for furnishing all labor, materials, and
technical supervision to perform training for equipment and special systems
described herein.
C.
This Section specifies that Contractor shall engage the services of a recognized
independent testing company for performing final inspections and tests as specified.
1.
1.02
The Construction Manager will witness Inspections and tests. Notify the
Construction Manager a minimum of 14 working days in advance of testing
date.
D.
The testing company shall provide all material, test instruments, equipment, labor,
and technical supervision to perform such tests and inspections.
E.
It is the intent of these tests to verify that electrical equipment is operational within
industry and manufacturer's tolerances, and is installed in accordance with these
specifications.
F.
Perform tests, calibration, adjustment of relays and inspections before energizing any
equipment.
G.
Upon completion of the tests and inspections specified, a label shall be provided in
accordance with NETA labeling.
H.
The new power and control equipment including protective devices shall be of equal
or better ratings and performance to the original equipment to be replaced. Protective
device settings shall be based on the original power system short circuit and
coordination study report findings and recommendations. Contractor shall prepare
and submit documentation with equipment ratings and proposed protective device
settings in coordination with the manufacturers and vendors of the new equipment
replacements, for Engineer’s final review and approval.
QUALITY ASSURANCE
A.
Reference Standards:
December 2013
Technical Specifications
16960-1
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
1.
OSHA Part 1910; Subpart S. 1910.308.
2.
American National Standards Institute: ANSI
3.
American Society for Testing and Materials: ASTM
4.
5.
Association of Edison Illuminating Companies: AEIC
Institute of Electrical and Electronics Engineers: IEEE
6.
Insulated Cable Engineers Association: ICEA
7.
National Electrical Manufacturers Association: NEMA
8.
National Electrical Testing Association: NETA
Note:
Information and procedures for acceptance testing taken from “Acceptance
Testing Specifications for Electrical Power Distribution Equipment and
Systems” is copyright by International Electrical Testing Association, PO Box
687, 231 Red Rocks Vista Drive, Morrison, Colorado 80465.
9.
National Fire Protection Association (NFPA):
a.
10.
B.
C.
1.03
70, National Electrical Code (NEC).
State of New Jersey and City of Newark Electrical Codes and Ordinances
All inspections and tests shall use the following references.
1.
Contract Specifications.
2.
Drawings.
3.
Manufacturer's instruction manuals and approved shop drawings for
applicable equipment.
4.
NETA “Acceptance Testing Specifications for Electrical Power Distribution
Equipment and Systems”.
Qualifications of Testing Company:
1.
The testing company shall meet OSHA 29 CFR 1907 criteria for
accreditation of testing laboratories.
A testing company with full
membership in NETA constitutes proof of meeting such criteria. Contractors
with employees that are full members of NETA are not acceptable.
2.
Contractor shall submit the testing company's qualifications and the resumes
of the personnel being assigned to this Project for the Construction
Manager's approval before commencement of the work.
SUBMITTALS
December 2013
Technical Specifications
16960-2
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
A.
In accordance with the General Provisions for Construction.
B.
Submit the testing company's qualifications and the resumes of the personnel being
assigned to this Project.
C.
Fixed test procedures as recommended by the equipment/system manufacturer.
D.
Submit proposed testing program and test procedures for review and approval by the
Construction Manager before beginning any testing. Each procedure shall include
the following as a minimum:
E.
1.
Statement of procedure objective and scope.
2.
List of equipment required to set up and perform the procedure.
3.
List of equipment or services required from areas outside Contractor's
control.
4.
List of prerequisite tests that need to be completed before the procedure can
be performed.
5.
Description of the required procedure setup, including diagrams illustrating
test equipment connections and identifying test points, where applicable.
6.
Step-by-step instructions for performing the procedure identifying the points
where data is to be recorded and the limits for acceptable data, in
accordance with referenced standards.
7.
Provisions for recording pertinent test conditions and environment at time of
test.
8.
Instructions for recording data on data sheets and verifying that procedure
steps have been completed.
Test Report (Draft and Final)
1.
December 2013
Technical Specifications
The draft and final test reports, shall include, but not be limited to, the
following:
a.
Summary of Project.
b.
Description of equipment tested.
c.
Description of test.
d.
List of test equipment used in calibration and calibration date.
e.
Test
results,
16960-3
including
plots/graphs
and
actual
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
readings/measurements taken including corrected values.
f.
Conclusions and recommendations.
g.
Appendix, including appropriate test forms.
h.
2.
3.
1.04
All test reports shall be signed by the Construction Manager's
authorized witness present at the test.
The final test report shall be bound and its contents certified.
Furnish ten copies of the completed final test report to the Construction
Manager no later than 15 days after completion of the inspection and testing.
F.
Instruments: Submit list of instruments and certification indicating that instruments
that will be used for testing have been calibrated and their accuracy certified within a
previous period of not more than one month. List types of instruments to be used,
manufacturer, model, serial number, latest date of calibration, and calibration
organization.
G.
Training: Submit for approval by the Engineer the training schedule and training
materials no later than 14 days prior to the proposed training start date.
DIVISION OF RESPONSIBILITY
A.
Contractor shall perform routine insulation resistance, continuity and rotation tests for
distribution and utilization equipment before tests performed by the testing company
specified.
B.
Contractor shall provide all power supplies and facilities for testing, at no additional
cost to the Construction Manager.
C.
Contractor shall notify the testing company when equipment becomes available for
acceptance tests. Work shall be coordinated to expedite project scheduling.
D.
Contractor shall supply a complete set of electrical plans, specifications and pertinent
change orders to the testing company before commencement of testing.
E.
The testing company shall notify the Construction Manager a minimum of two weeks
before commencement of testing.
F.
The testing company shall be responsible for implementing final settings and
adjustments on protective devices.
G.
System material or workmanship that is found to be defective based on acceptance
tests shall be reported to the Construction Manager. Contractor, without additional
cost shall make corrections to the Construction Manager.
H.
The testing company shall maintain a written record of tests and upon completion of
the work, assemble and certify a final test report. A draft final test report shall be
submitted to the Construction Manager for review and comment before the final
December 2013
Technical Specifications
16960-4
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
report is submitted.
I.
1.05
Contractor shall provide all necessary qualified technical personnel and materials for
the training. Training facility shall be provided by NJT. Training and presentation
material including handouts, printouts, manuals and other information shall be
included in the final O&M manuals. Six (6) hardcopies and six (6) electronic copies of
the training material in digital DVD or similar format shall be provided to the NJ
TRANSIT upon the completion of the training sessions.
TEST INSTRUMENT SERVICE AND CALIBRATION
A.
Calibration Program and Accuracy:
1.
The testing company shall have a calibration program that maintains
applicable test instrumentation within rated accuracy in accordance with
manufacturer’s recommendations and standard industry practice.
2.
The accuracy shall be traceable to the National Bureau of Standards (NBS)
in an unbroken chain.
3.
Instruments shall be calibrated in accordance with the following frequency
schedule:
4.
B.
a.
Field instruments: 6 months, maximum.
b.
Laboratory instruments: 12 months.
c.
Leased specialty equipment: 12 months (where accuracy is
guaranteed by the lessor)
Dated calibration labels shall be visible on test equipment.
Safety and Precautions:
1.
Safety practices shall include, but are not limited to, the following
requirements.
a.
OSHA
b.
Accident Prevention Manual for Industrial Operations, Seventh
Edition, National Safety Council, Chapter 4.
c.
Applicable State and local safety operating procedures.
2.
Acceptance tests shall be performed with apparatus de-energized, unless
otherwise specified.
3.
The testing company shall have a designated safety representative who
shall be present on the Project and supervise operations with respect to
safety.
December 2013
Technical Specifications
16960-5
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
1.06
1.07
1.08
4.
Circuits operating in excess of 600-volts between conductors shall have
conductors shorted to ground by a hot-line grounded device UL approved for
the purpose.
5.
In all cases, work shall not proceed until the safety representative has
determined that it is safe to do so.
6.
The testing company shall have available sufficient protective barriers and
warning signs. The testing company shall place the protective barriers and
warning signs in close proximity to the area where testing is being
performed.
DEFINITION OF TESTS
A.
Preliminary Inspection and Tests: Visual inspections of electrical equipment, wire
checks of factory wiring and any other preliminary work required to prevent delays
during performance of electrical acceptance tests. Contractor or testing agency shall
verify connections shown on the One-Line Diagram.
B.
Electrical Startup Tests: Those inspections and tests required to show that the
workmanship, methods, inspections, and materials used in erection and installation of
the electrical equipment conforms to accepted engineering practices, IEEE
Standards, the National Electrical Code, manufacturers' instructions, and Electrical
Work of this Contract, and to determine that the equipment involved may be
energized for operational tests.
C.
Operating Tests: Those tests performed on all electrical equipment installed as part
of the Electrical Work of the Contract and under other sections of the Specifications,
to show that the electrical equipment will perform the functions for which it was
designed.
AUTHORIZED WITNESSES
A.
Perform all acceptance, startup and operating tests in the presence of the
Construction Manager or designated authorized witness.
B.
Notify vendors and manufacturers of electrical equipment of the time of tests and
extend reasonable cooperation to them or their representatives to permit them to
witness tests should they so request.
DATA TO BE RECORDED
A.
Maintain reproducible test data sheets showing results of tests described in the
accepted test procedures. Provide reproducible data sheets, listing acceptable or
specified test limits and values actually measured. Retain one copy of test data
sheets at the site. Furnish four copies to the Construction Manager. Retain one copy.
B.
Provide data sheets showing test set-up, equipment used, names of persons
performing test, names of witnesses, date, location, and serial number of equipment
December 2013
Technical Specifications
16960-6
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
under test. Test data sheets will be reviewed by the Construction Manager and
accepted as submitted, or additional tests may be required. If additional tests are
required because initial test results do not comply with Specifications, document the
re-testing and submit as before at no additional cost to NJ Transit.
1.09
ENVIRONMENT
A.
Do not perform megger or high potential tests during times of high relative humidity.
B.
Do not perform tests on outdoor equipment during inclement weather. Do not
perform tests on direct burial ground conductors or on ground rods within a 48-hour
period following rainfall.
During cable tests, station a man at each point where cable has exposed
connections.
C.
D.
1.10
Schedule sequence of tests so that equipment can be energized immediately after
completion of the applicable tests and approval of test reports. Notify the
Construction Manager of time of test at least 48 hours before testing.
GUARANTEE
A.
Tests shall not alter Contractor's guarantee of the equipment. Replace and retest
work and materials found to be in non-compliance with the Contract Documents at no
additional cost to NJ Transit.
PART 2 - PRODUCTS
NOT USED
PART 3 - EXECUTION
3.01
GENERAL TESTING REQUIREMENTS
A.
Perform preliminary inspections and tests immediately before performing startup
tests.
B.
Do not perform more than one high potential test on any conductor unless specifically
authorized by the Construction Manager.
C.
Megger Tests
1.
Megger readings specified are the minimum readings desired at an ambient
temperature of 60 degrees Fahrenheit and at a relative humidity of less than
60 percent. When megger readings are taken at other than 60 degrees
Fahrenheit, convert readings to equivalent values at 60 degrees Fahrenheit.
2.
When megger readings fall below the specified minimum values at 60
degrees Fahrenheit, devise some means of applying heat for drying out the
December 2013
Technical Specifications
16960-7
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
equipment subject to the approval of the Construction Manager. If drying is
to be done by applying an electric potential to a piece of equipment, do not
exceed the continuous voltage or current ratings of the equipment being
dried, directly or by induction.
D.
Continuity Tests: Perform continuity tests with a dc type device using a bell, buzzer,
or multi-meter. Do not use telephones for continuity tests; use telephones only for
communication.
E.
Restore all connections and equipment to operating conditions after testing has been
completed.
3.02
NOT USED
3.03
TESTS ON WIRE AND CABLES RATED 600 VOLT AND BELOW
A.
General: Give each 480 volt power feeder and branch circuit cable a continuity test
and a megger test. Verify phase identification our each power feeder and branch
circuit. Verify identification of all lighting circuits and branch circuits on panel
directories and make operational checks on all lighting circuits and branch circuits to
prove that the circuits perform all functions for which they are designed. Check all
power feeder and subfeeder cable connections for workmanship and conformance
with standard practice by visual inspection.
1.
Visual and mechanical inspection
a.
Cables shall be inspected for physical damage and proper
connection in accordance with single line diagram.
b.
Cable connections shall be torque tested to manufacturer's
recommended values.
B.
Connections: Isolate power cable to be megger tested by opening switches or
breakers at each end of cable before testing where such disconnecting means exists.
Where cables are direct connected without a disconnecting means, do not
disconnect cables: Test as connected.
C.
Megger Tests
1.
Use a 1,000-volt megger for each megger test. Insulation resistance tests
shall be performed at 1,000 volts dc for 30 seconds.
2.
Apply megger tests between each conductor and ground with the other two
conductors in the conduit or cable grounded to the same ground. Test each
conductor in the same manner.
3.
Minimum acceptable readings: For disconnected cables, 100 megohm.
December 2013
Technical Specifications
16960-8
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
4.
When insulation resistance is to be determined with all switchboards,
panelboards, fuse holders, switches, and overcurrent devices in place, the
insulation resistance when tested at 500 volts dc shall be no less than Table
3.03.1.
D.
Acceptance: Cable must pass all inspections and tests.
E.
Records: Include the following information in test report on each power and branch
circuit cable rated below 600 volts:
1.
Complete cable identification and description of isolation means.
2.
Megger readings, including converted values.
3.
Approximate average cable temperature.
Conductor or Circuit Size
No. 14 & No. 12 AWG
25-ampere circuits & above
3.04
Table 3.03.1
Minimum Insulation Resistance
Minimum Resistance
1,000,000-ohms
250,000-ohms
TESTS ON CONTROL WIRING
A.
General: Give each single conductor and multi-conductor control wire or cable a
continuity tests and an insulation strength test. Verify identification of conductors.
B.
Connections: Disconnect and fan out conductors to be tested.
C.
Insulation Strength Tests
1.
Subject each control wire to a 500 volt, 60-Hertz test.
2.
Apply test between each conductor in a wire group and ground with all other
conductors in the wire group grounded to the same ground. Use a test set
having an accurate means of insuring 500 volt test voltage and provide a
series resistance to limit fault when a ground is found. Hold test voltage only
long enough to read instruments. Test each conductor in the same manner.
3.
Instead of the above insulation strength test, megger each control wire as
specified for 480-volt power conductors.
D.
Acceptance: Wires must pass all tests.
E.
Records: Include the following information in test report on each wire group.
1.
Wire and group identification.
2.
Type of test, insulation strength or megger.
December 2013
Technical Specifications
16960-9
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.
When megger testing is selected, include information as specified for 480volt power cables.
3.05
NOT USED
3.06
NOT USED
3.07
TESTS ON UNIT SUBSTATION LOW VOLTAGE SECTIONS
A.
General: Check and test all ground connections per paragraph “Tests on Grounding”.
Give each drawout breaker and bus a megger test. Perform operational tests on low
voltage switchgear, relays, breakers, and control devices. Perform ratio and polarity
tests on all instrument transformers and give each potential transformer a megger test.
Give each current transformer secondary a megger test. Perform tests on relays,
overcurrent trip devices and ground fault relays per Section 3.16 herein.
B.
Connections
C.
1.
Before performing megger test on main bus, isolate bus to be tested by rackingout or opening all breakers, short and ground current transformer secondaries,
remove potential transformer primary fuses, and ground housing.
2.
Perform megger tests on drawout breakers in the withdrawn position.
3.
Check tightness of bolted joints by calibrated torque wrench method. Bus torque
values shall be in accordance with manufactures recommended values.
Megger Tests
5.
Apply megger tests on switchgear bus and drawout breakers between each phase
and ground with the other phases grounded to the same ground.
6.
Apply megger tests on potential transformers between each winding and ground with
windings not under test grounded to the same ground.
7.
Apply megger tests on current transformer secondaries and associated wiring
between all phases tie together and ground.
8.
Hold all 1,000-volt megger tests until the reading reaches a constant value and until
three consecutive equal readings one minute apart are obtained.
9.
Minimum acceptable megger readings and megger voltage are as follows:
December 2013
Technical Specifications
16960-10
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.08
Equipment
Megger Voltage
Main Buses
1,000
Minimum Megger
Reading
in Megohms
10
Drawout Breakers
Potential Transformer Primary Windings
Current & Potential Transformer
Windings
1,000
1,000
100
50
1,000
5
Secondary
TESTS ON TRANSFORMERS RATED 600 VOLTS AND BELOW
A.
General: Check continuity and correctness of connections of windings and give each
winding a megger test.
1.
Visual and mechanical inspection
a.
Inspect for physical damage.
b.
Compare equipment nameplate information with latest single line
diagram and report discrepancies to the Construction Manager.
c.
Verify proper auxiliary device operation for components including,
but not limited to, fans, indicators, and tap changer.
d.
Check tightness of accessible bolted electrical joints in accordance
with Table 3.06.1. Check hardware, bushings, and vibration mats.
e.
Perform specific inspections and mechanical tests in accordance
with the manufacturer's instructions.
B.
Connections: Isolate transformer by opening the line side circuit breaker and
disconnect secondary conductors at panels. Tie conductors together on each
winding.
C.
Megger Tests
1.
Use a 1,000-volt megger for megger tests on 480-volt windings and a 500volt megger for megger tests on lesser voltage windings. Appropriate guard
circuit shall be used under bushings.
2.
Apply a megger test between each transformer winding tied together and
ground. Ground all windings not included in the test to the same ground.
Winding resistance tests shall be made for each winding at nominal tap
position. Perform a megger test of the secondary windings.
3.
Minimum acceptable readings: 480 volt winding to ground, 45 megohms:
lesser voltage winding to ground, 30 megohms.
4.
Hold all megger tests for at least one minute or until the reading maintains a
December 2013
Technical Specifications
16960-11
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
constant value for 15 seconds.
D.
E
Electrical tests
1.
A dielectric absorption test shall be made winding-to-winding and winding to
ground for ten minutes. The polarization index shall be computed.
2.
A turns ratio test shall be performed between windings for all tap positions.
The final tap setting shall be determined and set by the testing company
upon completion of the ratio testing acceptable values.
3.
AC over-potential test shall be made on all high and low voltage winding to
ground.
4.
Individual exciting current tests shall be performed on each phase in
accordance with established procedure.
5.
Perform special test and adjustments in accordance with the manufacturer's
instructions for tap changer, fan and controls, and alarm functions.
6.
Perform a double power factor excitation test with a 10 kV tester.
7.
Perform a core ground test.
8.
Test temperature control panel and verify alarm stages and interlock for
shutdown.
Test Values
1.
2.
F.
Insulation resistance and absorption test voltage shall be in accordance with
Table 3.08.1. Results shall be temperature corrected.
The absorption test polarization index shall be above 2.0 unless an
extremely high value is obtained at the end of 1 minute, that when doubled
will not yield a meaningful value with the available test equipment.
3.
AC high potential test voltage shall not exceed 75 percent of factory test
voltage or Table 3.08.2 for a one-minute duration. Evaluation shall be on
go, no-go, basis; NEMA ST-20.
4.
Power factor test values more than 3-percent shall be investigated.
5.
Winding resistance test results shall compare within 1-percent of adjacent
windings.
6.
Turns ratio test results shall not deviate more than 0.50 percent from
calculated ratio
Acceptance: Transformers must pass all inspections and tests.
December 2013
Technical Specifications
16960-12
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
G.
Records: Make complete and accurate records of each test. Include the following in
each test report:
1.
Complete identification of transformer.
2.
Megger readings, including converted values and ambient temperature at
time of test.
Table 3.08.1 - Insulation Resistance Test Voltage
Voltage Rating (Volts)
Test Voltage (Volts)
150 - 600
1,000
601 – 5,000
2,500
Values of insulation resistance (IR) less than manufacturer's minimum or kV plus 1 in
megohms shall be investigated. Over-potential tests shall not proceed until IR levels
are raised to specified minimum.
3.
Over-potential test voltages shall be applied in accordance with ANSI
C37.20c, Table 3.13.2.
Table 3.08.2 - Overpotential Test Voltages
Test Voltage kV
Rated kV
AC
14.3
5
DC
20.2
Test results are evaluated on a go, no-go basis by slowly raising the test voltage to
the required value and applying the final test voltage for 1 minute.
Table 3.08.3 - Applied Potential Test Voltages
Nameplate Winding Voltage
Test Potential, kV
Rating, Volts
0 – 250
2.5
251 – 1,200
4
1,201 – 2,500
10
2,501 – 5,000
12
5,001 – 8,660
19
8,661 – 15,000
31
3.09
NOT USED
3.10
NOT USED
3.11
TESTS ON CIRCUIT BREAKERS, LOW VOLTAGE (AIR)
A.
Visual and mechanical inspection
1.
December 2013
Technical Specifications
Inspect for physical damage and nameplate compliance with single line
diagram.
16960-13
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
B.
C.
2.
Mechanical operational tests shall be made in accordance with
manufacturer's instructions.
3.
Cell fit and element alignment shall be checked. Check and verify cell code
types.
4.
Check tightness of connections.
Electrical Tests
1.
A contact resistance test shall be performed.
2.
An insulation resistance test shall be performed at 1000 volts dc for 1 minute
from pole to pole, and from each pole to ground, and across open contacts
of each phase.
3.
Minimum pickup current shall be determined by primary current injection.
4.
Long time delay shall be determined by primary injection at 300 percent pick
up current.
5.
Short time pickup and time delay shall be determined by primary injection of
current.
6.
Instantaneous pickup current shall be determined by primary injection.
7.
Trip unit reset characteristics shall be verified.
8.
Adjustments shall be made for final settings in accordance with the results of
the power system studies specified in Section 16010.
9.
Auxiliary protective devices including, but not limited to, ground fault or
under voltage relays, interlocks and automatic controls shall be activated to
insure operation of shunt trip devices.
10.
Perform a secondary inspection test using the integral test panel trip unit
through all the settings.
11.
Functional and continuity tests to power SCADA STB's.
Test Values
1.
Contact resistance shall be determined in micro-ohms. Values exceeding
200-micro-ohms or values that deviate from adjacent poles or similar
breakers by more than 50 percent shall be investigated.
2.
Insulation resistance shall not be less than 50 megohms.
3.
Minimum pickup current, trip times and instantaneous pickup values shall be
December 2013
Technical Specifications
16960-14
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
adjusted in accordance with the results of the power system studies specified
in Section 16010. Test values shall fall within manufacturer's published
time-current characteristic tolerance band.
3.12
TESTS ON CIRCUIT BREAKERS, LOW VOLTAGE (MOLDED CASE)
A.
B.
C.
Visual and mechanical inspection
1.
Circuit breakers shall be checked for proper mounting, conductor size, and
feeder designation.
2.
Operate circuit breakers to insure smooth operation.
3.
Inspect case for cracks and other defects.
4.
Check tightness of connection with torque wrench in accordance with
manufacturer's instructions.
Electrical tests
1.
Contact resistance shall be measured.
2.
Time-current characteristic tests shall be performed by passing 300 percent
rated current through each pole separately. Trip time shall be determined.
3.
Instantaneous pickup current shall be determined by run-up or pulse method.
Clearing times shall be within 4-cycles or less.
4.
Insulation resistance shall be determined pole to pole, across pole and pole
to ground. Test voltage shall be 1,000-volts DC.
Test Values
10.
Contact resistance shall be compared to adjacent poles and similar breaker.
Deviations of more than 50-percent shall be investigated.
11.
Insulation resistance shall not be less than 50 megohms.
12.
All trip times shall fall within Table 3.12.1. Circuit breakers exceeding
maximum 300-percent time (Column 5) shall be replaced.
December 2013
Technical Specifications
16960-15
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
13.
Instantaneous pickup current levels shall be within 20-percent of
manufacturer's published values
Voltage for Volts
Protection*
(1)
240
240
600
600
240
600
600
600
600
600
*
3.13
able 3.12.1 - Values for Overcurrent Trip Test
(at 300% of Rated Continuous Current of Breaker)
Tripping Time, Seconds
Range of Rated
Magnetic
Continuous
Breakers
Thermal
Current,
Minimum
Breakers
Amperes
(4)
(3)
(2)
15 - 45
3
--50 – 100
5
--15 – 45
5
5
50 – 100
5
5
110 – 225
10
5
110 – 225
10
--250 – 450
25
--500 – 600
25
10
700 – 1,200
25
10
1,400 – 2,500
25
10
Magnetic
Breakers
Maximum
(5)
50
70
80
150
200
200
250
250
450
600
Maximum
Tripping
Times
(6)
100
200
100
200
300
300
300
350
600
750
These values are based on heat tests conducted by circuit breaker
manufacturers on conductors in conduit.
TESTS ON PROTECTIVE RELAYS
A.
B.
Visual and mechanical inspection:
1.
Relays shall be inspected for physical damage and compliance with these
specifications.
2.
Inspect cover gasket, cover glass, presence of foreign material, moisture,
condition of spiral spring, disc clearance, rust and contacts.
3.
Check mechanically for freedom of movement, proper travel and alignment,
and tightness of mounting hardware and tap screws.
4.
All settings shall be determined by the results of the power systems studies
specified in Section 16010.
Electrical tests
1.
Perform insulation resistance test on each circuit branch to frame. Do not
perform this test on solid state relays.
2.
Perform the following tests on the nominal settings determined by the results
of the power system specified in Section 16010.
a.
b.
December 2013
Technical Specifications
Pickup parameters on each operating element.
Timing test shall be performed at three points on time dial curve.
16960-16
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.
3.14
c.
Pickup target and seal in units.
d.
Special test as required to check operation of restraint, directional
and other elements in accordance with the manufacturer's
instructions.
Perform phase angle and magnitude contribution tests on differential and
directional type relays after energization to vectorially prove proper polarity
and connection.
TESTS ON INSTRUMENT TRANSFORMERS
A.
B.
Visual and mechanical inspection
1.
Inspect for physical damage and compliance with the Drawings.
2.
Check mechanical clearances and proper operations of all disconnecting
and grounding devices associated with potential transformers.
3.
Verify proper operation of grounding or shorting devices.
Electrical tests
1.
Current transformers (CT) shall have secondary saturation tests done at a
minimum of three points below and one point above knee of saturation
curve.
2.
Confirm transformer polarity electrically.
3.
Burden tests shall be performed at the secondary leads of the CT to assure
accurate translation of primary current.
4.
Verify connection at secondary CT leads by driving a low current through the
leads and checking for this current at applicable devices.
5.
Confirm transformer ratio.
6.
Measure insulation resistance of transformer secondary and leads with 500
volt Megohm meter.
7.
Measure transformer primary insulation with applicable over-potential tests.
8.
Verify connection of secondary potential transformer (PT) leads by applying
a low voltage to the leads and checking for this voltage at applicable
devices.
9.
Check for PT secondary load with secondary voltage and current
measurements. Load shall less than voltage ampere capacity of the PT.
December 2013
Technical Specifications
16960-17
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.15
TESTS ON METERING AND INSTRUMENTATION
A.
B.
3.16
Visual and mechanical inspection
1.
Examine devices for broken parts, indication of shipping damage and wire
connection tightness.
2.
Verify meter connections in accordance with single line meter and relay
diagram.
Electrical Tests
1.
Calibrate all meters at mid scale. Calibration instrument precision shall be
50-percent or less than the precision of the instrument being tested. (If the
instrument being tested has a precision of plus or minus 10-percent, the
precision of the calibration instrument shall be plus or minus 5-percent or
better.)
2.
Calibrate watt-hour meters to 0.50-percent.
3.
Verify instrument multipliers.
TESTS ON GROUND FAULT SYSTEMS (NEC ARTICLE 230-95)
A.
Visual and mechanical inspection
1.
Inspect for physical damage and compliance with the Drawings and
specifications.
2.
Inspect neutral main bonding connection to assure:
a.
Zero sequence system is grounded upstream of sensor.
b.
Ground strap systems are grounded through sensing device.
c.
Ground connection is made ahead of neutral disconnect link.
3.
Inspect control power transformer to insure adequate capacity for system.
4.
Monitor panels shall be manually operated for:
a.
Trip test
b.
No trip test
c.
Non-automatic reset
Proper operation and test sequence shall be recorded.
5.
December 2013
Technical Specifications
Zero sequence systems shall be inspected for symmetrical alignment of
16960-18
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.
B.
C.
3.17
core balance transformers about all current carrying conductors.
5.
6.
Ground fault device circuit nameplate identification shall be verified by
device operation.
7.
Pickup and time delay settings shall be set in accordance with the results of
the power system studies specified in Section 16010
Electrical test
1.
System neutral insulation resistance shall be measured to insure no shunt
ground paths exist, neutral ground disconnect link shall be removed, neutral
insulation resistance measured and link replaced.
2.
The relay pickup current shall be determined by primary injection at the
sensor and the circuit-interrupting device operated.
3.
The relay timing shall be tested by injecting 150 percent and 300 percent of
pickup current into sensor. Total trip time shall be electrically monitored.
4.
System operation shall be tested at 55-percent rated voltage.
5.
Zone interlock systems shall be tested by simultaneous sensor current
injection and monitoring zone blocking function.
Test parameters
1.
System neutral insulation shall be a minimum of 1-megohm or greater.
2.
Relay pickup current shall be within 10-percent of device dial or fixed setting,
and in no case greater than 1,200-amperes.
3.
Relay timing shall be in accordance with manufacturer's published timecurrent characteristic curves, but in no case longer than 1-second.
TESTS ON GROUNDING SYSTEMS
A.
General: Inspect ground conductors, ground buses, and connections for conformance
with design specifications and for satisfactory workmanship. Test resistance to earth
of each ground rod. Test ground paths for equipment and structural steel or
reinforcing bar grounding.
1.
B.
Visual and mechanical inspection: Inspect ground system for compliance
with the Drawings and specifications.
Connections
1.
December 2013
Technical Specifications
Maintain each ground rod isolated from the associated ground rods for tests
16960-19
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
on individual rods for resistance to earth.
C.
2.
Include associated ground rods and interconnecting wiring in test for
resistance to earth.
3.
Include ground bus on equipment, room and pullbox connections, and
associated intermediate copper ground conductors in tests on ground paths
for electrical equipment.
4.
Include structural steel or reinforcing bar connection, rod connection and
intermediate conductor in tests on ground paths for structural steel or
reinforcing bars.
Electrical tests
1.
Perform fall of potential test in accordance with IEEE 81, Section 9.04, on
the main grounding electrode or system.
2.
Perform the two-point method test in accordance with IEEE 81, to determine
the ground resistance between the main grounding system and major
electrical equipment frames, system neutral, and/or derived neutral points.
a.
3.
D.
Alternate method: Perform ground continuity test between main
ground system and equipment frame, system neutral and/or derived
neutral point. This test shall be made by passing a minimum of 10
amperes DC current between ground reference system and the
ground point to be tested. Voltage drop shall be measured and
resistance calculated by voltage drop method.
Tests on Individual Ground Rods
a.
Test each ground rod for resistance to earth by a standard method.
Use a Biddle Ground Tester (AVO International) or the method of
using two auxiliary ground rods as described in IEEE. The IEEE
method requires the use of ac test current. Place auxiliary test rods
sufficiently far away from the rod under test so that the regions in
which their resistance is localized do not overlap. Calculate ground
resistance from the readings taken.
Maximum acceptable
resistance to earth: 2-ohms.
b.
If the resistance is found to be higher than 2-ohms, drive additional
rods with a minimum separation of 20-feet and connect in parallel
with the rod under test until 2-ohms or less is obtained, or increase
the length of the rod under test until 2-ohms maximum is obtained.
Tests on Ground Paths: Test ground paths for electrical equipment, structural steel or
reinforcing bars for continuity by applying a low voltage dc source of current, capable
of furnishing up to 100 amperes. The ground path for electrical equipment, structural
steel, or reinforcing bars must conduct 100 amperes. Resistance as calculated from
the current and voltage must not exceed 0.010 ohms.
December 2013
Technical Specifications
16960-20
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
E.
E.
F.
3.18
Acceptance: Grounding materials and connections must pass all inspections and
must meet all specified maximum and minimum values.
Records: Make complete records of all tests. Include resistance values obtained,
calculations of same, and methods of test and calculation.
TESTS ON MOTOR CONTROL CENTERS
A.
B.
Visual and mechanical inspection
1.
Inspect for physical damage, proper anchorage, and grounding.
2.
Compare equipment nameplate data with the Drawings or starter schedule.
3.
Compare overload heaters with motor full-load current for proper size.
4.
Check tightness of bolted connections.
Electrical test
1.
C.
Insulation tests
a.
Measure insulation resistance of each bus section phase-to-phase,
and phase to ground for one minute. Test voltage and minimum
acceptable values in accordance with Table 3.09.1.
b.
Measure insulation resistance of each starter section phase to
phase, and phase to ground with starter contacts closed and the
protective device open. Test voltage and minimum acceptable
values in accordance with Table 3.09.1.
c.
Measure insulation resistance of each control circuit with respect to
ground.
2.
Motor overload units shall be tested by injecting primary current through
overload unit and monitoring trip time.
3.
Perform operational tests by initiating control devices to affect proper
operation.
Test Values
1.
Bolt torque levels shall be in accordance with Table 3.06.1, unless otherwise
specified by the manufacturer.
2.
Insulation resistance test shall be performed in accordance with Table
3.12.1.
3.
Control wiring insulation test voltage shall be 500 volts dc. Manufacturer
December 2013
Technical Specifications
16960-21
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
4.
3.19
shall be consulted for test voltage where solid state control devices are
utilized.
Overload tests shall be made at 300-percent of motor full-load current. Trip
times shall be in accordance with manufacturer's tolerances. Values more
than 120 seconds shall be investigated.
TESTS ON ROTATING EQUIPMENT
A.
General: Inspect all motors installed under other divisions of the Specification for
damage, moisture, alignment, proper lubrication, oil leaks, phase identification and
cleanliness. Check for proper rotation. Coordinate uncoupling of motors where
reverse rotation would damage equipment. Perform a megger test on each motor.
1.
B.
C.
Visual and Mechanical Inspection
a.
Inspect for physical damage.
b.
Compare equipment nameplate information with single line diagram
and report discrepancy to the Construction Manager.
c.
Inspect for proper anchorage, mounting, grounding, and connection.
d.
Special tests as recommended by the manufacturer such as gap
spacing and pedestal alignment, shall be performed where
applicable.
Connections
1.
For three phase motors, include cable back to the open starter.
2.
For singe phase motors, disconnect motor from service.
Electrical Tests
1.
Large motors: A dielectric absorption test shall be performed on motor and
starter circuit. Polarization index shall be determined for motor winding.
2.
Small motors: A dielectric absorption test shall be performed on motor
winding. The 30/60-second ratio shall be determined.
3.
Perform insulation resistance test on pedestal in accordance with the
manufacturer's instructions, where applicable.
4.
A rotation test shall be performed to insure proper shaft direction.
5.
Measure no load and full load running current and compare to nameplate.
6.
Observe proper operation and sequence of reduced voltage starters.
7.
Large motors: Perform vibration baseline test. Amplitude shall be plotted
versus frequency. Submit plot.
December 2013
Technical Specifications
16960-22
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
8.
Small motors: Perform vibration amplitude test.
9.
Check protective devices in accordance with other Sections of these
specifications.
10.
Perform over-potential test on winding to ground.
11.
Megger Tests (Insulation Resistance Tests)
a.
Apply megger tests on three phase motors between all phases tied
together and ground, with motor at ambient temperature.
b.
For single-phase motors, apply megger test between phase and
neutral conductor tied together and ground, with motor at ambient
temperature.
c.
Hold all megger tests for one minute or until the reading maintains a
constant value for 15 seconds.
d.
Minimum acceptable megger readings and megger voltage are
listed below:
Equipment
460-volt, 3-phase induction motor
115-volt, 1-phase, induction motor
Voltage
1,000
500
Minimum Megger Reading
(Megohms)
20
5
D.
Operating Tests: Run motor long enough to prove satisfactory performance
including operating temperature, lubrication and vibration.
E.
Test Values
1.
Dielectric absorption tests shall be made in accordance with test voltage
listed in Table 3.08.1. Polarization tests shall be for a ten-minute duration.
Sixty/thirty second ratio tests shall be performed for a one-minute duration.
Polarization index readings less than three shall be investigated. Sixty/thirty
second ratio readings less than 1.4 shall be investigated.
2.
Motor measured full load current shall not exceed nameplate value.
3.
Over-potential test shall be made at 80-percent of twice-rated voltage plus
1,000 volts.
4.
Vibration amplitudes shall not exceed values shown in NEMA 7, Table
3.19.1.
Table 3.20.1 Maximum Allowable Vibration Amplitude
Speed, RPM
Amplitude, Inches Peak-to-Peak
3,000 & above
0.001
1,500 – 2,999
0.002
December 2013
Technical Specifications
16960-23
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
1,000 – 1,499
999 & below
3.20
0.0025
0.003
F.
Acceptance: Motor must pass all inspections and tests. All fan motors that are
reconnected to the new MCC replacements MCC V1A, V1B, V5 and V6, and reenergized, are to be thoroughly tested as part of the MCC and electrical
equipment tests. Other Newark Penn Loop fan units, as defined by and at the
discretion of the Engineer, will be included in these acceptance tests.
G.
Records: Make complete and accurate records of all test and inspections. Include
the following in each test report:
1.
Megger readings, including converted values.
2.
Ambient temperature at time of test.
TESTS ON CONTROL DEVICES
A.
General: Perform operating tests on all control, alarm, or indicating devices installed
under Mechanical and Electrical Work of this Contract.
B.
Connections
1.
Include motors and protective control devices in test circuitry where
operation of motors will not damage attached equipment.
2.
Where equipment could be damaged by energizing motors, disconnect
motor leads at the load side of starters.
3.
Jumper or disconnect, as applicable, control devices installed under other
divisions of the specifications as necessary to permit testing those devices
and circuitry installed under Electrical Work of this Contract
4.
Coordinate these connections and tests with Contractor responsible for the
installation of motors.
C.
Acceptance: Control devices and circuitry must pass all tests to prove that all design
functions are satisfactorily performed, including manual and automatic operation and
interlocking.
D.
Records: Make complete records of all tests.
3.21
NOT USED
3.22
NOT USED
3.23
TESTS ON PANELBOARDS
A.
Perform operational tests on each main and branch circuit breakers.
December 2013
Technical Specifications
16960-24
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
3.24
TESTS ON SPECIAL SERVICE SYSTEMS
A.
3.25
General: Perform complete operational tests on all special service systems to verify
that all design functions are performing in accordance with the Contract Documents.
Special service systems include:
1.
Fire Detection and Alarm Systems
2.
SCADA System Remote Terminal Units (RTU’s) and Interface with
Ventilation Control Center, and the Alternate Ventilation Control Center.
SYSTEM FUNCTION TESTS
A.
General
1.
Each system specified shall be function tested to confirm total system
operation.
2.
Upon completion of equipment tests, the system functional tests shall be
performed. System functional tests shall show the proper interaction of
sensing, processing, and action devices to affect the design end product or
results.
3.
Implementation
a.
3.26
The testing company shall develop a test matrix that includes, but is
not limited to, the following:
1)
Input signal or stimuli.
potential transformers.
Example: Current transformers;
2)
Decision process. Example: Pilot Wire Relay System
3)
Action device. Example: Circuit Breaker - OCB
4)
End product or result. Example: Zone Fault Protection
5)
SCADA System Indications and Controls
b.
All interlocks safety devices and fail-safe functions shall be tested in
addition to design function.
c.
The testing company shall propose methods to initiate the sensing
device by physical stimuli and quantitatively monitor the result or
output by measurement.
TRAINING
A.
Total of two (2) days of classroom and two (2) days of field training on the installed
ventilation system segment's maintenance and the integrated ventilation system
operation shall be provided .
B.
Classroom size shall not exceed ten (10) students.
16960-25
December 2013
Technical Specifications
Contract No. 14-017X
ELECTRICAL ACCEPTANCE AND START-UP TESTING AND
C.
Training material shall be delivered both in electronic format and as a hard copy.
Each student shall receive one set of training materials (electronic and hard copy);
five (5) additional training material sets shall be provided to NJT.
PART 4 – MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum
Price for all the work, labor and materials necessary therefore and incidental
thereto as shown on the Contract Drawings and described in the Specifications.
END OF SECTION 16960
December 2013
Technical Specifications
16960-26
Contract No. 14-017X
SECTION 17025
SAFETY AND SYSTEMS ASSURANCE
PART 1 - GENERAL
1.01
DESCRIPTION
A.
This Section specifies the descriptions of, and the general requirements for the
Contractor’s Safety & Systems Assurance Program, including system safety
engineering, reliability engineering, and maintainability engineering.
Requirements for human factors (human engineering) and quality assurance,
although not addressed directly herein, are integral parts of system assurance
and are to be considered in the development of the Systems Assurance Program
Plan (SAPP).
B.
Develop and implement the SAPP in accordance with the latest revision at time
of award of Contract of the following documents:
C.
MIL-STD-882D
System Safety Program Requirements.
MIL-STD-721B
Definitions of Effectiveness Terms for Reliability,
Maintainability, Human Factors and Safety.
MIL-HDBK-217E
Reliability Analysis Handbook
AFSC DH 1-6
Design Handbook - System Safety.
APTA START
Guideline for Preparation of System Committee Safety
Program Plans. DRAFT TASK-2
Objectives and Criteria:
1.
December 2013
Technical Specifications
The primary objective of the Systems Assurance Program shall be to
optimize the system safety, reliability, and maintainability characteristics
of the systems by:
a)
Defining major safety tasks and their place as an integral part of
the design, development and manufacturing process.
b)
Eliminating critical and catastrophic hazards.
c)
Providing a high degree of reliability.
d)
Minimizing downtime during maintenance and malfunctions.
e)
Evaluating the hardware and software through analysis, testing
and reviews.
f)
Providing proper training and technical publications.
17025-1
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
1.02
2.
A secondary objective of the Systems Assurance Program shall be to
minimize the magnitude and seriousness of those events or
malfunctions which could result in injury to patrons or personnel and
damage to equipment or property, but which cannot be completely
eliminated.
3.
Formulate and document criteria to satisfy the requirements for systems
assurance through the construction phase of the Contract.
D.
During design and installation of the systems, employ the objectives,
requirements, criteria, and methodology stated in the Systems Assurance
Program Plan to accomplish the goals of system safety.
E.
Apply scientific and engineering principles to identify and analyze potential
hazards and to recommend the necessary action to eliminate, control, or
minimize those hazards.
SUBMITTALS
All submittals shall be in accordance with the General Provisions for Construction.
A.
Submit a SAPP for approval and revise as necessary throughout the project.
B.
Submit the following system safety analyses for the project elements:
1.
Preliminary Hazard Analysis
2.
System Hazard Analysis
3.
Operating and Support Hazard Analysis
4.
Fault Hazard Analysis
5.
Quantitative analyses such as fault tree or logic network, as necessary.
C.
Submit the Safety Critical Items List (SCIL).
D.
Submit the Safety Test Plan, and schedule of data submittals and completion.
E.
Submit status reports of progress achieved in the areas of safety and systems
assurance based on the milestones in the SAPP.
F.
Submit an overall testing report of system safety test results. Include test data,
test log summaries, and corrective action recommendations. This report shall
be submitted prior to the final acceptance audit.
G.
Submit a Safety Certification Program for each project element. .
H.
Submit six (6) copies for each of the above items (A through G).
December 2013
Technical Specifications
17025-2
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
PART 2 - PRODUCTS
2.01
2.02
SYSTEMS ASSURANCE PROGRAM PLAN
A.
Produce a Systems Assurance Program Plan (SAPP) integrating the system
assurance elements in all phases of this Contract. Incorporate a disciplined
approach to evaluate all system designs regarding system safety, reliability and
maintainability, with the objective of prescribing corrective action in a timely and
cost effective manner.
B.
Organize the SAPP to include specific sections for the disciplines of system
safety, reliability, and maintainability.
C.
Describe the procedures to perform the specific tasks necessary to meet system
safety, reliability, and maintainability requirements.
D.
Clearly define the responsibilities and functions of personnel directly associated
with systems assurance policies and implementation of the program. Describe
the systems assurance organization. Identify and formally document authority
delegated to the systems assurance organization and the relationship between
that organization and all other organizational components.
E.
Identify systems assurance interface requirements between the systems and
other NJ Transit systems. These requirements include man/machine interfaces,
maintenance, training, rules, and procedures.
SYSTEM SAFETY PROGRAM PLAN (SSPP):
Include a detailed System Safety Program Plan (SSPP) as part of the SAPP, including:
A.
Task listing and time phasing of each safety task.
B.
Organization and responsibility of key personnel.
C.
Procedures to accomplish the system safety tasks, including provision to:
1.
Correct system safety deficiencies noted during the design phase as
soon as possible, but not later than system design acceptance.
2.
Evaluate system design and design changes.
3.
Conduct system safety analyses of each subsystem and their interface
areas.
4.
Take immediate corrective actions to prevent personal injury or system
damage when a Category I and/or Category II hazards are identified.
December 2013
Technical Specifications
17025-3
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
D.
E.
5.
Determine which Category III hazard conditions should be made
Category IV by modifications, giving precedence to those hazards with
the highest probability of occurrence and greatest impact on safety; and
whether the remaining are adequately controlled or minimized.
6.
Implement safety changes which are Contractor-initiated and reviewed
by the Project Construction Manager, and those initiated by the
Construction Manager which fall within the Contractor’s area of
responsibility.
7.
Coordinate the activities of the Contractor’s system safety program with
the overall system safety objectives established by NJ Transit.
System safety criteria shall be consistent with NJ Transit system safety design
criteria. Implement the approved criteria throughout all aspects of design
development, testing, delivery, installation, and maintenance. The criteria shall
include requirements for the following:
1.
Design Safety: Employment of system safety techniques that optimize
the design to minimize or control hazards identified by failure analyses.
Coordination with reliability, maintainability, and design engineers to
avoid potential hazards resulting from complexity of design.
Maintenance of standardization of design by utilization of proven
standards of the transit industry and applicable regulatory codes.
2.
Potential Failures: Assurance that a single point failure in a dynamic
system will not result in a critical or catastrophic hazard. Elimination or
minimization of the hazards by design, except in specific cases where
high reliability, fail-safe items may be used, based upon a properly
documented past history of low failure rate, if reviewed by the
Construction Manager after submission of the history of these items.
Control of potential failures of less than a critical classification through
use of safety devices and approved operating or maintenance
procedures.
3.
Redundancy: Incorporation of redundant circuits and components in a
coordinated system safety, reliability, and maintainability engineering
review to ascertain mutual agreement of system enhancement.
4.
Human Factors: Prevent/minimize human error(s) when responding to
field and operational conditions by eliminating conflicting or ambiguous
alarms and status indications; conflicting or ambiguous instructions;
lengthy or complicated instructions; inherent design errors/problems;
unclear or incomplete supporting hardware and software documentation.
A data collection and feedback system shall be used to establish requirements
for redesign, design changes, and corrective actions. Utilize a follow-up
procedure to verify results of completed action as follows:
December 2013
Technical Specifications
17025-4
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
F.
2.03
1.
During the early phases of system development, data shall include
hazards identified during various analyses.
Submit data to the
Construction Manager to inform of problems in design and hardware
development, and to facilitate early remedial action.
2.
In the latter stages of system development, and during installation,
indicate appropriate corrective action, and verify the requirements and
results of corrective action taken.
Training: Include information on system safety methods and procedures,
protective devices, and emergency equipment in training manuals and
procedures prepared.
RELIABILITY PROGRAM
A.
Prepare a description of the Contractor’s reliability program as part of the SAPP,
including:
1.
Organization and responsibilities of key personnel.
2.
Interfaces between reliability, maintainability, system safety, and other
closely related programs, and support to efforts such as:
a)
Logistic support and maintenance planning
b)
Design
c)
Quality assurance and quality control
d)
Standardization
e)
Systems engineering
f)
Personnel subsystem program (human engineering, life support,
training, and personnel resources)
g)
Translation specification requirements
3.
Provisions for closed loop data control system for collecting, analyzing
and recording failures occurring on the project.
4.
Provision for source selection, first article inspection, and surveillance of
Subcontractor’s reliability activities.
5.
Verification of compliances with specified requirements.
6.
Procedures and controls, including piece part selection and screening,
manufacturing process controls, procurement controls, and test
December 2013
Technical Specifications
17025-5
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
procedures, to be utilized during production to provide achievement of
reliability requirements.
2.04
Provisions to evaluate operational and design changes for possible
effects upon system reliability.
8.
Reliability engineering analyses and predictions in historical data.
MAINTAINABILITY PROGRAM
A.
2.05
7.
Prepare a description of the Contractor’s Maintainability Program as part of the
SAPP, including:
1.
The provisions of Article 2.03.A.1 through 2.03.A.8 inclusive herein.
2.
Provisions for early fault detection and rapid fault isolation to the proper
service level for minimization of costs and MTTR.
3.
Provisions for simplification of fault detection, isolation, and repair, to
minimize the skill levels and training requirements for maintenance
personnel by use of maintenance aids or test equipment.
4.
Provisions for accessibility for maintenance tasks.
5.
Provisions for reduction of the following:
complexity of the
maintenance, design-dictated maintenance activities and related costs,
maintenance down-time and effects on system operation, maintenance
costs, potential for maintenance error, and man/machine interface
problems.
6.
Provisions to evaluate operational and design changes for possible
effects upon maintainability requirements.
7.
Maintenance analysis performed on all defined maintenance tasks have
been defined.
SYSTEMS RELIABILITY DEMONSTRATION TEST
A reliability demonstration test shall be performed by the Contractor to show compliance
with the specified system reliability requirements. This shall be a fixed length test of one
year of operation and the specified reliability shall be demonostrated with a 90 percent
confidence or, as approved by the Construction Manager, a Probability Ratio Sequential
Test Plan III-D with a true consumer and producer risks of 12.8 percent and
discrimination ratio of 2.0, in general accordance with MIL-STD-781D and MIL-HDBK781 requirements. NJ Transit will operate and maintain the system according to
procedures described in the approved Contractor documentation.
December 2013
Technical Specifications
17025-6
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
Prior to initiating reliability tests, all equipment shall accumulate 200 operating hours.
Failures occurring during this period shall not be chargeable to the demonstration tests,
but shall, however, be properly documented.
All decisions to accept or reject the subsystems shall be based upon actual operation
experience, or performance under conditions like those under which the equipment will
be required to operate throughout its lifetime. The Contractor may submit for the
Construction Manger’s approval a plan for accelerating the test through increased
equipment operating cycles and stress under simulated revenue service conditions.
Subject to the Construction Manager’s approval, certain cycle equipment may be
operated at increased cycles and stress to simulate increased operational activity, thus
reducing the test duration appropriately. The test logs maintained by the Construction
Manager and the Contractor shall be analyzed on a daily basis and summarized on a
weekly basis to provide:
A.
Total accumulated operating time per equipment type.
B.
Total accumulated chargeable failures per equipment type with details of each
failure.
C.
Total accumulated repair and restore time for the chargeable failures.
The demonstration test shall be conducted in an environment representative of the
anticipated operational conditions, including traffic, operating modes, temperatures,
electromagnetic interference, shock, and vibration. Increased cycles or equipment
stress may be factored to achieve test acceleration.
If the subsystems/equipment do not meet the specified requirements, the Contractor
shall be required to make the necessary corrections so that the specified reliability
requirements are met.
The Contractor shall maintain a failure summary record which contains all the
information necessary to calculate the reliability values of the subsystems, and
equipments to verify the successful demonstration of the reliability requirements. The
failure record shall be available for review by the Construction Manager.
A failure review board composed of one person designated by the Contractor and one
person designated by the Construction Manager, and others as may be designated by
the Construction Manager, shall resolve by consensus questions regarding failure
events, downtime, and any changes to the demonstration plan. In instances where
mutual agreement cannot be reached, the Construction Manager’s position shall prevail.
2.06
SYSTEM SAFETY ANALYSES
A.
Definitions:
1.
December 2013
Technical Specifications
Hazard Category I - Catastrophic: Operating conditions such that
personnel error, environment, design deficiencies, subsystem or
17025-7
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
component failure, or procedural deficiencies may cause death or
system loss.
B.
2.
Hazard Category II - Critical: Operating conditions such that personnel
error, environment, design deficiencies, subsystem or component
failure, or procedural deficiencies may cause severe injury to personnel,
severe occupational illness, or major system damage.
3.
Hazard Category III - Marginal:
Operating conditions such that
personnel error, environment, design deficiencies, subsystem or
component failure, or procedural deficiencies may cause minor injury,
minor occupational illness, or minor system damage.
4.
Hazard Category IV - Negligible: Operating conditions such that
personnel error, environment, design deficiencies, subsystem or
component failure, or procedural deficiencies will not result in injury to
personnel, occupational illness, or system damage.
Perform safety analyses to identify potentially hazardous conditions. Perform
and document quantitative analyses as required to ascertain adequate safety
consideration. Apply system safety analyses to:
1.
Evaluate alternatives.
2.
Evaluate and verify safety requirements of the signal system.
3.
Evaluate
the
requirements.
4.
Provide visibility of relative safety and risk within system components.
operation/emergency
procedures
and
training
C.
Perform analyses of subsystems and potential hazard areas of the system.
D.
In performing the required analyses, the depth of detail shall be dictated by
hardware components incorporated in the final design, identified critical items,
and unresolved potential failures of critical or greater hazard severity. The
following types of analyses shall be utilized:
1.
Preliminary Hazard Analysis (PHA)
2.
System Hazard Analysis (SHA)
3.
Operating & Support Hazard Analysis (O&SHA)
4.
Failure Mode, Effects and Criticality Analysis (FMECA)
5.
Fault Hazard Analysis (FHA)
6.
Quantitative analyses such as fault tree or logic network.
December 2013
Technical Specifications
17025-8
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
7.
2.07
Critical/Catastrophic Items List (CCIL)
E.
The analyses shall be documented in an approved format.
F.
Maintain a compilation of safety-critical items identified during system safety
analyses.
The format shall be reviewed by the Construction Manager.
Document for approval any rationale in lieu of corrective action. Conduct a
special review of unresolved critical items with the Construction Manager.
G.
Existing analyses and data that are properly documented and verifiable and that
present the material in a neat, concise and logical manner may be submitted for
identical or manifestly similar equipment and applications.
H.
Eliminate all identified Category I (catastrophic) hazards by redesign or other
corrective action.
I.
Eliminate or control all identified Category II (critical) hazards and submit
documentation of the methods used.
SAFETY TEST AND VERIFICATION PLAN
Verify that design safety requirements have been met. A combination of analytical and
test methods shall be considered. Integrate safety tests into the appropriate test plans
developed in accordance with other Sections.
A.
Where complete safety testing in an operational environment is not feasible or
could cause system damage, demonstrate and verify safety characteristics in
design and procedures by laboratory tests, functional mock-ups, or failure
simulation. Use induced or simulated failures to demonstrate an acceptable
degree of safety for the failure modes identified as critical by the Contractor’s
safety analyses. Acceptable safety shall be a controllable Category III hazard.
B.
Verify, by analytical means, failure modes, identified during analyses, that were
resolved by rational or operating/emergency procedures.
C.
The Contractor shall submit a list for specific safety verifications items for each
system. A hardware/circuit/software system matrix shall be reviewed to show
program/project plan relationships of all safety tests and status.
D.
The detailed test plans for all tests shall be reviewed to ascertain that:
1.
Safety is adequately demonstrated.
2.
Testing will be carried out in a safe manner.
3.
Any additional hazard introduced by testing procedures, instrumentation,
and test hardware is properly identified and minimized.
4.
Include provisions for compiling all safety verification data on simulation
and testing into the systems testing report. Include the results of failure
December 2013
Technical Specifications
17025-9
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
documentation. Maintain documentation throughout the program as
evidence of proper safety in system design, installation, and operation.
2.08
SAFETY CERTIFICATION PROGRAM
A.
The Contractor shall prepare a Safety Requirements Checklist for each safetycritical system element to certify that all safety requirements have been effected
in the design, construction, installation and test phases of that element, in
accordance with all applicable Technical Specifications of the Contract.
B.
The Contractor shall submit for review by the Construction Manager, the Safety
Requirements Checklist as required for all system locations.
C.
Each of the Safety Requirements Checklist Items shall be signed and dated by
the Contractor’s Representative to certify that the required certification tests,
inspections, and analyses have been successfully completed.
Safety Requirements Checklists shall be the basis upon which the Contractor
demonstrates the systems readiness for, and compliance with certification
requirements. The Contractor shall prepare these checklists consistent with the
outline and level of detail of the checklists provided as a sample in the
Appendix.
D.
The Contractor shall be responsive to the requirements of the State of New
Jersey, Department of Transportation, State Oversight Agency, Fixed Guideway
Program Standards, as it applies to their particular area of Work. The
Contractor shall identify and document design decisions regarding safety, fire/life
safety and security, and provide evidence of such documentation. The
Contractor shall identify each safety certifiable system element, and implement
a program to sufficiently formalize the compliance with the mandatory
requirements of the Technical Specifications.
PART 3 - EXECUTION
3.01
PROGRAM PLAN
Implement and maintain the various aspects of the SAPP during the design and
installation phases of the Contract.
3.02
SYSTEM SAFETY ANALYSES
Perform safety analyses, as specified, during the design phase of the Contract.
3.03
COORDINATION
A.
Design Impact: Closely coordinate the systems assurance program and results
of system safety analyses with design disciplines, particularly where the results
affect design and hardware development. Make recommendations for redesign
or modifications to ascertain compliance with specified requirements including,
December 2013
Technical Specifications
17025-10
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
as required, installation of test points and built-in test capabilities, installation of
in-service status display indicators to facilitate fault isolation and testing, the
utilization of high reliability parts with easy accessibility and quick disconnect
connectors, and the use of mechanical keying to reduce errors during
installation.
3.04
B.
Design Problems: Document instances where evaluation or analyses indicate an
unresolved problem area, and formulate appropriate recommendations.
Maintain records documenting that follow-up action has been taken to resolve
the problem.
C.
Design Reviews: Ascertain participation by the system assurance organization
in all design reviews.
RECORDS MANAGEMENT
Maintain documentation of systems assurance throughout the design. Documentation
shall be available for examination by the Construction Manager.
3.05
DESIGN
During consideration of precedence in the control of system hazards, take cognizance of
human limitations as a design constraint. Take actions to satisfy requirements in the
following order of precedence
A.
Design or redesign for minimum hazards, reducing or minimizing the probability
that the system will enter a hazardous mode. Give consideration to the
following:
1.
Incorporation of fail-safe features to cause the system to transfer from a
high loss or risk mode to a lower loss or risk mode upon the occurrence
of a critical failure.
2.
Reduction of the probability of occurrence of a failure by increased
component reliability, or by provision of redundant components.
B.
Use safety devices to reduce the magnitude of the loss or risk once a hazardous
mode has been entered. Ascertain, however, that the safety device does not
introduce an additional hazard or system malfunction.
C.
Use warning devices and systems that are audio/visual portions of fail-safe
systems in which the human is the responder.
D.
Recommend special equipment operating procedures to reduce the probability
of a hazardous event and provide for a training program. Recommend the level
of training required based on the complexity of the task and minimum trainee
qualifications required.
December 2013
Technical Specifications
17025-11
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
PART 4 - PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum
Price for all the work, labor and materials necessary therefore and incidental
thereto as shown on the Contract Drawings and described in the Technical
Provisions.
December 2013
Technical Specifications
17025-12
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
APPENDIX
December 2013
Technical Specifications
17025-13
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
CERTIFIABLE
ELEMENT:
Item
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
TUNNEL & EMERGENCY
VENTILATION SYSTEM
TECHNICAL REQUIREMENTS
NERL PROJECT
SELF-CERTIFICATION
PROGRAM
CONFORMANCE CHECKLIST
DATE: __/__/__
___
SAFETY:
______________________ DATE:
__/__/__
Spec. or
Drawing No.
SECURITY:
Reference
Document
PAGE ____ OF
VERIFICATION APPROVAL:
Status
VERIFICATION
Date
Design
Verified
Constr.
Engineering Manager shall verify that the tunnel is
designed to conform to design specifications and
applicable codes and standards.
Construction Manager shall verify that the tunnel is
constructed according to the design drawings and
specifications.
Engineering Manager shall verify all Operation and
Maintenance Manuals are provided for all installed
equipment and systems.
Site work
Verify demolition conducted in accordance with an
approved Demolition Plan.
Verify demolition conducted in accordance with Safety
Requirements for Demolition, ANSI A10.6.
Verify protection of Persons, Property, and the
Protection of Utilities during all demolition work.
Verify the control of water and safety of excavations at
all times.
Verify Site Conditions are maintained to prevent erosion,
and control dust and dirt.
Construction Manager shall verify plans and methods of
protecting the Railroad during performance of his Work.
December 2013
Technical Specifications
17025-14
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
CERTIFIABLE
ELEMENT:
Item
No.
10.
11.
12.
13.
14.
15.
16.
17.
18.
TUNNEL & EMERGENCY
VENTILATION SYSTEM
TECHNICAL REQUIREMENTS
NERL PROJECT
SELF-CERTIFICATION
PROGRAM
CONFORMANCE CHECKLIST
DATE: __/__/__
___
SAFETY:
SECURITY:
______________________ DATE: __/__/__
Spec. or
Drawing No.
Reference
Document
PAGE
____
VERIFICATION APPROVAL:
Status
VERIFICATION
Date
Design
Verified
Constr.
Formwork
Field verify concrete mix meets design requirements.
Field verify all materials and finishes meets design
requirements and construction standards.
METALS
Field verify all welding is performed by certified
welders including a review of welders qualifications
Perform inspections and tests of all welding in
accordance with ANSI/AWS D1.1, as required.
Construction Manager shall perform inspection and
tests on a random sample of welds.
Field verify structural steel meets design
requirements.
Field verify fabrication and installed work is
performed by qualified personnel.
Field verify all measurements necessary before
fabrication.
Thermal and Moisture Protection
Field verify thermal and moisture protection meets
design requirements.
December 2013
Technical Specifications
17025-15
OF
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
RTIFIABLE
ELEMENT:
Item
No.
19.
20.
21.
22.
23.
24.
25.
26.
27.
TUNNEL & EMERGENCY
VENTILATION SYSTEM
TECHNICAL REQUIREMENTS
NERL PROJECT
SELF-CERTIFICATION
PROGRAM
CONFORMANCE CHECKLIST
DATE: __/__/__
___
SAFETY:
SECURITY:
______________________ DATE: __/__/__
Spec. or
Drawing No.
Reference
Document
PAGE
____
VERIFICATION APPROVAL:
Status
VERIFICATION
Date
Design
Verified
Constr.
Special Construction
Verify Seismic Anchoring and Vibration Isolation
requirements for Mechanical and Electrical
Equipment are properly implemented.
Field verify SCADA Systems meet design
requirements for Mechanical and Electrical Systems.
Field verify SCADA Systems are installed, tested, and
function in accordance with operational requirements.
Construction Manager shall verify all Subcontractor
provided SCADA Equipment meets design and
performance requirements established for SCADA
System.
Field verify Dry Sprinkler Systems meet design
requirements.
Field verify Dry Sprinkler Systems are installed,
tested, and function in accordance with operational
requirements.
Mechanical
Verify all Mechanical work is performed in accordance
with applicable codes and standards.
Field verify the protection available during the
conduct of all Mechanical Work.
Verify Tunnel Ventilation Fans meet design
requirements.
December 2013
Technical Specifications
17025-16
OF
Contract No. 14-017X
SAFETY AND SYSTEMS ASSURANCE
CERTIFIABLE
ELEMENT:
Item
No.
TUNNEL & EMERGENCY
VENTILATION SYSTEM
TECHNICAL REQUIREMENTS
NERL PROJECT
SELF-CERTIFICATION
PROGRAM
CONFORMANCE CHECKLIST
DATE: __/__/__
___
SAFETY:
______________________ DATE: __/__/__
Spec. or
Drawing
No.
SECURITY:
Reference
Document
PAGE
____
OF
VERIFICATION APPROVAL:
Status
VERIFICATION
Date
Design
Verified
Constr.
Mechanical
Field verify Tunnel Ventilation Fans are furnished,
installed and tested to meet operational requirements.
Verify Tunnel Ventilation Fans are furnished with
29.
operational and maintenance instructions and any
other information relative to permit safe operations.
Construction Manager shall verify Tunnel Ventilation
30.
Fans meet all performance requirements
Electrical
31.
Verify operational and maintenance manuals are
provided for all equipment and systems involved in
Electrical work.
Verify Power System Studies and Tests are
32.
performed to ensure safe integration and operation of
equipment.
Verify testing of electrical systems to ensure they
33.
meet performance criteria.
Verify safeguards are in place and cautionary signage
34.
posted in designated equipment areas.
Verify required training is made available to NJ
35.
Transit Maintenance and Operations Personnel, as
required.
Construction Manager shall witness inspections and
36.
test and verify Start-Up Testing and Training is
complete prior to acceptance of the Electrical System.
Design Elements shall be verified by Project Engineering. Construction Elements shall be verified by Construction Management
December 2013
Contract No. 14-017X
17025-17
28.
Technical Specifications
SAFETY AND SYSTEMS ASSURANCE
END OF SECTION 17025
December 2013
Technical Specifications
17025-18
Contract No. 14-017X
SECTION 17035
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
PART 1 - GENERAL
1.01
DESCRIPTION
A.
The primary objectives are to provide a high degree of reliability and minimize
downtime during maintenance and malfunctions. This section covers the
reliability, maintainability, and dependability of Project elements, subsystems
and assemblies and defines the system assurance goals that will be used to
measure the effectiveness of the Contractor’s efforts.
The following general design concepts shall be incorporated to maximize
systems assurance:
1.
Use of standard, proven designs
2.
Use of interchangeable, modular components
3.
Extensive and prominent labeling of parts and wires
4.
Use of unique serial numbers for traceability of components
5.
Use of simplified tier numbering of systems, and corresponding
components for easy reliability calculations
6.
Use of standard, prewired harnesses instead of wiring performed
individually in cramped quarters
7.
Use of weatherproof seals and latches that promote access, while at the
same time, preventing intrusion of the elements.
In achieving compliance, the Contractor shall recognize the inherent
interrelationship and inseparability of reliability, maintainability, and safety
(RM&S) principles and methods in many aspects of analysis, design, test,
demonstration, and failure correction. The Contractor shall consider RM&S
requirements and criteria as an integrated whole.
In addressing a problem of noncompliance with a given requirement, the
Contractor shall employ an integrated RM&S approach to corrective action. This
shall recognize that while there may be separate reliability and maintainability
actions that could each solve the problem, either action might impact safety. In
any such situation, the Contractor shall not, without NJ Transit approval, assume
that the problem must be solved only by reliability action or maintainability
action.
B.
The Contractor shall establish Reliability and Maintainability (R/M) Programs.
These programs shall be planned, integrated and developed in conjunction with
design and production functions to provide that the overall system operates
December 2013
Technical Specifications
17035-1
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
dependably and economically.
shall include:
C.
1.02
The Reliability and Maintainability programs
1.
Pre-delivery prediction of systems reliability and maintainability.
2.
Field reliability and maintainability monitoring and analysis and
implementation of corrective measures.
3.
Application of management controls directed toward maintaining the
reliability and maintainability inherent in each system.
4.
Provision of information for further N J Transit use regarding systems
failures, their effects and their frequencies.
5.
Post-delivery verification of each system reliability and maintainability.
The equipment and subsystems included in the analysis shall be provided by the
Contractor and agreed by N J Transit. The Contractor shall provide detailed
reliability and maintainability information on all major systems and subsystems
provided within the scope of this contract.
DEFINITIONS
The following definitions apply specifically to terms used in this Section. Meanings of
terms not defined herein are in accordance with the definition in MIL-STD-721 and the
latest edition of “Rapid Transit Systems Glossary of Reliability, Availability, and
Maintainability Terminology,” as prepared by the American Public Transit Association,
Washington, DC.
A.
Mean Time Between Failures (MTBF)
The average time that an equipment will operate without a chargeable failure:
MTBF =
B.
operating time
number of chargeable failures
Importance Index (I.I.)
A factor used to convert the MTBF of all line items (as identified by the
Contractor and agreed by N J Transit) to a common base for the purpose of
trade-off analysis. The following factors are considered in selecting the value of
the I.I. for each line item:
1.
Impact of failures in this line item on system operation.
2.
Repair time required per failure.
3.
Estimated quality used in system.
December 2013
Technical Specifications
17035-2
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
C.
Mean Time to Restore (MTTR)
The average active repair time required to perform all the tasks associated with
a complete corrective maintenance action. This includes the times to isolate the
fault, obtain access, remove and repair/replace defective components or parts,
perform required adjustments, perform tests to see that the fault has been
corrected, and replace all removed parts, covers, seals, etc. Active repair time
does not include maintenance team travel time, time to transport failed
components to the site, time waiting for parts, personnel, or space, etc. MTTR is
a measure of the maintainability of the design and equipment. The time
required to locate and repair dependent (non-chargeable) failures shall be
included in the total restore time.
MTTR =
restore time accumulated
number of chargeable failures
All MTTR estimates shall assume the following:
D.
1.
Troubleshooting and repair will be performed by a qualified, certified
professional electrician, or by a high school graduate who has two years
of technical school training and one year of experience and has at
his/her disposal all of the Contractor’s printed maintenance literature.
2.
All spare part quantities and test equipment, as mutually agreed
between the Contractor and the Construction Manager shall be available
and in a state of readiness.
Failure
Any malfunction or fault that prevents or limits equipment from performing its
function in accordance with these Technical Provisions.
1.
Failure Rate
The reciprocal of MTBF. For this reliability assessment program, the
failure rate is assumed to be constant throughout the life of the
equipment.
2.
Independent Failures
A failure that will independently cause equipment performance outside
of specified limits -- one which occurs without being related to the failure
of the associated items.
3.
Dependent Failure
A failure of part that is a direct result of an independent failure - one
caused by the failure of an associated item (2). Dependent failures are
not chargeable failures.
December 2013
Technical Specifications
17035-3
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
4.
Simultaneous Failures
In the event that simultaneous, or multiple independent failures occur,
each failure that will independently prevent satisfactory equipment
performance shall be counted as an equipment failure.
5.
Chargeable Failure (m)
All failures requiring repair or replacement of a component or part are
chargeable unless specified otherwise herein, or unless determined by
the Construction Manager to be caused by a condition external to the
equipment under test. Failure due to workmanship deficiencies shall be
counted as chargeable. Also, transient conditions that temporarily
prevent a function from being successfully performed shall be counted
as chargeable failures, unless it is shown that they are the result of
external influences beyond the requirements of these specifications.
6.
Non-Chargeable Failures
Failures proven to be the result of conditions exceeding those specified,
(e.g., floods, derailments, vandalism, human error not normally
protected against, etc.), shall be classed as non-chargeable and shall
not be included in the reliability evaluation. Failure of parts installed by
others (such as insulated joints, rails, normal and reserve ac power
sources, etc.) that cause a dependent failure of the Contractor’s
equipment shall not be included in the reliability evaluation.
1.03
SUBMITTALS
A.
Reliability Program
The Contractor shall submit a proposed Reliability Assessment Program for
review. The program shall include the following:
1.
Organization and responsibilities of the proposed reliability effort.
2.
Details of the design and component selection and screening processes
proposed to be used to meet the reliability requirements.
3.
Details of the procedures proposed to be used to calculate MTBF and
MTTR predictions.
4.
Identification of sources proposed to be used for component reliability
data.
5.
Proposed serialized type forms and reports, including preventive
maintenance and discrepancy reports.
December 2013
Technical Specifications
17035-4
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
B.
Maintainability Program
The Contractor shall submit a proposed Maintainability Assessment Program for
review. The program shall include the following:
C.
1.
Task listing and time phasing for each task.
2.
Organization and responsibilities of key personnel.
3.
Internal procedures and controls for implementing the maintainability
program.
4.
Interfaces with, and support to, reliability, system safety, and other
closely related programs, and support to system design effort as a
whole.
5.
Methods for ascertaining that Subcontractor’s and Suppliers’
maintainability efforts are consistent with overall system requirements.
6.
Descriptions of maintainability analyses to be used during design and
development for estimating maintenance resource requirements, and for
demonstrating compliance with the maintainability requirements.
7.
Provisions that features for accessibility, early fault detection, rapid fault
isolation to the proper service level, and simplification of fault
detection/isolation/repair tasks, are incorporated in the design.
8.
Provisions to evaluate operational and design changes for possible
effects upon maintainability requirements.
9.
Provision of a plan for formal verification of compliance with
maintainability requirements.
Predicted Reliability Reports
1.
The Contractor shall provide a list of major systems and sub-systems
together with predicted reliability values as part of the tender package.
The Contractor shall supply sufficient supporting information to allow
review of the predicted values as part of the tender evaluation process.
2.
Within 60 days after award of the Contract, a reliability study shall be
made and a report showing the predicted reliability for each subsystem
shall be forwarded to the Construction Manager. If areas of common
failure appear inherent in the design or equipment specified, an alternate
design or equipment change shall be proposed to the Construction
Manager. This document shall be approved by NJ Transit.
December 2013
Technical Specifications
17035-5
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
3.
The approved subsystem reliability calculations shall be used as
requirements for the reliability demonstration test. Additionally, the
reliability study will assure at the design stage that the MTBF
requirements will be achieved and potential sources of unreliability in the
design are identified and corrected.
4.
A Basic Reliability model shall be used to calculate the MTBF for all
equipment. In the basic model, the elements of an item are modeled in
series, regardless of redundancy or alternate modes of operation. The
basic reliability model estimates the demand for maintenance and
logistic support. The failure rates for the equipment of each subsystem
shall be obtained from historical performance wherever possible. When
historical performance data is not available, equipment failure rates shall
be calculated using MIL-HDBK-217 or obtained from NPRD (Nonelectronic Parts Reliability Data) published by the Reliability Analysis
Center (RAC). The Contractor may use other standards, handbooks, and
sources with Authority approval
When possible, the reliability calculations shall be based on historical
performance of like equipment in an application and environment similar
to that of the Project. As a minimum, the historical performance
reliability calculations shall identify the following:
December 2013
Technical Specifications
a.
Equipment identification by Lowest Line Replaceable Unit
(LLRU) part number.
b.
Prior application and environment.
c.
Precise design use of LLRU in the Project.
d.
Description of modifications since accumulation of prior use
data.
e.
Adjustment factors and related reasons used to modify historical
data to Project equivalent performance. Adjustments shall
consider differences in application including level of use and
duty cycle, environment, and modification as a minimum.
f.
Location and date of use.
g.
Number of individual LLRUs in use.
h.
Number of hours of use per unit and total.
i.
Number of failures experienced during the operating hours for
which the analyses is presented.
j.
Calculated subsystem and equipment level MTBF.
17035-6
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
5.
D.
Whenever deviations of the predicted reliabilities are encountered
during design (i.e., prior to production), an updated reliability report shall
be forwarded to the Construction Manager. If these reports indicate a
marked decrease in predicted reliability, the Construction Manager may
require an alternative design or equipment change to increase the
predicted reliability to at least that level identified in the proposal.
Reliability Testing Procedures
Review of detailed test procedures shall be obtained from the Construction
Manager before field reliability assessment testing begins. The test procedures
shall include the following details:
E.
1.
A listing of components, by description, part number, and quantity
comprising each line item in the Table of Reliability Goals.
2.
Test equipment to be used.
3.
Method for monitoring test equipment.
4.
Graphic sample presentation of the test plan and table to be used.
5.
Burn-in (debugging) time.
6.
Performance parameters to be measured.
7.
Performance limits beyond which a failure has occurred.
8.
Sample of report and log forms to be used.
Monthly Assessment Reports
The Contractor shall submit a monthly Reliability Assessment Report
comparing field reliability testing results with accept-reject criteria for
each line item in the Table of Reliability Requirements.
F.
Final Documentation
Upon completion of specified reliability testing, the Contractor shall submit a
final Reliability Assessment Report.
G.
Maintenance Concept Report
1.
The Contractor shall submit a Maintenance Concept Report defining the
repair, corrective, and preventive maintenance program plans, policies,
and support requirements for all equipment supplied under this Contract.
The report shall include, but not be limited to the following requirements:
a)
December 2013
Technical Specifications
Minimize each level of maintenance consistent with costs of any
system reliability/maintainability requirements.
17035-7
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
2.
b)
Be fully responsive to the operating concept, duty cycles, and
the design requirements of the system.
c)
Provide recommendations for all maintenance engineering,
plans and procedures, facilities planning, maintenance tools and
equipment selection, maintenance staffing, logistic support
planning, and related system objectives.
d)
Recommend policies and practices to provide that, at the time of
a failure, qualified maintenance personnel will be available, will
be promptly notified, will be strategically located to minimize
travel time, and will have the necessary documentation, tools,
test equipment and spare parts to effect the repair in a minimum
of time within the limits of reasonable cost/benefit
considerations.
The Contractor shall implement a maintainability program of sufficient
depth and scope to assure attainment of and demonstrate compliance
with all applicable maintainability requirements. Features shall be
incorporated into the design of Project elements to minimize the MTTR
and preventive maintenance time. The subsystems and components
shall incorporate the following design features:
Accessibility: All routinely serviced subsystems and components shall be
readily accessible for service and inspection. Accessibility of
components shall be proportional to frequency of maintenance and
repair. No active electrical or mechanical components that can
foreseeably require maintenance shall be structurally embedded to
preclude convenient access for repair or replacement.
Modular Design: Modular design principles shall be employed to the
greatest extent practicable. Components shall be packaged together in
replaceable subassemblies according to the logical function that they
perform. Components or subassemblies requiring occasional removal
shall preferably be plug-in units.
Interchangeability: Assemblies or components that are functionally
interchangeable shall be physically interchangeable. Assemblies or
components that are not functionally interchangeable shall not be
physically interchangeable.
Adjustments: The need for adjustments shall be avoided. Where
adjustment points cannot be avoided, they shall be readily accessible,
adequately identified, and self-locking to prevent inadvertent adjustment
or drift.
Special Tools: The number of special tools required for maintenance
and repair shall be minimized. However, if they are required, they shall
be defined and furnished in a quantity determined as part of the Work of
this Contract.
December 2013
Technical Specifications
17035-8
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
Panels and Openings: Panels and openings shall be of sufficient
quantity, size, and placement to permit ready access from normal work
areas and positions. Adjustment controls, fittings, safety valves, and
such, shall be directly accessible through panels and openings. Selfretaining fasteners shall be used wherever possible. Special access
opening tools shall not be used unless considered necessary to prevent
vandalism.
Cable Connections: Cable connectors shall be spaced far enough apart
so that they can be grasped firmly for connecting and disconnecting.
Connectors shall be properly labeled and keyed so that they cannot be
interchanged or improperly installed. Signal and power pins shall not be
adjacent.
Lifting Assists: Handles, lifting lugs, or reviewed functional equivalents
shall be provided on components of 18 kg (40 lbs.) or more.
Visual Inspection: Visual inspection of equipment shall be unobstructed.
Structural Elements: Access to structural components shall be provided
to the greatest extent practicable to allow inspection for cracks,
corrosion and structural integrity.
Test Points: Built-in test points shall be provided and marked. Major
components having test panels or test points shall be located for easy
accessibility and shall permit external monitoring of critical functions.
Test points shall be protected against environmental damage and
human error.
Fault Isolation: Failure indicators shall be provided and identified.
Systematic fault isolation procedures shall be developed and included in
the maintenance manuals.
Labeling: All test points, fault indicators, modules, wire junctions, pipes,
tubes, wires, etc., shall be identified by name plates, color coding,
number coding, or other means to assist maintenance personnel. All
ROMs, PROMs and EPROMs shall be labeled with the version and date
of stored software.
Hardware: Standard, commercially available industrial components and
hardware shall be used wherever possible.
Vandalism: The use of vandal and damage resistant materials shall be
used whenever possible.
December 2013
Technical Specifications
17035-9
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
PART 2 - PRODUCTS
2.01
MATERIALS
The Contractor shall supply all the materials, documents, tools, testing, and monitoring
equipment, computer time, reference literature and other items necessary to meet the
requirements of the Reliability and Maintainability Assessment Program.
PART 3 - EXECUTION
3.01
3.02
3.03
RELIABILITY ASSESSMENT PROGRAM
A.
Verification that the equipment fulfills the reliability requirements described
herein shall be accomplished via a reliability assessment program generally in
accordance with MIL-STD-781 B, as prescribed herein.
B.
The Reliability Test Plan and requirements of this Section do not replace design,
performance, environmental, reproduction, individual component, or other
required tests and inspections specified elsewhere herein.
C.
Reliability values and requirements specified herein shall not be interpreted as a
relaxation of fail-safe design requirements of the systems.
RELIABILITY TESTING
A.
The reliability of the various equipment types and subsystems shall be proposed
by the Contractor and agreed by NJ Transit as detailed in Part 1 above. The
reliability figures defined in the reliability study and agreed by NJ Transit shall be
met or exceeded.
B.
All equipment subsystems shall be tested.
C.
Any subsystem or component part rejected by the reliability assessment program
shall be modified or replaced by the Contractor. Any such modification or
replacement shall be subject to the review of the Construction Manager and
shall be subjected to the same reliability assessment program as the original
equipment.
TEST PREPARATIONS
A.
The Contractor’s personnel assigned to participate in reliability testing shall be
fully trained in their assigned tasks, and shall be familiar with the approved
reliability test plan.
B.
All required spare material shall be made available by the Contractor for the
Technical Support Material specified hereinafter. The Contractor shall provide
other logistic support determined by the approved test plan.
December 2013
Technical Specifications
17035-10
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
3.04
FAILURE MODE AND EFFECT ANALYSIS
The Contractor shall perform a Failure Mode and Effects Analysis (FMEA) to identify
potential system weaknesses. The Contractor shall evaluate each potential failure to
determine its effect on the system and sub-system operation. The Contractor shall
investigate the identified failures and quantify them by logic network analysis to
determine necessary design improvements or corrective action required to eliminate the
causes. FMEA shall be a continuing effort to furnish design guidance and improve
reliability.
The Contractor shall prepare a procedure for conducting FMEA. These procedures shall
as a minimum:
3.05
A.
Ascertain that all equipment failures or malfunctions are reported promptly and
documented in a systematic manner.
B.
Ascertain that the root cause of each failure or malfunction is determined and
eliminated.
C.
Describe a tracking and reporting system that provides prompt follow-up on all
failures or malfunctions until the cause is eliminated.
D.
Evaluate each potential failure to determine its effects on the system and
subsystem operation, and thus determine its criticality and whether the failure is
a service failure.
FAILURE DOCUMENTATION
A.
Any malfunction or fault that prevents or limits equipment from performing its
function in accordance with these Specifications shall be reported and formally
recorded.
B.
All failures shall be initially dispositioned as “Chargeable”. The Contractor is
responsible to gather any data and information necessary to challenge the initial
disposition.
C.
A “Chargeable” failure is defined as a failure that requires repair or replacement
of any subsystem component which is not an approved consumable item, or
which is an approved consumable but has not achieved its design service life,
and which failure has not either been due to:
1.
A failure occurrence in another system or sub-system.
2.
A failure of NJ Transit to perform the recommended preventative or
service maintenance actions.
3.
Vandalism or physical mistreatment at a human interface.
4.
Operating or weather conditions of unusual aspect or severity beyond
those specified in TP Section 4.0.
December 2013
Technical Specifications
17035-11
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
5.
3.06
An accident.
PROCEDURE
A.
Test Logs
1.
B.
The logs shall contain the following information:
a)
Identification of the component and subsystem by location,
function, serial numbers, and line item of Reliability Study
Report to which the equipment is charged.
b)
Number of like components and subsystems in service.
c)
Date and time equipment was placed in service.
d)
Date and time equipment was restored to test after shutdown.
e)
Date and time of each failure.
f)
Cause of each failure.
g)
Classification of each failure (chargeable, not chargeable).
h)
Time to troubleshoot from time of arrival on site.
i)
Time to repair when spare parts are available on site.
2.
All repairs and adjustments made and reasons for same.
3.
Once each week, the logs shall be reviewed and the following entries
shall be made:
a)
Accumulated operating hours per line item.
b)
Accumulated chargeable failures per line item.
c)
Accumulated repair time for chargeable failures (actual
troubleshooting and repair time only) per line item.
Preventive Maintenance
Preventive maintenance procedures specified in the approved operating and
maintenance manuals for the equipment during normal operation shall be
performed during the reliability-testing period.
No additional preventive
maintenance will be allowed during the reliability test period or during actual
equipment repair unless specifically reviewed by the Construction Manager.
December 2013
Technical Specifications
17035-12
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
Other maintenance actions required on behalf of other equipment, such as
troubleshooting, checkout or downtime investigations, shall be termed
preventive maintenance, and classed as non-chargeable failures, when
performed in connection with reliability assessment.
C.
Equipment Failure Record
A failure record shall be maintained for each line item. The record shall be
designed to permit keeping the entire test history of each line item on a single
sheet so that widely divergent differences in test behavior between line items
may be easily recognized. This record shall show all component failures for the
line item.
D.
Verifying Repair
Following repair or corrective action and prior to resumption of reliability testing,
it shall be permissible to operate a maximum one-week burn-in test to verify the
effectiveness of the repair. Failures and repair time during this period shall be
recorded and reported, but shall not be used in determining compliance with
MTBF and MTTR requirements.
E.
Corrective Action
When any reliability test reaches a reject decision, the test shall be discontinued
for that line item. The Construction Manager shall be immediately notified, and
the Contractor shall develop and propose a plan for correction of the
deficiencies. The Construction Manager will review such corrective action. The
action may require handling as a design change or modification.
3.07
F.
Failure Summary Record
G.
The Contractor shall maintain a failure summary record containing all the
information needed to reach an accept/reject decision on the system under test.
All entries shall be made directly, and there shall be no need to process data
prior to an accept/reject decision. The summary shall include all component
failures considered chargeable on all like equipment under test. The record shall
present the current test status, including information on the total hours of test,
failures, MTTR and MTBF of all units on test.
RELIABILITY REVIEW BOARD
A Reliability Review Board, composed of representatives of the Construction Manager
and the Contractor shall be established to review failure-related discrepancies. The
duties of this Board shall be to determine the proper assignment of failures to chargeable
or non-chargeable categories for test scoring purposes, and to review the corrective
action and assessment procedures. This Board shall meet on a regular monthly basis, or
as acceptable by the Construction Manager.
December 2013
Technical Specifications
17035-13
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
3.08
FAILURE OF A RELIABILITY TEST
In the event that a reliability test indicates a failure to comply with the specified
requirement, or falls below the requirement for three (3) consecutive months, the
Contractor will notify NJ Transit. The Contractor shall be responsible, at no cost to NJ
Transit, for design, manufacture and installation of changes to the subsystem and spare
parts required to achieve the specified reliability. Such correction shall be to NJ Transit’s
satisfaction and approval. The reliability test for the affected system shall be repeated to
verify compliance. Additionally, corrections shall be incorporated in all Project equipment
and spare parts, including those for which the materials and workmanship warranty
period have expired.
3.09
FAILURE REPORTING, ANALYSIS, AND CORRECTIVE ACTION SYSTEM (FRACAS)
Throughout the reliability demonstration and Warranty periods, the Contractor shall
maintain an approved closed-loop FRACAS system to determine the cause of all
unscheduled part removals, and maintain accumulative summary of all failure analyses,
identifying the failed parts and the pertinent data and actions relating to each failure. The
Contractor’s FRACAS data shall also include the total operating time (t) accumulated by
the total population of identical Line Replaceable Units (LRU), and the calculated MTBF
for each type of LRU and corresponding subsystem.
On a continuing basis, the Contractor shall systematically evaluate the FRACAS data to
identify and monitor failure trends, no trouble found incidents, and new failure effects.
3.10
MAINTAINABILITY ANALYSIS
A.
Perform maintainability analysis on the train control system design. Update this
analysis as the design configuration undergoes various iterations.
1.
Develop predictions to judge adequacy of the proposed design to meet
maintainability quantitative requirements, and to identify design features
requiring corrective action during early stages of design and
development.
2.
Identify and document all significant maintenance tasks to be performed
on the system, including scheduled maintenance and corrective
maintenance.
In documenting corrective maintenance, give failure mode, failure
mechanism, failure effect, task description and time to repair.
3.
December 2013
Technical Specifications
The time to repair for each task shall be expressed as mean time to
repair (MTTR). Task MTTR’s shall be averaged appropriately to obtain
estimates of MTTR for the subsystems.
17035-14
Contract No. 14-017X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
4.
Using results of the maintainability analyses, develop recommendations
for:
a)
3.11
5.
Controlled simulation tests shall be employed, as well as data from
actual unscheduled maintenance actions occurring during the reliability
test period.
6.
Task selection shall be based on criticality of failures and on expected
failure frequencies.
7.
The plan shall identify all Contractor-furnished equipment and other
support required.
8.
The plan shall identify all NJ Transit special facilities and personnel
required to support conduct of the test.
MAINTAINABILITY VERIFICATION
A.
3.11
Depth and frequency-of-maintenance requirements at each
level.
The maintainability program plan shall provide for formal verification of
compliance with maintainability requirements.
1.
The Contractor shall state in the program plan whether demonstration
testing alone will provide verification of requirements, and if not, what
the role of testing is to be within the program.
2.
If test data are to be augmented with other information, the program
plan shall contain an explicit statement of the procedure for combining
period test data and analysis with demonstration testing in order to verify
compliance.
3.
The verification procedure shall be implemented by means of the final
acceptance audit.
FINAL ACCEPTANCE AUDIT
Conduct a final acceptance audit at the completion of all demonstration testing to
establish the operational baseline of the train control system. The audit shall include a
detailed review and analysis of the test results. Document the results of the audit and
assign action items to resolve deficiencies.
PART 4 - PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
The work of this Section will not be measured for payment.
December 2013
Technical Specifications
17035-15
Contract No. 14-107X
RELIABILITY AND MAINTAINABILITY ASSESSMENT PROGRAMS
4.02
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum
Price for all the work, labor and materials necessary therefore and incidental
thereto as shown on the Contract Drawings and described in the Technical
Provisions.
END OF SECTION 17035
December 2013
Technical Specifications
17035-16
Contract No. 14-017X
SECTION 17040
CONFIGURATION MANAGEMENT
PART 1 - GENERAL
1.01
DESCRIPTION
A.
1.02
This Section specifies the requirements for the Contractor’s Configuration
Management Program, which should include planning, identification, definition,
implementation, control, and accountability, in order to control the development
of a complex system with multiple designers.
CONFIGURATION MANAGEMENT PROGRAM
A.
Establish a Procurement Baseline description of the system and controlling
changes to the baseline as the design progresses. Define the Project in terms of
the documentation required to produce it, including the plans, designs, and
procedures.
B.
Identify the entities with authority over this program, their organizations, and
their relationship with production, change control and design review processes.
C.
Establish record keeping procedures for each element under the control of the
Configuration Management Plan.
D.
Interface Control:
Identify the individual functional disciplines and the
corresponding authorities.
Establish a systematic approach to exchange
information between these separate disciplines and control all design and
performance interfaces. Establish criteria for verifying the final functionality of
the integrated system.
E.
Document Control: Establish the physical requirements, equipment and staffing
for a Document Control Center. Maintain a safe and secure document control
area.
F.
1.
Establish a process to maintain and disseminate documents established
by the Configuration Management Program.
2.
Identify which documents will be Controlled Documents, and establish a
procedure for approvals and tracking changes.
3.
Maintain and make available to the Construction Manager accurate and
current configuration records throughout the period of performance of
the Contract and for a five-year period after final Contract payment.
Change Control: Changes to the Procurement Baseline shall be controlled by
the processing of Engineering Change Proposals (ECP’s) in accordance with the
procedures described herein. All ECP’s shall be reviewed by the contractor’s
organization responsible for configuration control for total impact evaluation prior
to recommendation and submittal to the Construction Manager for review.
December 2013
Technical Specifications
Contract No. 14-017X
17040-1
CONFIGURATION MANAGEMENT
G.
Classification of Changes
1.
2.
December 2013
Technical specifications
A proposed engineering change to any part, assembly, or equipment
item for the Supplier’s product shall be designated as a Class I change
when one or more of the following is affected.
a)
Form, fit, and function interchangeability.
b)
Reliability and maintainability.
c)
Weight or balance (where it is a factor).
d)
Administration-furnished equipment.
e)
Safety.
f)
Electro-magnetic interference characteristics.
g)
Delivered product (retrofit).
h)
Delivered training, operation, or maintenance manuals (where
additional Contract funds are required to revise manuals).
i)
Sources of repairable items (source control drawings).
j)
Schedules or deliverables.
k)
Initial provisioning.
A proposed change to computer software shall be designated as a Class
I change when one or more of the following factors is affected:
a)
Function, performance, including reliability, maintainability,
correctness, efficiency, flexibility, testability, usability, and
outside stated tolerance.
b)
Interface characteristics.
c)
Cost.
d)
Schedules.
e)
Safety.
f)
Skill levels, training or human engineering design.
Contract No. 14-017X
17040-2
CONFIGURATION MANAGEMENT
3.
Any engineering change not affecting form, fit, function, or
interchangeability, nor failing within the preceding definition of a Class I
change shall be designated as a Class II change. Some examples of
Class II changes are correction and clarification of documents and
drawings, substituting alternative materials or hardware, and those
changes which do not affect the preceding listed Class I factors.
H.
Accountability: Maintain records such that the configuration of any items being
delivered shall be definable in terms of its components part numbers. Account
for differences between the as-built configuration and the engineering released
documentation. Record status of change approvals and incorporation at each
point in product development, test, production, or operational usage. Maintain a
serialization and configuration record. Maintain the status of interface technical
provisions, control documents and plans. Maintain status of software once a
baseline has been defined.
I.
Engineering Change Proposal (ECP)
J.
1.
Process each Class I change as an ECP and submit to the Construction
Manager for review prior to initiating any implementation action. Any
action or cost necessary to correct problems in the product or
documentation arising from the Contractor’s misclassification shall be
borne by the Contractor. The Contractor shall also classify and control
changes originating from subcontractors. Submit six (6) copies of the
ECP to the Construction Manager accompanied by the technical
documentation and the cost information necessary to fully evaluate the
change.
2.
Report all Class I changes that affect safety immediately. Identify the
change by ECP number if reported verbally, and confirm the change in
writing to the Construction Manager within twenty-four (24) hours. Class
II ECP’s shall be submitted to the Construction Manager for information.
Design Reviews and Audits:
1.
December 2013
Technical specifications
Design reviews and audits shall be conducted jointly by the Construction
Manager and the Contractor shall not constitute relief from contractual
obligations. Submit all documentation, plans, and design data for the
reviews and audits at least ten (10) working days prior to the date of the
review. The individual subsystems software design and programs, and
hardware will not necessarily progress at the same rate. The likelihood
of multiple PDR’s, and CDR’s must be considered in planning for
reviews and audit. Software reviews and audit shall be in accordance
with ANSI/IEEE Standard 730 (latest revision).
Contract No. 14-017X
17040-3
CONFIGURATION MANAGEMENT
K.
2.
Preliminary Design Review (PDR): Evaluate the design progress,
technical adequacy of the selected design and hardware approach,
determine their compatibility with the performance requirements and
interfaces of the Contract and the schedule to complete all tasks. Notify
the Construction Manager within thirty (30) days after Notice to Proceed
of the date when a satisfactory PDR can be performed. The review shall
be held on a mutually agreeable date consistent with the Contractor’s
design schedule at the Construction Manager’s facility, but no later than
one hundred twenty (120) days after Notice to Proceed.
3.
Critical Design Review (CDR): Conduct the review(s) when detail
design of an item(s) is essentially complete and the production drawings
are ready for release. CDR’s shall be completed no later than ninety
(90) days after the Preliminary Design Review. Determine that the detail
design of the system element under review will satisfy the design
requirements established in the Contract Technical Provisions and to
establish the exact interface relationships between the item and other
items of equipment and facilities. The reviews shall be held on mutually
agreeable dates consistent with the Contractor’s design schedule at the
Construction Manager’s facility unless another location is reviewed by
the Construction Manager.
4.
First Article Inspection (FAI):
a)
Evaluate the assembled, in-place system by formal examination
against the production drawings, technical provisions, and
factory testing. Verify that the system meets all requirements,
and that its documentation is internally consistent. This will
occur at the Contractor’s facility prior to installation on the
contract.
b)
Prior to FAI, provide the Contractor’s Construction Manager with
the factory test procedures and an indentured list of all drawings
to the lowest levels of repair and replacement, identified by
revision or issue. The list shall be as complete as necessary to
identify the baseline. Upon satisfactory completion of the audit,
the data package shall be corrected to incorporate any changes
found during the audit.
c)
Schedule FAI’s for all subsystems as applicable prior to first
shipment from the subsystem supplier’s plant.
HARDWARE & SOFTWARE
1.
December 2013
Technical specifications
Do not procure nor produce any hardware or software until such items
have been reviewed by the Construction Manager.
Contract No. 14-017X
17040-4
CONFIGURATION MANAGEMENT
1.03
2.
All items, beginning with the lowest level of repair or replacement,
identified by the same part number shall have the same physical and
functional characteristics, shall be equivalent in performance and
durability, and shall be interchangeable without alteration to themselves
or associated items, other than normal field adjustments. An item shall
not be considered interchangeable if it requires modification for fit or
performance. Old and new configuration items that require segregation
shall be identified either by a new drawing number or a dash number
added to the original drawing.
3.
Hardware Identification: Mark all hardware components to the lowest
level of repair and replacement with part number identification. The
hardware identification marking shall coincide with the officially released
engineering data. Nameplates on major equipment items will provide
space for inventory numbers to be added by the Contractor at the
direction of the Construction Manager. Serialization is required on each
item of equipment delivered unless otherwise reviewed by the
Construction Manager.
Assign an individual serial number in a
numerical sequence established for the type or model series equipment
being supplied. Do not use duplicate serial numbers within a type or
model series. Serial numbers shall not exceed ten (10) digits in length.
SUBMITTALS
Unless otherwise specified, all submittals shall be in accordance with the General
Provisions for Construction and Article 2.03 herein.
A.
Configuration Management Plan
B.
Complete set of final (as-built) drawings, with all changes incorporated into the
set.
C.
Design review and audit documentation.
D.
All submittal listed on the Contract Data Requirements List.
E.
Civil and Systems plans and equipment location designs.
F.
FAI audit results.
G.
Shipping Plan.
PART 2 - PRODUCTS
2.01
CONFIGURATION MANAGEMENT PLAN
Prepare and submit a Configuration Management Plan that provides technical
coordination processes for the development of the complex system with multiple
December 2013
Technical specifications
Contract No. 14-017X
17040-5
CONFIGURATION MANAGEMENT
disciplines. The plan should address configuration control, change control, design
review control and document control.
2.02
CONTRACT DATA REQUIREMENTS LIST
Prepare and submit a comprehensive Contract Data Requirements List, which shall
expand upon the list in this Contract.
2.03
DRAWINGS AND DESIGN REVIEW DATA
A.
In support of the design reviews for each location, provide five (5) half-size
prints and two (2) half-size reproducible of sufficient quality to make legible
prints of those engineering drawings and documents that provide all the
essential data necessary to permit a meaningful evaluation and feasibility study
of the proposed design. All engineering drawings and documents required to
support design reviews shall be delivered to the Construction Manager at least
fifteen (15) working days prior to the scheduled start of the review. All drawings
shall be dimensioned in English units.
B.
In addition to the other drawing requirements specified in these Technical
Provisions, five (5) full-size prints and two (2) full-size reproducible of sufficient
quality to make legible prints of the following shall be submitted for the
Construction Managers review:
C.
1.
Installation drawings for each type of field equipment.
2.
Single line, control schematic, functional block diagrams, and wiring
diagrams.
3.
Outline drawings of all major equipment components showing:
a)
Overall dimensions, orientation, points of normal support, and
method of mounting and removal;
b)
Location of access doors and covers showing the relation to
equipment inside the enclosure.
c)
Required drawout space and space for opening of access doors.
Manufacturing Drawings / Shop Drawings
1.
December 2013
Technical specifications
Throughout the design and manufacturing process, submit a continually
updated list of manufacturing interconnect and assembly drawings and
engineering change orders. Detail drawings shall be submitted at the
Construction Manager’s request. Five (5) full-size prints and two (2) fullsize reproducible of sufficient quality to make legible prints of
manufacturing drawings shall be submitted to the Construction Manager
within fifteen (15) calendar days of their release or revision.
Contract No. 14-017X
17040-6
CONFIGURATION MANAGEMENT
2.
Prior to completion of the Contract, the Contractor shall submit to the
Construction Manager a complete set of the final (as-built)
manufacturing drawings with all changes incorporated thereon. Two (2)
reproducible and eight (8) copies of the above drawings shall be
submitted.
D.
Drawing Quality and Updating: Drawings shall be of a quality where every line,
number, letter and symbol is clearly legible. Reproducible drawings shall be
capable of reproducing drawings to this quality level. The Contractor shall
update each drawing, incorporating all outstanding approved changes, at least
once every sixty (60) days. In no event shall more than five (5) approved
changes be accumulated against a drawing without incorporation, irrespective of
its scheduled update. Changes to drawings shall be incorporated sequentially.
Copies of all updated drawings, which were submitted to the Construction
Manager in earlier revision, shall be resubmitted in the original quantity and
format.
E.
Calculations: Furnish calculations and other required data on standard 8-1/2 by
11 inch sheets, printed on one side only. Each sheet shall bear the following:
Contract Name and Number; Title and Number of Pages; Data and Revision
Status.
F.
Drawing Approvals: If reviewed by the Construction Manager a reproducible
copy of each drawing will be identified as having received such review by being
so stamped and dated. Drawings stamped “not reviewed” or “reviewed” subject
to.....” and with required corrections shown will be returned to the Contractor for
correction and resubmittal. Resubmittals will be handled in the same manner as
first submittals.
G.
SHIPPING PLAN: Prepare and submit a shipping plan at least 90 days prior to
the first shipment of the electrical and mechanical equipment. The plan shall
include details on how the Contractor plans to ship the equipment from the
factories to the site for installation.
PART 3 - EXECUTION
3.01
PROGRAM PLANS
Implement and maintain the plans during all phases of the Contract. Provide schedule of
audits to be conducted on the Configuration Management Plan.
3.02
CONTRACT DATA REQUIREMENTS LIST
Implement and maintain the list to plan, schedule and track status of all submittals required by
the Contract.
3.03
REVIEW AND AUDITS
Conduct reviews and audits in accordance with specified requirements and procedures.
December 2013
Technical specifications
Contract No. 14-017X
17040-7
CONFIGURATION MANAGEMENT
PART 4 - MEASUREMENT AND PAYMENT
4.01
MEASUREMENT
A.
4.02
The work of this Section will not be measured for payment.
PAYMENT
A.
Payment for the work of this Section will be made at the Contract Lump Sum Price for
all the work, labor and materials necessary therefore and incidental thereto as shown
on the Contract Drawings and described in the Technical Provisions.
END OF SECTION 17040
December 2013
Technical specifications
Contract No. 14-017X
17040-8
REFERENCE DOCUMENTS
The following manual is for the original fans that are to be replaced by the MCC/FAN RESTORATION
PROJECT and is included for reference only:
VENTILATION FANS
MAINTENANCE, INSTALLATION
AND OPERATION MANUAL
FOR
V1-F1; V1-F2, V1-F3, V1-F4, V1-F5, V1-F6, V1-F7, V1-F8, V1F9, V1-F10, V1-F11 AND V1-F12
94 JMTS/40/4/9
3.7/30 HP, TWO SPEED MOTORS
CONTRACT 03-078
NEWARK CITY SUBWAY (NERL)
NCS #7, NJT
DAIDONE ELECTRIC
FLAKTWOODS NO. P203321
NOVEMBER 2005
REVISED 1 MARCH 2006
FINAL COPY
TABLE OF CONTENTS
This book covers maintenance for all the 94 fans V1-F1 thru V1-F12
DESCRIPTION
SECTION 1
Fan-motor unit removal and replacement procedures
SECTION 2
Fan-motor unit disassembly and reassembly
SECTION 3
Components List-Three Levels of Maintenance
SECTION 4
Test procedure for repair accuracy
SECTION 5
Preventative Maintenance Schedule
-Motor lube tables & grease bulletin
SECTION 6
Special Tools for Maintenance
SECTION 7
Mylar Template for Blade Angle Setting
-Template
SECTION 8
Maintenance Tools and Test Equipment
SECTION 9
After Emergency Service
SECTION 10
Troubleshooting and Fault Isolation Procedure
SECTION 11
General Arrangement Drawings
Central Panel Monitor Drawings
Motor drawing
SECTION 12
Fan Monitor Instrumentation Data
PAGES
1-2
3-4
5
6
7-14
15
16
17
18
19
10 of 10
Revised 1 March 2006
SECTION 1FAN-MOTOR UNIT REMOVAL AND REPLACEMENT
PROCEDURES.
CAUTION! Follow all safety rules and regulations before working on any
fan. Before starting any work for tunnel ventilation fan removal or
replacement, follow lock-out, tag-out procedures to lock out and tag any
electric power supplies to the motor, winding heaters and instruments, and
disconnect all respective cables.
UNIT REMOVAL
The 94JMTS Ventilations fans are completely assembled and ready to be installed at site.
The fan is mounted by use of mounting plates on site. The V1 fans have one silencer that
is attached to the impeller side of the fan.
The fan is attached to the mounting plate. The silencer is installed to the fan, with the
silicone gasket installed between the silencer and fan flanges.
To remove the unit, use a suitable lifting device to hold the fan and silencer in place
while the mounting hardware is removed from the mounting plate. Holding the fan and
silencer by the lifting eyes remove the fan from the installation position and lower to the
floor. The fans should only be lifted by means of the lifting eyes or lifting eyes and sling
around the center of the fan.
If so desired, the silencer can be disconnected from the fan first and the unit taken down
in two sections.
FAN REPLACEMENT PROCEDURES
If the entire unit is being replaced, lift the fan unit into position. Use a suitable lifting
device with sufficient precision, movment capability of 2-4 inches to permit the fan to be
positioned correctly. Bolt the fan into position and ensure that no unnecessary stresses
are brought onto the fan fixing plates. To lift the fan, use the lifting eyes provided on the
fan and silencers. A sling can be used with the lifting eyes, centered around the fan.
15
Revised 1 March 2006
Do not lift fan by means of a sling only.
The power supply cable is connected to the terminal box on the outside of the fan casing.
The supply cable must be sufficiently flexible so that normal movements of the fan are
not impeded. Connect the supply cable to the fan motor terminal box.
If the silencer was removed separately, replace at this time, lifting into place by means of
a lifting device and lifting eyes, hold in place and bolt to the fan. Replace the gasket
material while attaching the silencer to the fan. Also re-connect any cables to the fan
auxiliary boxes for sensor readings or motor leads.
Once the fan is re-installed, and before starting the fan, check the impeller and make sure
it rotates freely and that there are no foreign objects in the fan or in the vicinity of the fan.
Start the fan and verify that the impeller rotates in the correct direction according to the
direction arrows on fan casing.
The fans’ instrumentation is wired to a central control panel. Wiring diagrams are
provided in the drawing section.
15
Revised 1 March 2006
SECTION 2FAN-MOTOR UNIT DISASSEMBLY AND REASSEMBLY
Disassembling the V1 fanRemoving the impeller
1. Turn off fan, and follow Lock Out-Tag Out procedures.
2. Turn off the safety switches and remove the fuses for the fan motor.
3. Remove the fan if only one person is removing the impeller. If two people, the
impeller can be removed while it is installed. The silencer must be removed to
reach the impeller.
4. Loosen the hub bolts.
5. Pull off the impeller from the motor axis. Lift off the impeller from the motor
shaft. Mark front of impeller for re-assembly.
Removing the motor-Dismount fan if motor is being removed.
1. Once the impeller has been removed, remove the motor cable and conduit from
the connection box outside of the fan casing. Remove any instrumentation cable
and conduit from the auxiliary box outside of the fan casing.
2. Loosen the motor fixing bolts on the motor mounting brackets. The motor is
normally lifted using a lifting eye screwed into the end of the motor shaft.
Re-Assembly of the V1 fanReplacement of the motor and impeller
Assembly of the motor is made in reversed order.
Tighten the motor fixing bolts to a torque specified on a torque table provided.
Make sure the motor is placed in same position and meet with mounting arms.
Mount the impeller on the motor shaft, being careful the impeller is turned
correctly.
5. The heads of the blade fixing bolts should be on the motor side.
6. Replace and tighten the hub bolts. Retighten the bolts according to the torque
specified on the torque table-table 2 provided.
1.
2.
3.
4.
15
Revised 1 March 2006
7. Re-check the clearance between the tip of the blades and the casing, making sure
it is sufficient. The clearance should be measured with the motor shaft horizontal.
Remedy if required. The minimum clearance for this fan is specified in Table 1.
8. Attach all the motor leads and instrument cables from the motor back into the
flexible conduit inside the fan and out to the motor and auxiliary boxes and
terminate the wires to the termination strips in the box.
9. Reinstall the fan in the tunnel, along with the fan silencer.
10. Re-connect the power supply cables to the fan.
TABLE ONE-BLADE TIP CLEARANCE
This table is for fans V1-F1; V1-F2; V1-F3; V1-F4; V1-F5; V1-F6; V1-F7; V1-F8; V1-F9;
V1-F10; V1-F11 and V1-F12
TEMP
70 °
MAX.
¼”
6.35 MM
MIN
7/64”
2.70 MM
TABLE TWO-TORQUE VALUES
Torque values specified in the table below apply to hexagon bolts with coarse metric
thread. Tighten the bolts with a dynamometric wrench or a nut setter with torque
control. Range of variation max +_ 5%
NOTE: Impact wrenches must not be used.
When lubricant is applied, both thread and contact surfaces should be lubricated.
Material
Type of
Lubrication
Dimension
¼”/M6
5/16” /M
3/8”/M10
½”/M12
5/8”/M16
¾”/M20
1”/M24
1 1/8”/M30
Steel 8.8
Fe/Zn
Dry
Steel 8.8 Fe/Zn Steel A 4-80
Steel Grade 2
Oil/MoS2
Oil/MoS2
Dry
Torque ft-lb
(Nm)
7 (9.4)
21 (28)
41 (55)
70 (95)
170 (230)
332 (450)
575 (780)
1185 (1400)
Torque Ft-Lb
(Nm)
6 (8.4)
19 (26)
37 (50)
64 (87)
156 (211)
302 (410)
523 (710)
1050 (1400)
Torque Ft-Lb.
(Nm)
57 (78)
14 (19)
27 (37)
47 (64)
116 (157)
226 (306)
391 (530)
780 (1040)
Torque Ft-Lb
(Nm)
4 (5)
8 (11)
14 (19)
35 (48)
66 (90)
140 (190)
295 (400)
520 (700)
15
Revised 1 March 2006
SECTION 3COMPONENTS LIST-THREE LEVELS OF MAINTENANCE
On –Site Maintenance
The following repairs, maintenance, adjustment can be made on site:
1.
2.
3.
4.
5.
Adjust blades angle of the impeller.
Remove and replace impeller.
Remove and replace motor.
Visual Inspection of the fan for damage.
Cleaning of fans when required.
Engineer’s Shop
The following repairs, maintenance, adjustment can be made in the engineer’s shop:
1. Impeller replacement-replace blades
2. Motor replacement
Manufacturer
The following repairs are made at the Manufacturer’s facility:
1. Replacement of motor bearing(s).
2. Fan refurbishment following emergency fire use.
15
Revised 1 March 2006
SECTION 4TEST PROCEDURE FOR REPAIR ACCURACY
After any work is done on the motor and /or impeller of the fan, the fan should be run
and checked for high vibration and/or high bearing or winding temperatures.
This includes repairs, such as blade replacement, and blade adjustments.
Replacement of impellers or blade(s) can cause an unbalance to occur. The fan will
vibrate at levels outside the running parameters. The impeller will have to be
balanced by adding weight to the impeller and running a vibration check again before
putting fan back in service.
Once repairs are complete, start up the fan and check vibration levels. If vibration
alarm sounds, stop the fan the re-balance. Once re-balanced, start up fan and check
levels again. Repeat until vibration levels are in acceptable range.
Vibration level should not exceed 0.10 inches per second (peak) velocity at maximum
motor operating RPM. Two-speed units will be tested at both motor operating
speeds. Reversible flow units shall be tested in both the forward and reverse flow
directions.
If unit does not have vibration sensors installed, use a hand-held vibration meter, such
as a CSI unit to read vibration. Place the probe on fan casing, or motor casing if
accessible.
15
Revised 1 March 2006
SECTION 5PREVENTATIVE MAINTENANCE SCHEDULE
IMPORTANT! Always cut off the power supply using the safety switch if fitted,
before carrying out any work on the fan. If there is no safety switch, the current can
be cut off at the nearest fuse box. Always ensure that the power supply to the fan is
disconnected and that the fan cannot start while work is in progress. Use proper Lockout, Tag-out procedures before performing any work on the fans.
Visual Inspection
Every six months inspect the fan for damages and clean if required. Repair damage
on the paint of motor and fan.
Bearing Replacement
After 30,000 hours running or maximum 7 years duration, the bearings should be
replaced.
Cleaning
As required following visual inspection. The fan should be kept clean, which can
usually be carried out using a brush and vacuum cleaner. Dust accumulations may
cause vibration, poor motor cooling and unsatisfactory silencing.
Motor Maintenance-One to Four month intervals
One to Four Month intervals- Listen to the fan running. A uniform hum is a sign that
a bearing is running perfectly. Bearing temperature control is also part of routine
maintenance. A clicking noise could indicate a failing bearing.
Constant temperature control is done with the aid of external thermometers or by
embedded thermal elements. The motors are equipped with grease lubricated ball
bearings. Bearings should be lubricated to avoid metallic contact of the moving parts,
and also for protection against corrosion and wear. Lubricant properties deteriorate in
the course of time and mechanical operation. All lubricants are subject to
contamination under working conditions.
15
Revised 1 March 2006
Weg motors are supplied with sufficient grease for a long running period.
Lubrication intervals, the amount of grease and the type of bearing used in Frames
140T to 580T are found in tables 11, 12 and 13 of the Weg motor manual. This
manual is provided at the end of this section. Lubrication intervals depend upon the
size of the motor, speed, working conditions and type of grease used.
Fans V1-F1 through V1-F12 have WEG-Two speed motor 3.7/30 HP, 326Y frame,
and 1765/890 RPM.
Fans should be re-greased with Krytox GPL 226-High Temperature, Anti-Corrosion
Grease. Krytox is a trademark of DuPont and can be purchased through their Krytox
division. (See Product Data bulletin at end of this section). Do not use other grease as
they may not be compatible.
Grease is added to the motors through the grease supply lines. These are located on
the outside of the fan casing for easy access.
Trouble-Shooting
GENERAL
Listed in the table below are those faults considered most likely to occur. Logical
trouble-shooting is assumed to be carried out in respect of any other fault
symptoms that might occur.
Symptom
Fan Vibration
Probably Cause
Dust deposits on impeller
Impeller blade damaged
Damaged bearing
Remedy
Clean impeller
Replace the blade set
Check all bearings by
means of vibration
analysis. Replace as req.
15
Revised 1 March 2006
SECTION 6SPECIAL TOOLS FOR MAINTENANCE
The performance of the Fan can be changed by alteration of the angle of the fan
blades. Note that the motor current also increases with increases in blade angle.
SPECIAL TOOL
1. Mylar Template to set blade angles. Template provided in manuals.
15
Revised 1 March 2006
SECTION 7
MYLAR TEMPLATE FOR MAINTENANCE
This mylar template is provided to set the blade angle on the fan blades. The
instructions to use the template on printed on the template itself. The torque values
are also included.
Templates should be kept in a safe place where they can be located if a blade angle
change is required.
15
Revised 1 March 2006
SECTION 8MAINTENANCE TOOLS AND TEST EQUIPMENT
The tools required to maintain these fans are limited to the equipment, in
both imperial and metric configurations, found in a standard millwright’s
toolbox. A typical listing of these tools would include the following:
Note: These tools are not supplied by Flakt Woods, Inc.
1. Complete set of wrenches (box end and open end) in both metric and imperial
sizes, ranging from approximately ¼” to 1 ½” (6 mm to 36 mm).
2. Complete set of sockets and ratchets (3/8” & ½” Drives) in the same sizes as
above.
3. Complete set of nut drivers in the same sizes.
4. Complete set of screw drivers (straight and Phillips).
5. Complete set of pliers (standard, Pump & self-locking).
6. Set of adjustable wrenches.
7. Set of Allen Wrenches in metric and imperial sizes.
8. Complete set of Machinist’s precision tools (squares, dial indicators, micrometers,
calipers, levels, etc.).
9. Complete Set of cold chisels.
10. Complete set of mill flat & bastard files, with file cleaner.
11. Complete set of punches.
12. Pair of tin snips.
13. Ball Peen hammer, rubber mallet & 3 lb sledge.
14. Grease gun and caulking gun.
15. Flashlight.
16.
Winding temperature readings and vibration readings taken from sensors on motors.
Additionally, vibration readings of the fan and/or motor can be taken with a hand-held
vibration unit.
15
Revised 1 March 2006
SECTION 9AFTER EMERGENCY SERVICE
Following emergency service (temperatures of 250° for one hour), the fans need to be
removed and returned to the factory for complete refurbishment.
Make sure no power is on before removing the fan. Disconnect all power supply to
the fan(s) and secure the fan with lifting equipment.
Disconnect the silencers from each end of the fan. The removal center-body of the
silencer on the motor side should be removed from the fan after the silencer is
removed. The silencers will need to be returned to the factory for refurbishment.
Once the silencers are disconnected from the fan, remove the mounting bolts and
brackets and lift the fan down. The fan should be placed on a skid and secured.
Return the fan to the factory. Once at the factory, the fan will be completely disassembled. The impeller, motor, sensors, auxiliary and motor box, and all connection
hardware will be discarded.
A new motor, impeller, boxes, sensors and electrical and grease hardware are
required to refurbish the fan. The fan casing itself will be inspected for heat damage,
buckling, etc., to see if it can be sandblasted and repainted. If it is re-usable, the
casing will be refurbished and re-fitted with new internal and external components.
Fan (s) will be tested in the same manner and procedure as new factory fans and will
be certified as re-furbished.
Alternatively, complete new fans can be manufactured to replace the damaged fans.
It is recommended by the fan manufacturer to re-furbish all fans exposed to a fire
emergency.
15
TROUBLE-SHOOTING FLOWCHART
Trouble-Shooting
Fan Vibrations
Fan Temperature
No
No
Alarm?
Alarm?
Yes
Yes
Dust deposits on impeller
Clean Impeller
High Bearing
Temperature?
Yes
Check Motor Bearing
Add Grease
Impeller Blade Damaged
Replace the blade set
No
No
Alarm?
Damaged Motor Bearing
Replace Motor Bearing
High Winding
Temperature?
Alarm?
No
Yes
Damaged Motor Bearing
Consult Motor Manufacturer Manual
Yes
Motor Damaged Or Overloaded
Yes
Consult Motor Manufacturer Manual
Contact FlaktWoods
Consult FlaktWoods For Further
Investigation
Run Fan
As Normal
Trouble-Shooting Flowchart Rev1.xls
Page 19
Printed:4/4/2006
Newark Light Rail Sandy Recovery at Penn Station
Contract No. 14-017X, Specification 15831-3.04.4
Tunnel Airflow Performance Test Information
The following provide the necessary information to the Contractor for conducting the Tunnel
Airflow Performance Test per 15831-3.04.4.
A.
General:
1.
The purpose of this Field Test is to determine the effectiveness of the as-installed
Emergency Ventilation System in providing the desired tunnel airflow management.
This test is not to determine the installed airflow of the individual fans. Measurement
shall be of tunnel air velocities at the designated Measurement Planes.
2.
Per 15831-3.04.4, there will be one test configuration. The test configuration will be
comprised of a particular set of stopped trains, a particular overall ventilation system
Operating Mode (some with fan-out modifications), a particular air velocity measurement
plane, and the required air velocity at that plane. Velocities may exceed the requirement
without concern, but may not be less than required. Exceptions will require Engineer’s
review.
3.
Per 15831-3.04.4, the velocities shall be taken with vane anemometer traverses of the
entire tunnel cross-section. Traverse readings shall be taken at multiple fixed
measurement points and then averaged mathematically, not by “waving” the sensor.
4.
Per 15831-3.04.4, a minimum of two traverses shall be taken at each location, with
further repeats unless and until a variance of less than five percent between two
consecutive traverse results is achieved.
5.
Traverse details and number of measurement points for each Measuring Plane shall be
determined in advance and submitted as part of Test Procedure. Number and spacing of
traverse points shall take into account the local geometry of the tunnel at the
Measurement Plane. Test Procedure submittal shall include a scale diagram of the actual
tunnel cross-section at the Measurement Plane with field-confirmed dimensions. This
diagram shall be used to substantiate the proposed traverse arrangement for the Test
Procedure.
Note: A suggested traverse pattern is a maximum 2’-0” thick perimeter rectangular
annulus divided in to 8 roughly equal area segments (half of each “side” of the annulus),
and the remaining center area divided into at least 9 equal areas, for 17 points total. For
the twin tunnel sections divided by center columns, repeat the pattern on each side of the
columns (consider the columns as “sides”), for 34 points total.
6.
A traverse shall be taken at the measurement location with the fans off to determine the
ambient tunnel air velocity. Tunnel ambient velocity shall be used to correct the Test
velocities for comparison with the required velocities using the equation:
Vcomparison = SQRT { Vtest2 – ( |Vamb| * Vamb ) }
Where:
Vtest is traverse result with fans on; Vamb is traverse result with fans off; Vcomparison is
value to compare with the Required Minimum Cold Flow Air Velocity; and direction of
sign is positive in the required direction of air flow.
Page 1 of 3
7.
Newark Light Rail Sandy Recovery at Penn Station
Contract No. 14-017X, Specification 15831-3.04.4
Tunnel Airflow Performance Test Information
If the ambient tunnel air velocity is greater than 150 feet per minute in either direction,
the test shall be postponed until ambient tunnel air velocity is less than 150 feet per
minute. When the two successful consecutive test traverses are completed, after test
velocities have decayed to ambient, measure the center “cell” air velocity (two readings
at the double-width locations) to confirm that ambient is within 5 percent of the initial
ambient traverse readings for the same “cells”. If not within 5 percent, record a full
tunnel ambient air velocity traverse.
8.
The test procedure submittal shall include as a minimum the following:
- The traverse location, confirming the field identified location and configuration of the
traverse.
- The system condition for the traverse (operating mode, modifications).
- Required train position confirming the field identified location as coordinated with NCS
Operations.
- The preliminary traverse diagram locating traverse points and respective areas.
- The form to record individual traverse readings for each data set.
- The method of calculation of average velocity.
- The list of test instruments proposed with current calibrations.
- All forms and procedures shall be detailed and tailored to actual methods to be used.
9.
Data for the test location shall include as a minimum the following:
- The date and time of the traverse.
- The traverse location.
- The measured and confirmed train location.
- The vent system condition for the traverse (ambient, operating mode, modifications).
- The dimensioned traverse scale diagram locating all traverse points and respective
areas, including field confirmed total area for the traverse.
- The individual traverse readings for each data set (whether used as final data or not).
- The calculation of average velocity for the traverse.
- The temperature at the plane of measurement during the traverse.
- The list of specific test instruments used and proof of current calibration at time of test.
10.
Per 15831-3.04.5, adjustment of fan duty at relevant ventilator or Jet Fan locations may
be determined to be required if tunnel performance test results do not meet design “cold”
air velocities. Fan power input derived from prior individual fan field tests and factory
fan curves will be used to support amount of adjustment if any adjustment of fan duty
(blade angle) is determined to be required as result of tunnel performance test results.
B.
Tunnel Airflow Performance Test Location 1:
1.
Incident Location / Ventilation Response to be tested:
Zone 140, Operating Mode 24:
V1 Forward (Exhaust)
V5, V6, V7, V8 Reverse (Supply)
JF9, JF10 Forward (toward V1)
V2, V3, V12, V13 Closed.
Penn Station doors to mezzanine closed.
Page 2 of 3
2.
Newark Light Rail Sandy Recovery at Penn Station
Contract No. 14-017X, Specification 15831-3.04.4
Tunnel Airflow Performance Test Information
Modifications to Pre-Programmed Operating Mode for Test:
none.
3.
Train Location:
One train only in the outside Penn Station Loop track (Track 1), between V1 and
Outbound Platforms. Train stopped with the back of the train aligned with the center of
the Emergency Exit door (measured perpendicular to track centerline). No other trains or
other vehicles anywhere in the tunnel system.
4.
Measurement Plane:
In the Penn Station Loop between V1 and Outbound Platforms, at 20 feet towards the
stopped train, measured from the end of Ventilator V1 (last column), and measured along
the centerline of the outside Loop track. Measurement Plane includes entire cross-section
of tunnel, and shall be perpendicular to the centerline of both tracks.
5.
Direction of Airflow:
Toward V1, away from the Penn Station outbound platforms.
6.
Required Minimum Cold Flow Air Velocity:
410 feet per minute.
End
Page 3 of 3