EXHIBIT S TECHNICAL SPECIFICATIONS DIVISION 1 …

Exhibit S

Specifications

Bid No. 15-65 Exhibit S – Table of Contents

EXHIBIT S

TECHNICAL SPECIFICATIONS

TABLE OF CONTENTS

DIVISION 1 GENERAL REQUIREMENTS

01 11 00 SUMMARY OF WORK

01 25 13 MATERIAL AND EQUIPMENT

01 30 00 ADMINISTRATIVE REQUIREMENTS

01 31 19 COORDINATION AND MEETINGS

01 35 24 SAFETY

01 35 25 HAZARD COMMUNICATION PROGRAM

01 42 13 REFERENCES – CODES AND STANDARDS

01 43 33 MANUFACTURERS’ FIELD SERVICES

01 45 16.13 CONTRACTOR QUALITY CONTROL

01 50 00 CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

01 61 00 COMMON PRODUCT REQUIREMENTS

01 77 00 CONTRACT CLOSEOUT

01 78 23 OPERATION AND MAINTENANCE DATA

01 78 43 SPARE PARTS

01 91 14 EQUIPMENT TESTING AND COMMISSIONING

Exhibit S

Specifications

Bid No. 15-65 Exhibit S – Table of Contents

DIVISION 2 EXISTING CONDITIONS

02 41 19 SELECTIVE REMOVAL AND MODIFICATIONS

02 82 13.01 CLASS II ASBESTOS ABATEMENT

02 83 33.13 LEAD BASED PAINT REMOVAL AND DISPOSAL

DIVISION 5 METALS

05 05 23 WELDING

05 05 24 FASTENERS

05 50 00 METAL FABRICATIONS

05 56 00 CASTINGS

05 58 10 FORGINGS

DIVISION 9 FINISHES

09 90 04 PAINTING

DIVISION 26 ELECTRICAL

26 08 00 ELECTRICAL TESTING

26 25 13 BRIDE CRANE RUNWAY CONDUCTOR

DIVISION 41 MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 05 13.13 BASIC MECHANICAL REQUIREMENTS FOR BRIDGE CRANE

41 22 10.13 BRIDGE CRANE MECHANICAL REHABILITATION

41 22 11.13 BRIDGE CRANE ELECTRICAL REHABILITATION

END OF EXHIBIT S TOC

Exhibit S

Specifications

Bid No. 15-65 Summary of Work – 01 11 00 Page 1

SECTION 01 11 00

SUMMARY OF WORK

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2

1.1 BACKGROUND ..................................................................................................... 2 1.2 SUMMARY OF WORK ............................................................................................ 2 1.3 ACCESS TO THE SITE ........................................................................................... 6 1.4 PROVIDED BY THE CONTRACTOR .......................................................................... 6 1.5 PROVIDED BY THE DISTRICT ................................................................................. 7 1.6 OTHER DISTRICT WORK ....................................................................................... 7 1.7 DISTRICT OPERATIONS ........................................................................................ 7 1.8 CONTRACTOR’S STAFF ........................................................................................ 7

2.0 PRODUCTS (NOT USED).................................................................................. 12 3.0 EXECUTION (NOT USED) ................................................................................. 12

Exhibit S

Specifications


SECTION 01 11 00

SUMMARY OF WORK

1.0 GENERAL

1.1 BACKGROUND Public Utility District No. 1 of Chelan County (District) owns and operates the Rocky Reach Hydroelectric Project on the Columbia River near Wenatchee, Washington. The powerhouse with its 11 generating units is over 1,470 feet in length and includes two 250 ton bridge cranes. The bridge cranes are electric motor driven with double bridge girders that support a single top running trolley. Each crane is equipped with a 250 ton main hoist with a single sister hook and one auxiliary hoist with a capacity of 25 tons. The cranes can be operated independently or can be mechanically linked with a 470 ton lifting beam for large capacity picks.

The Work consists of rehabilitating both 250 ton bridge cranes in the Rocky Reach Dam Powerhouse.

1.2 SUMMARY OF WORK 1.2.1 General The Contractor shall furnish all planning, labor, materials, and equipment required for the Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment Project as detailed in the Contract Documents. These Contract Documents cover the performance requirements for manufacturing, painting, shop assembly testing, shipping, handling, erecting, field-testing, and commissioning of the crane system.

The Contractor shall provide a single source of supply throughout all aspects of the Work to provide consistency in design, engineering, component selection, manufacturing, and all other aspects of performing the Work required for modification of the bridge crane system.

Shop Drawings and data submitted by the Contractor and reviewed by the District supplement the Contract Documents, but do not become part of the Contract Documents.

A descriptive summary of Work is provided below. It is not intended that this summary description be all-inclusive, but rather a general overview.

1.2.2 Schedule A Summary (Base Bid) Schedule A Work covers the requirements for selective removal, access and walkway improvements, electrical controls retrofit maintaining and reusing the existing runway

Exhibit S

Specifications


conductor system, and mechanical repair and refurbishment. The Contractor shall provide the following:

1. Participate in post-award conference and pre-installation meetings per Section 01 31 19 Coordination and Meetings.

2. Provide all submittals as described in Section 01 30 00 Administrative Requirements.

3. Contractor shall execute and be responsible for the design, engineering, manufacture, shop testing, inspection, shipment, delivery, erection, installation, startup and commissioning of the modified bridge crane system as specified; including a 125% load test of the refurbished crane system.

4. Contractor shall supply, transport to the Site, unload, and store the following supplementary materials: a. Consumable materials required for disassembly, removal, and disposal of

existing equipment. b. Consumable materials required for installation and assembly of new

equipment and materials. c. Accessories needed for handling and manipulating equipment, including

slings, spreader beams, lifting equipment, and working platforms. d. Contractor shall provide all construction equipment as necessary for

completion of the Work including but not limited to: mobile cranes, lights, signage, barricades, winches, rigging lines, compressors, working platforms, hoses for distribution of compressed air and all other equipment required for execution of the Work.

e. Contractor shall transport parts and equipment including personnel. 5. Modify main hoist equipment and controls for both bridge cranes as follows:

a. Modify main hoist reducer to remove all mechanical load brake (MLB) components as well as design, furnish and install new input and intermediate gear sets and shafts to replace the MLB components removed. Provide new bearings for all replaced components, replace all remaining hoist bearings and gear sets as specified.

b. Modify the idler-end drum pillow block bearing housing and its mounting. c. Furnish and install new motors, brakes, machined motor and brake bases,

motor coupling, and Flux Vector Variable Frequency Drives (VFD’s). d. Furnish and install new main hoist control panels and wiring (Note: all

existing electrical power and control wiring shall be removed and replaced with new wiring).

e. Furnish and install new limit switches for all hoist functions. f. Furnish and install new wire rope. g. Furnish and install new equalizer bar. h. Furnish and install hoist drive-based overload system with warning light.

6. Furnish all-new auxiliary hoist equipment and controls for both bridge cranes as follows:

Exhibit S

Specifications


a. Remove existing hoist reducers and furnish and install new reducers. b. Remove existing hoist drum and furnish and install new drum. c. Remove existing drum bearings and their pillow blocks and supports as

required to accommodate the new drum and reducer. Furnish and install new motors, brakes, machined motor and brake bases, motor coupling and Flux Vector VFD’s.

d. Furnish and install new auxiliary hoist control panels and wiring (Note: all existing electrical power and control wiring shall be removed and replaced with new wiring).

e. Furnish and install new limit switches. f. Furnish and install new wire rope. g. Furnish and install new lower block. h. Furnish and install new equalizer bar. i. Furnish and install hoist weighing system with scoreboard-type display and

overload protection. 7. Modify bridge drive system for both bridge cranes as follows:

a. Completely remove existing cross-shaft drive system including motors, brakes, hydraulic piping, pedal and bleeder system, hydro-pneumatic system, motor couplings, drive shafts, bearings and supports, pinion gears etc.

b. Modify two existing drive trucks on each crane to equip the trucks with an independent drive motor, brake, pinion shaft and reducer assembly as specified. Replace one of the drive wheel assemblies with an idler wheel assembly. Remove the existing wheel gears and pinion shaft bearings and provide new.

c. Modify two existing idler trucks on each crane to equip the trucks with drive wheel assemblies removed from the drive trucks described in paragraph 1.2.1(7)(b) above. Supply independent drive motor, brake, pinion shaft and reducer assemblies as specified. Supply new wheel gears and pinion shaft bearings.

d. Install new scalar VFD controls for bridge drive system on each crane. Includes all wiring and control panels.

8. Modify trolley drive system for both bridge cranes as follows: a. Furnish and install new motor, brake and motor coupling (existing reducer,

cross-shaft, output couplings and drive wheels to be re-used). b. Furnish and install new scalar VFD controls for trolley drive system on each

crane. Includes all wiring and control panels. 9. Remove and replace all bridge and trolley wheel bearings. 10. Maintain existing runway conductor system for the main power feed to the

crane (maximum 200 Amps.) Collectors shall be reused with existing runway conductor system. System ground shall be added to the power system by providing at least two bridge-mounted grounding shoes which shall receive the

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Specifications


ground through the crane rails. The contractor shall verify that the rails are continuously grounded.

11. For each crane, provide all crane controls including equipment and enclosures as specified. Cranes will also be equipped with radio control equipment for all crane functions and features. All existing controls and wiring will be removed and replaced with new equipment as specified. Existing crane conduits shall remain and be re-used, except that all flexible conduit shall be replaced, and all existing electrical metal tubing (EMT) type conduit shall be removed.

12. Existing trolley wire bus systems shall be removed and replaced with new festoon systems as specified.

13. For each crane, furnish and Install new bridge and trolley walkways, platforms and ladders as specified.

14. For each crane the existing operator’s cab and master switches shall be re-used but cab switches, indicators, power panel and other hardware shall be replaced / furnished as specified.

15. Provide the spare parts specified in Section 01 78 43, Spare Parts. 16. Provide abatement in all areas of the Work where existing hazardous materials

are encountered and disturbed during performance of the Work. All abatement Work shall be in compliance with all applicable federal, state, and local regulations.

17. Degrease and clean entire crane structure. 18. Removal and inspection of weld traces from prior attachments of angles and

other structural items that were previously attached and removed from the bridge girder web plates as specified. Payment for weld repairs shall be in accordance with General Conditions paragraph GC-40, Changes in the Work- Field Work Order/Change Orders.

19. Touch-up painting for all areas where existing bridge crane structure coatings or shop applied equipment coatings have been damaged or disturbed as part of the Work.

20. Additional field touch-up painting of existing damaged coating areas on the crane structure as Directed by the District.

21. The Contractor shall establish and maintain an effective quality control system and perform such inspections as necessary to ensure that the Work conforms to the Contract documents.

22. All existing equipment removed and not reinstalled or salvaged shall become the property of the Contractor, removed from the Project site, and disposed of in compliance with all applicable federal, state, and local regulations.

1.2.3 Schedule B Summary (Additive Alternate 1 for installation of a new runway

conductor ground) Schedule B Work covers the requirements for the addition of a new runway conductor ground system to the existing three bar system. If selected by the District, this Work will

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Specifications


be in addition to the Schedule A Work described in paragraph 1.2.2 above. The Contractor shall provide the following for Schedule B:

1. Modify the existing three phase conductor system support brackets. 2. Furnish and install a new system ground for both cranes complete with

collectors and expansion joints. 3. Furnish and install all on-crane wiring to connect to the new system ground.

1.2.4 Schedule C Summary (Additive Alternate 2 for Installation of a new runway

conductor system) Schedule C Work covers the requirements for the replacement of the existing three-bar runway conductor system with a new four-bar system. If selected by the District, this Work will be in addition to the Schedule A Work described in paragraph 1.2.2 above. The Contractor shall provide the following for Schedule C:

1. Remove and dispose of the existing runway conductor system. 2. Design, fabricate, furnish and install a new four-bar runway conductor system. 3. Furnish and install all necessary ancillary materials, equipment, and supports to

provide a complete installation.

1.3 ACCESS TO THE SITE The Project Site is located adjacent to the Rocky Reach Hydroelectric Project, located approximately five (5) miles north of Wenatchee, Washington. Access to the Contractor’s work areas shall be from Highway 97 A on the west bank (Chelan County side) of the Columbia River onto the dam entrance road.

1.4 PROVIDED BY THE CONTRACTOR Contractor shall provide all labor, materials, facilities, equipment, utilities, sanitary facilities, hazardous materials/substance handling, inspection, and other services and work necessary for design, manufacturing, testing (including test weights), shipment, installation, start-up and commissioning of the refurbished powerhouse bridge cranes; to provide a complete Project as required by the Specifications.

All work, material, and services, even if not expressly called for in these Specifications, if necessary or appropriate for the complete and proper operation of the Work, shall be provided and installed by the Contractor.

The Contractor shall perform, at no extra cost to the District, any minor items of work not specifically shown on the Contract Drawings or called for in the Specifications, but clearly required in order to meet the intent of the design and current industry standards specified.

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Specifications


The Contractor shall be responsible for all transportation and housing costs and subsistence expenses of its personnel.

1.5 PROVIDED BY THE DISTRICT The District will provide the following:

1. Designated laydown and storage space. 2. Existing Powerhouse Bridge Cranes, crane runway, and crane runway

conductor system. 3. Utilities as described in Section 01 50 00 Construction Facilities and Temporary

Controls. 4. Output gear set for north bridge crane.

1.6 OTHER DISTRICT WORK District may have operations and maintenance work and capital construction projects ongoing 24 hours per day, seven (7) days a week, during the course of this Contract. Other work includes but is not limited to:

1. Normal powerhouse operations and maintenance. 2. Unit 8 – 11 Turbine Repairs.

1.7 DISTRICT OPERATIONS District operations require the use of the access roadways, parking lot areas adjacent to the powerhouse roll-up door, and access into the powerhouse on a daily basis. Consequently, the Contractor shall schedule and coordinate all Work in accordance with Section 01 50 00 Construction Facilities and Temporary Controls.

1.8 CONTRACTOR’S STAFF 1.8.1 General Contractor shall provide an experienced and competent workforce for the Work. The positions and functions described herein shall be included. All members of Contractor’s onsite workforce shall work safely and harmoniously with co-workers, District, and others’ personnel.

Contractor’s personnel shall meet the minimum requirements identified. Any changes of personnel identified in the Contractor’s Bid Proposal shall be subject to the approval by the District. The District shall have the right to require Contractor to replace any person who does not possess the skills to perform the work, shows incompetence, or fails to comply with Contract Document requirements.

Exhibit S

Specifications


1.8.2 Project Manager The Contractor’s Project Manager shall have a minimum of five (5) years experience in the design, manufacture and installation of custom crane equipment, and/or in mechanical and electrical modification of high-capacity or high-power overhead bridge or gantry cranes, for hydroelectric facilities similar to that described in this Contract. In accordance with Instructions to Bidders ITB 16, Bidders Data, the Contractor shall provide a copy of the proposed Project Manager’s resume with the Bid showing details of the work experience for Approval by District. Contractor Project Manager shall be fluent in the English language, both written and oral.

The purpose of the Contractor’s Project Manager will be to provide one focal point within the Contractor’s organization, for all interfaces and communications with the District, and others, relevant to successful implementation and completion of the Project.

The Contractor’s Project Manager shall direct, coordinate, and be responsible for all efforts of all entities performing services for or supplying components to Contractor on the Project, and shall provide the lead and impetus necessary to properly achieve Project objectives, the schedule and Contract obligations. To accomplish this, the Contractor’s Project Manager shall be authorized to perform the following:

1. Be the primary contact for the Contractor with the District and its agents or representatives;

2. Determine the overall project plan and approve the individual schedules of the Contractor’s Subcontractor forces;

3. Control and approve all Subcontractors’ Work; 4. Monitor project progress with right to decide corrective action and resolve

problems that adversely affect project objectives and Contract commitments; 5. Execute changes to the Contract; and 6. Monitor, control, and direct the Contractor’s Superintendent, Subcontractors,

and other staff.

1.8.3 Contractor’s Superintendent The Contractor shall provide onsite Superintendence in accordance with General Conditions GC 55 Contractor Superintendence and the requirements of this paragraph. Contractor Superintendent shall have a minimum of five (5) years experience with the installation of similar powerhouse crane work and have acted as Superintendent for at least three (3) projects similar to that which is called for in this Contract. In accordance with Instructions to Bidders ITB 16, Bidders Data, the Contractor shall submit a copy of the proposed Contractor Superintendent’s resume with the Bid. Contractor Superintendent shall be fluent in the English language, both written and oral.

Exhibit S

Specifications


Contractor shall submit to the District for approval, before starting the Work, the identity of its Contractor Superintendent qualified to perform the duties assigned. The Contractor Superintendent shall be present at the site of Work during shifts when Work is in progress and must be able to be present on the Site within two (2) hours at District's request. The Contractor Superintendent shall be supported by competent assistants as necessary. All directions delivered or mailed to the Contractor Superintendent by District, shall be binding as if given to Contractor.

The Contractor Superintendent shall oversee all activities of the Contactor’s crews. These crews shall report directly to the Contractor Superintendent. As a minimum, the Contractor Superintendent shall have the authority to perform the following:

1. General layout and Work schedule; 2. Qualifications and composition of crews; 3. Increasing/Decreasing Crew Size as required to meet Contract requirements; 4. Reassignment of crew members; 5. Disciplinary action and removal offsite of Contractor’s personnel, if necessary.

The Contractor Superintendent shall also have the responsibility to:

1. Provide to the District and maintain an accurate and up-to-date list of all Contractor personnel onsite. List shall identify all Contractor and Subcontractor personnel.

2. Ensure crew members meet minimum qualifications as specified in Contract; 3. Ensure Contract materials are onsite; 4. Ensure proper quality of the Work; 5. Ensure proper installation procedures are being followed; 6. Ensure consumables and installation tools, equipment and materials are in

adequate supply; 7. Monitor work status and progress; 8. Represent the Contractor at site progress meetings, providing updates on the

work in progress; 9. Establish and ensure safe work practices for Contractor’s personnel.

1.8.4 Site Quality Representative In accordance with Section 01 45 16.13 Contractor Quality Control, the Contractor shall establish and maintain an effective quality control system.

The Contractor shall provide a Site Quality Representative responsible for overall management of the Contractor’s Site Quality Program and to ensure a quality installation. The Site Quality Representative shall have authority to act in all quality matters for the Contractor.

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Specifications


The Site Quality Representative shall be qualified by training and education, with a minimum of five (5) years experience with similar installations. In accordance with Instructions to Bidders ITB 16, Bidders Data, the Contractor shall provide to the District a copy of the proposed Site Quality Representative's resume with the Bid showing details of work experience.

As a minimum the Site Quality Representative shall:

1. Direct all inspection activities, schedule, and reporting; 2. Review and approve all inspection reports, nonconformance reports, field

changes, and other quality assurance documentation; 3. Remain objective and independent from the personnel doing the assembly and

installation work; 4. Interface with District Inspectors, Engineer, and other District personnel

regarding quality issues, inspections and tests; 5. Ensure all inspections, tests, nonconformances, field changes and other quality

issues are properly documented and rectified in accordance with the Contractor’s Site Quality Program.

The Site Quality Representative shall be present at the site of work during activities that require inspection and testing. The Site Quality Representative shall be supported by competent inspectors as necessary. Different Site Quality Inspectors may be used for assembly and installation to provide the requisite experience.

1.8.5 Site Safety Representative In accordance with Section 01 35 24 Safety, the Contractor shall establish and maintain an effective safety program. Contractor’s Site Safety Representative shall have a minimum of three (3) years of construction experience with similar installations. In addition, the Site Safety Representative shall have completed a 30-hour OSHA construction safety class or equivalent within the last three (3) years and have competent person training as necessary for all aspects of the Work. The Site Safety Representative shall have overall responsibility for compliance with Contractor’s Site Safety Plan, applicable laws and codes, and District safety policies as may be amended. This position may be a combined responsibility with other positions of the Contractor’s staff with Approval of the District. The Site Safety Representative shall be onsite and conducting safety related work a minimum of six (6) hours per week. As a minimum the Site Safety Representative shall:

1. Conduct daily safety and health inspections and maintain a written log which includes area / operation inspected, date of inspection, identified hazards,

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recommended corrective actions, estimated and actual dates of corrections. Safety inspection logs shall be attached to the Contractor’s daily quality control report;

2. Conduct mishap investigations and complete required reports; 3. Maintain applicable safety reference material on the job site; 4. Attend the pre-work conference, pre-work meetings including preparatory

inspection meeting, and periodic in-progress meetings; 5. Implement and enforce accepted accident prevention plans and activity hazard

analysis plans; 6. Maintain a safety and health deficiency tracking system that monitors

outstanding deficiencies until resolution; 7. Ensure subcontractor compliance with safety and health requirements.

Failure to perform the above duties will result in dismissal of the Site Safety Representative and a suspension of the Work. The Work suspension will remain in effect pending District Approval of a suitable replacement for the Site Safety Representative. The Contractor shall submit a copy of the proposed Safety Representative’s resume showing details of work experience.

1.8.6 Craft Labor Contractor shall provide a skilled labor force with experience in fabrication, manufacturing, assembly, testing, installation, startup, and commissioning of crane systems similar to that required by this contract.

Prior to commencement of the field work, and each time the Contractor makes any change to the craft labor, resumes and any other documentation which the District may reasonably request shall be promptly provided to the District. 1.8.7 Test Engineers Contractor’s Test Engineers shall have a minimum of three (3) years experience with similar installations. The Test Engineers shall prepare test procedures, and direct testing at the site including commissioning tests. Contractor’s Test Engineers shall be fluent in the English language, both written and oral. The Contractor shall submit a copy of the proposed Test Engineers resume showing details of work experience.

As a minimum, the Test Engineers shall:

1. Direct all test activities, schedule, and reporting; 2. Review and approve all test reports; 3. Interface with District Inspectors, the Engineer, District Test Engineer, and other

District personnel regarding tests and test schedules; 4. Ensure all tests are properly documented.

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Specifications


2.0 PRODUCTS (NOT USED)

3.0 EXECUTION (NOT USED)

END OF SECTION 01 11 00

Exhibit S

Specifications

Bid No. 15-65 Material and Equipment – 01 25 13 Page 1

SECTION 01 25 13

MATERIAL AND EQUIPMENT

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 DEFINITIONS ....................................................................................................... 2 1.2 MATERIAL AND EQUIPMENT .................................................................................. 2 1.3 PROPOSED SUBSTITUTIONS OR “OR-EQUAL” ITEM ................................................. 4

2.0 PRODUCTS (NOT USED).................................................................................... 5 3.0 EXECUTION (NOT USED) ................................................................................... 5

Exhibit S

Specifications


SECTION 01 25 13

MATERIAL AND EQUIPMENT

1.0 GENERAL

1.1 DEFINITIONS Definitions in this paragraph are not intended to negate the meaning of other terms used in the Contract Documents, including "specialties, systems, structure, finishes, accessories, furnishings, special construction," and similar terms, which are self-explanatory and have recognized meanings in the construction industry. Products, Materials and Equipment as defined in this section, does not apply to machinery and Equipment used for preparation, fabrication, conveying, and erection of the Work. 1.1.1 Products The word "Products," as used in the Contract Documents is defined to include purchased items for incorporation into the Work, regardless of whether specifically purchased for the project or taken from Contractor's stock of previously purchased Products. 1.1.2 Materials The word "Materials," is defined as Products which must be substantially cut, shaped, worked, mixed, finished, refined, or otherwise fabricated, processed, installed, or applied to form Work. 1.1.3 Equipment The Word "Equipment" is defined as Products with operational parts, regardless of whether motorized or manually operated, and particularly including Products with service connections (wiring, piping, and other like items).

1.2 MATERIAL AND EQUIPMENT All Materials incorporated into the Work shall be new and both workmanship and Materials shall meet or exceed the District’s quality standards, be free of defects, and where indicated by the Specifications, Drawings, and Reference Drawings, of the classification and grades designated therein. Material specifications shall be suitable for the intended purpose and shall comply with the latest specifications of the ASTM or equal. If Contractor intends to use equivalent standards for selection of Materials, submit a complete list of such Materials, their equivalent to ASTM and identification of parts for which the Material will be used. The equivalent standards shall be subject to Engineer review and Approval.

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Clearly identify Material specifications or standards, including grade, class, or type, for each component on Contractor’s Shop Drawings. The standard, type, and grade of Materials for the Equipment, except where specified elsewhere in these Specifications, shall be selected based upon the Contractor’s design. Materials and mechanical Equipment shall conform to the requirements indicated or specified, and if not specified, then Materials and mechanical Equipment of the best commercial grade and quality suited to the intended use and as Approved shall be furnished. The manufacturer's name, address, and catalog number shall be permanently displayed on a nameplate securely attached to each major item of Equipment. All Products, Materials, and Equipment shall be new and shall be typical of standard Products of recognized manufacturers regularly engaged in the Production of the type of Equipment and Materials specified in the Contract Documents. Contractor is responsible for ensuring Equipment is complete with fittings, trimmings, and parts necessary for complete operating installations. To the greatest extent possible, Contractor shall provide Products, Materials, and Equipment of a singular generic kind from a single source. Furnish interchangeable components of the same manufacturer for similar components. Where more than one (1) choice is available as options for Contractor’s selection of Product, Material, or Equipment, Contractor shall select an option that is compatible with other Products, Materials, or Equipment. Compatibility is a basic general requirement of Product, Material, and Equipment selections. The sizes, ratings, capacities, and dimensions of the various standard Equipment items listed on the Drawings, if any, are based on currently available standard Products. Reasonable deviations will be allowed to permit supply of standard Equipment. In no case shall the capacity furnished be less than that specified, unless Approved by the Engineer. Provide items such as shims, fasteners, grout, grease fittings, lubricants, and fluids necessary for installation and testing procedures. Label excess lubricants and deliver to District upon completion of Work. The Engineer shall make the final selection of all grease and lubricants. Remove rejected or damaged Material from site.

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1.3 PROPOSED SUBSTITUTIONS OR “OR-EQUAL” ITEM 1.3.1 General The Contract will be based on Materials and Equipment described and specified in the Contract Documents. Whenever it is indicated in the Contract Documents that a substitute or "Or Equal" item of Material or Equipment may be furnished or used by the Contractor, if acceptable to the Engineer, the application for such acceptance will not be considered until after the execution of the Contract. The use of Approved substitutes or "Or Equals" shall in no way relieve the Contractor from compliance with the Contract Documents. The listing of any manufacturer or supplier in the Contract Documents does not, and is not, intended to grant any: right, title, or interest in the Contract for the benefit of the named manufacturer or supplier. Where a Material or Equipment item is specified by two (2) or more manufacturer or supplier names, the Contractor may provide either one (1) of the Materials or Equipment so specified, providing that all requirements of the Contract Documents are met. Only one (1) brand, kind, or make of Material or Equipment shall be used or installed throughout the Work, notwithstanding that Material or Equipment from two (2) or more manufacturers may be specified for the same purpose.

1.3.2 Requirements Whenever Materials or Equipment are indicated in the Contract Documents by using the name of a proprietary item or the name of a particular manufacturer, the naming of the item is intended to establish the type, function, and quality required, unless stated otherwise.

If the name is followed by the words "Or Equal" indicating that a substitution is permitted, Materials or Equipment of other manufacturers may be accepted if sufficient information is submitted by the Contractor to allow the Engineer to determine that the Material or Equipment proposed is equivalent or equal to that named, subject to the following requirements:

1. The burden of proof as to the type, function, and quality of any such substitution Product, Material, or Equipment shall be upon the Contractor.

2. The Engineer will make the final decision as to the type, function, and quality of any such substitution and that decision shall be final.

3. The Engineer may require the Contractor to furnish additional data about the proposed substitution.

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4. The Engineer may require the Contractor to furnish a special performance guarantee or other surety with respect to any substitution.

5. Acceptance by the District of a substitution item proposed by the Contractor shall not relieve the Contractor of the responsibility for full compliance with the Contract Documents and for adequacy of the substitution.

6. The Contractor shall pay all costs of implementing accepted substitutions, including redesign and changes to Work necessary to accommodate the substitution.

1.3.3 Evaluation Factors The Contractor's application shall address the following factors, which will be considered by the Engineer in evaluating the proposed substitution: Whether the evaluation and acceptance of the proposed substitution will prejudice the Contractor's achievement of the agreed upon Project Completion date.

1. Whether acceptance of the substitution for use in the Work will require a change in any of the Contract Documents to adapt the design to the proposed substitution.

2. Whether incorporation or use of the substitution in connection with the Work is subject to payment of any license fee or royalty.

3. Whether all variations of the proposed substitution from the items originally specified are identified.

4. Whether available maintenance, repair, and replacement service are indicated. The manufacturer shall have a local service agency that maintains properly trained personnel and adequate spare parts and is able to respond and perform repairs within twenty-four (24) hours.

5. Whether an itemized estimate of all costs that will result directly or indirectly from acceptance of such substitution, including cost of redesign and claims of other contractors affected by the resulting change has been provided.

6. Whether the proposed substitute item meets or exceeds the experience and/or equivalency requirements listed in the appropriate technical specifications.




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Bid No. 15-65 Administrative Requirements – 01 30 00 Page 1

SECTION 01 30 00

ADMINISTRATIVE REQUIREMENTS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 PROJECT CORRESPONDENCE ............................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 7 1.3 PROJECT SCHEDULES ....................................................................................... 15 1.4 CONTRACT CLOSE-OUT SUBMITTALS .................................................................. 16

2.0 PRODUCTS (NOT USED).................................................................................. 17 3.0 EXECUTION (NOT USED) ................................................................................. 17 4.0 LIST OF APPENDICES ..................................................................................... 18

4.1 REQUIRED SUBMITTALS ..................................................................................... 19 4.2 SAMPLE: CONTRACTOR SUBMITTAL AND DISTRICT REPLY FORM ........................... 30 4.3 SAMPLE: SPEEDY MEMO .................................................................................... 31 4.4 SAMPLE: RECORD OF CONVERSATION ................................................................. 32 4.5 SAMPLE: SHOWING HOW TO PROPERLY IDENTIFY EMBEDDED DOCUMENTS,

CATALOG CUT SHEETS, ETC............................................................................... 33

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SECTION 01 30 00

ADMINISTRATIVE REQUIREMENTS

1.0 GENERAL

This section describes the requirements and procedures for all correspondence, document and Drawing submittals to the District, Engineer and all parties involved with the Contract. The District reserves the right to revise or modify these procedures as necessary to facilitate proper and consistent communication between related parties.

This section provides examples of forms to be used by the Contractor in the Appendices. Alternate forms may be used subject to Approval by the District’s Engineer.

1.1 PROJECT CORRESPONDENCE

Correspondence between the Contractor and the District will be handled through the District’s document management web site, also known as Submittal Exchange (found on the internet at https://gov.submittalexchange.com). All correspondence (as listed in this section) will be posted to the web site. The web site utilizes Microsoft® Internet Explorer (which is required). The following are highly recommended for efficient correspondence processing:

1. A high speed internet connection; 2. Document scanning capability; 3. Adobe® Acrobat 7 for PDF (*.pdf) files

(http://www.adobe.com/products/acrobat/readermain.html); 4. Autodesk® Design Review 2013 for DWF (*.dwf) files,

(http://www.autodesk.com/ ), select country and proceed with downloading of: “Autodesk DWF Viewer It’s Free” button).

Acceptable file formats are as listed in Paragraph 1.2.7 Format.

Submittal Exchange provides internet based training on behalf of the District. After logging in, self directed training is available at the button. Webinar style training can also be coordinated with the District and Submittal Exchange upon request.

The District utilizes a specific “Smart Number” file naming convention described further in Serialized Correspondence Numbering (Smart Numbering), see Paragraph 1.1.8.

https://gov.submittalexchange.com/

http://www.adobe.com/products/acrobat/readermain.html

http://www.autodesk.com/

https://www.submittalexchange.com/help/default.aspx�

Exhibit S

Specifications


The following Project correspondence will be utilized for the duration of the Contract:

1. Serialized Letters 2. Serialized Speedy Memos 3. Request for Information (RFI) 4. Records of Conversation (telephone and personal contacts) 5. Emails 6. Serialized Contractor Submittals 7. District Submittal Responses

1.1.1 Serialized Letters Serialized letters shall be used for all correspondence from any Project entity that addresses Contract scope, budget, schedule, or other contractual issues.

Serialized letters shall be posted to the Submittal Exchange web site and followed immediately by the signed original via regular or express mail, by courier service, or hand carried to the District.

If the District determines that there is any change to the Contract scope, budget, or schedule, then the District will issue a Field Work Order/Change Order (FWO/CO) and post the executed FWO/CO on Submittal Exchange.

1. All Serial Letters shall include (on the first page): Contract Number: 15-65, Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment

2. Sender’s Name 3. Sender’s Company Name 4. Date: MM/DD/YYYY 5. Serial Letter Number

Additionally, each page shall indicate page number and total number of pages, formatted as “Page X of Y”, and Serial Letter Number.

1.1.2 Serialized Speedy Memos Speedy Memos (Section 01 30 00 Appendix 4.3) shall be used for requesting information, clarifications, or interpretations of the Contract. Speedy Memos may be initiated by Contractor, District, or Engineer.

It is Contractor’s responsibility to initiate a Serialized Letter identifying any contractual changes that may result from a Speedy Memo response.

Speedy Memos shall be posted to the Submittal Exchange web site. No hard copy is required.

Exhibit S

Specifications


1.1.3 Requests for Information (RFI) Requests for Information shall be used by the Contractor for requesting specific information (i.e. change in material, paint color, etc.) 1.1.4 Telephone and Personal Contact Records Telephone and personal contact discussions (except meeting minutes) and particularly those which could result in a change to scope, schedule or budget, shall be recorded by the Contractor on a Record of Conversation Form (Section 01 30 00, Appendix 4.4). Completed Record of Conversation Forms shall be posted to the Submittal Exchange web site within three (3) calendar days of the conversation.

1.1.5 E-Mail Communications Parties to the Project may use e-mail for items other than those identified in the list of Project correspondence.

E-mail shall not be used for official correspondence as direction to proceed or to alter terms of the Contract.

E-mail may be used as a mechanism to transmit courtesy copies of other documents. Each e-mail shall contain a single subject. In rare cases similar subjects may be combined in a single e-mail if necessary for understanding. The Subject Line shall reference the:

1. Contract Number: 15-65, 2. Project Name: Rocky Reach Dam Powerhouse Bridge Cranes

Refurbishment, and 3. The email contents clearly described.

1.1.6 Serialized Contractor Submittals The Contractor Submittal & District Reply Form (Section 01 30 00, Appendix 4.2) shall be used as the cover sheet for all Contractor submittals. Contractor shall post the cover sheet and attachments combined as one (1) document to the Submittal Exchange web site, followed immediately by one (1) signed original with attachments via regular or express mail, by courier service, or hand carried to the District. Documents shall be CHECKED by Contractor before being submitted. All drawings shall be stamped by Contractor as having been checked, including the name or initials of the person checking the drawings and the date.

If documents are changed subsequent to the original submittal, Contractor shall post the revised document(s) in accordance with the naming convention, to the Submittal Exchange web site for information or review and Approval consistent with the original requirement.

Exhibit S

Specifications


Resubmittals shall have the same number and title as the original submittal with a numeric revision code (example: 1565-XXXX-S-0001-1) added to the submittal cover sheet and file name until submittal is Approved with no further action required.

New submittals shall not be combined with resubmittals.

1.1.7 District Submittal Response The Engineer will respond to submittals within two (2) weeks after posting to the Submittal Exchange web site.

Engineer will mark Submittal with one of the following:

SUBMITTAL RESPONSE & ACTION DESCRIPTION APP Approved Document is approved for use. AAN Approved as Noted Document is approved, possible minor edits AAN – SR Approved as Noted –

Resubmit for Record Submit for Record (As-built, O&M Manual, QA/QC Dossier). Final revision in correct format required [i.e. drawing in tiff or pdf shall be submitted in dwg format for Final Record Documents

ANR Approval Not Required Applicable to documents submitted for information only.

NOT APP Not Approved Contractor shall revise, take required action and incorporate comments, if any and repost the document addressing all comments within two (2) weeks of the District’s posted response.

Any work undertaken by the Contractor prior to submittal approval shall be at the Contractor's sole risk.

1.1.8 Serialized Correspondence Numbering (Smart Numbering) Serial numbers shall begin at 0001 for each type of correspondence from each sender. Numbers shall be consecutive. Correspondence initiated by Subcontractors shall be routed and tracked through the Contractor. The Engineer shall approve all deviations to this requirement. If a deviation is agreed to in writing, then Contractor shall ensure that Subcontractors shall be bound by the same requirements as the Contractor, as provided herein.

Exhibit S

Specifications


Correspondence Smart Numbers and file names for this Project shall be formatted as follows:

DOCUMENT TYPE NUMBERING CONVENTION AND FILE NAME

Serial Letters 1565-XXXX–L-001-0

Speedy Memos 1565-XXXX–M-001-0

RFI 1565-XXXX-RFI-001-0

Submittals 1565-XXXX–S-(Document Name)-0

Examples: 1565-HHI-L0001-0

1565: (Bid Number)

XXXX: (Contractor Designation, e.g. Hyundai Heavy Industries)

L-001: (Correspondence Type and sequential number)

0: (Revision number)

L-001-0 Letter Number - 01, Revision 0;

M-009-C1 Speedy Memo number 9, revision C1 (Revisions are with alpha characters (0, A, B, C…) If a Memo needs to be revised prior to a response, then use sequential numbering, following that revision alpha character.

S-0054-3 Submittal Number 54, Revision 3 (Revision with sequential numeric character (0,1, 2, 3….)

The District will assign Contractor Codes for all parties involved.

1.1.9 Address Information All Project correspondence shall be addressed as follows:

US Mail: P.U.D. No. 1 of Chelan County Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment Project Manager, Steve Wiest ATTN: Judy Ursic P.O. Box 1231 Wenatchee, WA 98807-1231

Exhibit S

Specifications


Physical Address, (Fed Ex, UPS, oversized mail): P.U.D. No. 1 of Chelan County Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment Project Manager, Steve Wiest ATTN: Judy Ursic 327 N. Wenatchee Ave. Wenatchee, WA. 98801

1.2 SUBMITTALS 1.2.1 General The Contractor is required to provide information to support its engineering, design, fabrication, and installation process and provide this information in sufficient detail to demonstrate the Work is being performed in accordance with these Contract Documents.

The required submittals are not limited to those on the List of Required Submittals (Section 01 30 00, Appendix 4.1). The District or Engineer may, at any time throughout the duration of the Contract, require the Contractor to provide additional information pertaining to the Work. The Contractor shall comply by providing the information in the form of a Submittal.

Documents and Shop Drawings shall be posted to the Submittal Exchange web site for information, or review and Approval. Contractor shall supply complete documentation and Shop Drawings for the equipment provided in accordance with the format and procedures established by these Contract Documents.

Non-paper submittal items such as hardware, samples, material items, etc. that cannot be posted to the District’s Submittal Exchange web site shall be sent to the Project Manager along with a signed Contractor Submittal/District Reply cover sheet (see Section 01 30 00, Appendix 4.2).

Documents shall be submitted in a timely manner to support Contractor’s engineering, design, and fabrication process. All delays due to untimely submittal of documents to District shall be the responsibility of the Contractor. Contractor shall arrange the submittal schedule such that no more than 25 documents or Shop Drawings are posted per week, except as otherwise Approved in writing (in advance), by the Engineer, or in the case of As-Built Drawings.

It is in the Contractor’s best interest to post submittals and resubmittals far enough in advance of the District’s submittal review time so that mobilization and construction start dates are not delayed while waiting for submittal Approval. The District has the right to delay work if required pre-construction submittals are not Approved. Onsite work will not be allowed to proceed prior to the Approval of the Contractor's work plans, safety plan,

Exhibit S

Specifications


and QA/QC plan. No increase in Contract Price or extension of the Completion date will be allowed if this delay occurs.

The Contractor shall furnish descriptions and drawings of the equipment it proposes to furnish, showing the dimensions of all parts, the materials from which the parts are to be made, the general arrangement and cross-sectional assembly, critical tolerances, and an outline drawing of each assembly of equipment to be supplied. Drawings shall show overall dimensions, limiting space requirements, and foundation requirements, in accordance with the submittal schedule.

The Contractor shall provide equipment documentation and Shop Drawings with overall dimensions and interfaces with other equipment in sufficient detail for the District’s Engineer to review with the intent of verifying the Work is being performed in accordance with these Specifications. Where both design calculations and drawings are prepared, they shall be posted together to allow complete review.

Materials shall be identified with the corresponding code or serial numbers referring to the standards of ASTM or to other standards recognized in the United States of America.

Contractor shall be responsible for the accuracy and correctness of dimensions and details on the documents and Shop Drawings. The Approval of such documents and Shop Drawings by the Engineer shall not relieve Contractor of this responsibility.

Any document required by this Specification which is produced by a sub-supplier, or subcontractor shall first be REVIEWED and noted as being APPROVED by Contractor and then submitted to the Engineer for review and Approval.

Contractor shall assume all responsibility and risk for conditions due to any error on Shop Drawings regardless of drawing Approval or field acceptance of material or delivery.

Any fabrication or other Work performed in advance of Contractor’s receipt of review comments and Approval shall be entirely at Contractor’s risk. After review, Contractor shall not deviate in any way from the design, details, dimensions, or other information shown on the drawings without the written Approval of Engineer.

1.2.2 Documents and Drawings Documents and drawings submitted by the Contractor, as a minimum, shall refer to information specifically required in the Submittal Schedule and elsewhere in this Specification. This information shall include all drawings, diagrams, illustrations, manufacturer’s product data, catalog data, brochures, performance charts, and other information required to illustrate distinct portions of work.

Exhibit S

Specifications


Documents and Drawings shall include all the details necessary for fabrication, assembly, installation, repair, and maintenance of furnished items. The minimum drawings required are specified in individual sections of the Specifications. Contractor shall furnish detailed fabrication drawings (Shop Drawings) and procedures for installation and assembly of all items provided.

If standard drawings or catalog cut sheets are submitted, the applicable items and devices furnished shall be clearly marked, e.g., arrows pointing to text, text highlighted, and/or items enclosed with boxes, separating the intended item from others on the page (see Section 01 30 00, Appendix 4.5).

1.2.3 Submittal Schedule Contractor shall prepare and submit a Submittal Schedule inclusive of all Drawings, calculations, procedures, and other documentation specified in these Contract Documents. The Submittal Schedule shall be prepared and submitted in Microsoft Excel (*.xls) or other Approved file format. The Submittal Schedule shall reflect submittal number, revision, description, anticipated submittal date, actual submittal date, District reference number (if applicable) and specification section number.

The Submittal Schedule shall be updated and maintained over the course of the Contract. The Submittal Schedule shall be updated and resubmitted monthly to reflect changes and for Progress Meetings, or as requested by Engineer.

1.2.4 District's Review The purpose for requiring Contractor submittals is to permit the District’s Engineer to monitor the Contractor’s progress and to determine conformance with the intent of these Specifications.

Contractors and Subcontractors who use unapproved documents do so at their own risk and may be required to repeat activities that were performed if the document used is subsequently rejected by Engineer.

Submittals reviewed by the Engineer do not become Contract Documents and are not Change Orders.

Engineer’s review, acceptance, or Approval of schedules, Shop Drawings, lists of materials, and procedures submitted or requested by the Contractor shall not add to the Contract amount and additional costs shall be solely the obligation of the Contractor.

The District will not be precluded, by virtue of review, acceptance, or Approval, from obtaining a credit for fabrication and/or construction savings resulting from allowed concessions in the Work or materials provided. Any savings shall be mutually agreed upon by the Engineer and the Contractor and evidenced by an executed FWO/CO.

Exhibit S

Specifications


The Engineer’s review of Contractor submittals is not intended to be a rigorous engineering analysis of the Contractor’s design or proposal. Engineer reserves the right to require the Contractor to make changes to Contractor’s submittals, which may be necessary, in their opinion, to make the Work conform to the provisions and intent of these Specifications. Any additional cost to correct a submittal, including work to maintain the schedule that may result from any delay to review a resubmittal, shall be solely the obligation of the Contractor.

The District will not be responsible for furnishing engineering or other services to protect the Contractor from additional costs accruing from submittals.

1.2.5 Ownership All documents (i.e., Shop Drawings, data, manuals, calculations, schedules, etc., as well as plans and procedures for installation or testing) shall become the property of the District. The District shall have full rights to reproduce and submit to others any document for bids on future projects, notwithstanding any indication otherwise on the Drawing or elsewhere.

1.2.6 Language All documents (i.e. Shop Drawings, data, manuals, plans, procedures, calculations, schedules, digital photographs, etc.) submitted to the Engineer shall be in the English language. Dual language is acceptable on Drawings, provided all information is also provided in English. All numeric data shall use foot-pound-second system of units of measurements. All elevations shall be dimensioned in feet.

1.2.7 Format 1.2.7.1 Electronic File Format The following list of software and file formats shall be used for all submitted documentation or as approved by the Engineer.

SOFTWARE FILE FORMAT USAGE EXAMPLES MathCAD® MCD (*.mcdx) Engineering calculations

Microsoft® Word DOC (*.docx) Text files, forms

Microsoft® Excel XLS (*.xlsx) Spreadsheets, forms, calculations

Microsoft® Access MDB (*.accdb) Databases

Adobe® PDF (*.pdf) Text, pictures, reports, manuals, calculations

Audio editing WAV (*.wav) Audio files

Exhibit S

Specifications


SOFTWARE FILE FORMAT USAGE EXAMPLES

Autodesk Inventor

Part (.ipt) Files Assembly (.iam)

Files Presentation (ipn)

Files Drawing (.idw,

.dwg) Files

3D parametric design

Autodesk® AutoCAD® DWG (*.dwg) 2013 or earlier Shop Drawings

Autodesk® DWF Viewer™ DWF (*.dwf) Shop Drawings

All software used shall be the latest version or as approved by the Engineer. The only exception is for Autodesk® AutoCAD®, which shall be version 2013 (or earlier)

1.2.8 Drawings Project drawings include the following:

1. Contract Drawings (as provided by District with the Bid); 2. Shop Drawings (all drawings provided by Contractor or Subcontractor, as

required by Contract); 3. Reference Drawings (as provided by District with Bid or at Contractors request

– all dimensions and locations of existing equipment shall be field verified, as necessary, by Contractor). These Reference Drawings may be hard copy or electronic or both.

ALL Drawings prepared by Contractor or Subcontractor shall be in compliance with the following sections.

1.2.8.1 Contract and Reference Drawings (Existing Drawings) Any existing Drawing (electronic or hard copy) requested by the Contractor will be scanned (if necessary) and sent via email, FTP site, or CD via mail, with a CD copy going to the Project Manager.

The Contractor shall make all changes to these Drawings adhering to the following conventions:

1. Color RED (AutoCAD color 242)- any additions. 2. Color GREEN (AutoCAD color 82) - any deletions.

Exhibit S

Specifications


3. Color BLUE (AutoCAD color 160) - general notes to explain changes. (NOTE: these general notes will not be added to the final Drawing.)

Approved District Format: Electronic file format shall be as described in Electronic File Format, above. The District's preference is to receive DWG (*.dwg) files, but DXF (*.dxf) or TIF (*.tif) files may be accepted with the District's prior Approval.

Revision tracking shall be done in capital alpha character, after the initial numeric revision provided (e.g., revisions to ‘Rev 4.0’ would be ‘Rev 4.0A’, ‘Rev 4.0B’, etc.).

The Contractor shall provide modified Contract and Reference Drawings, in approved format, as follows:

1. Posted to the Submittal Exchange web site, one (1) copy each electronic media (soft copy) including an enclosed master drawing list (with all image reference files included);

2. Mailed entire set of all drawings on CD, DVD or USB flash drive, including an enclosed master drawing list (with all image reference files included);

3. One (1) copy each, as a hard copy.

1.2.8.2 Shop Drawings (New Drawings) 1. Approved District Format:

a. Electronic file format shall be as described in Electronic File Format, above. The District's preference is to receive DWG (*.dwg) files, but DXF (*.dxf) or TIF (*.tif) files may be accepted with the District's prior approval.

b. Contractor shall comply with the National CAD Standard in these areas: 1) CAD Layering Guidelines 2) Tri-Services Plotting Guidelines (plot file will be provided by the District) 3) Drafting Conventions 4) Terms & Abbreviations 5) Symbols

2. Exceptions to the National CAD Standard shall be as follows: a. All Shop Drawing files shall be drawn at full scale (1:1) in Model Space. b. Acceptable hard copy size shall be as follows as defined in ANSI Y14.1

(preferred size will be at the Engineer’s discretion): 1) B-size 11"x17" 2) Arch C-size 18"x24" 3) ANSI D-size 22"x34" 4) Arch E1-size 30"x42"

c. Font shall be simplex.shx (provided by District) d. Any use of cross-references (“X-REF”) shall be bound within each Shop

Drawing.

Exhibit S

Specifications


e. Contractor shall use title block(s), border(s), and Shop Drawing numbering system provided by the District. (DO NOT MODIFY TITLE BLOCK. Other than populating existing attributes.)

f. All drawing files shall be individually named and numbered with a distinct drawing number per sheet. EXAMPLE: Drawing file name: 0505-61WD-0001.dwg Drawing number: 0505-61WD-0001. Only one (1) drawing per file will be accepted.

g. All sections, views and details shall be referenced to and from each appropriate sheet using the District’s drawing number.

3. Each Shop Drawing shall be identified with the following data: a. Rocky Reach Dam b. Date: YYYY-MM-DD c. Project designation: Powerhouse Bridge Cranes Refurbishment d. Contract number: 15-65 e. Drawing information:

1) Title 2) Number: 0220-61aa-nnnn 3) Revision number

f. Contractor information: 1) Name 2) Job reference number

4. Each Shop Drawing shall include: a. A revision-tracking log to indicate changes made since the last revision; b. Date revised; c. A clear mark near each change indicating the revision of the change; d. An area three (3) inches by three (3) inches left clear, located near the title

block for the District’s use in marking the drawing’s review and approval status.

District drawing numbers shall be placed on all Shop Drawings by the Contractor. This identification number will be supplied by the Engineer at earliest appropriate time prior to final Shop Drawing Approval and added by the Contractor to each individual Shop Drawing.

The Contractor shall be responsible for making sure that all Subcontractors conform to these same standards.

A graphical scale and component weights shall be included on each physical drawing.

Non-destructive examination scope, procedures, and acceptance criteria shall be indicated on physical drawings where applicable.

All deviations from the Contract Documents shall be conspicuously marked on the Shop Drawings or noted on the submittal form and accompanied by a request for deviation.

Exhibit S

Specifications


1.2.8.3 Electrical Shop Drawings Electrical Shop Drawings; schematics, wiring drawings, and panel layout drawings shall be in accordance with established District practice, as reflected in sample drawings provided as part of the Reference Drawings, for typical arrangement, layout, and format or as approved by Engineer.

Electrical Shop Drawings shall have sufficient detail to facilitate installation and maintenance of items including terminal block identification, component values for resistors, capacitors, etc., and industry standard designations on all semiconductor devices. 1.2.8.4 Project Record The Contractor shall maintain at the jobsite, one (1) complete set of Contract Documents including all Drawings (Contract Drawings, Reference Drawings, and Shop Drawings), Specifications, Addenda, Field Work Orders/Change Orders, and that are part of the Contract as awarded and one (1) complete set of all Contractor prepared drawings.

Each of these documents shall be clearly marked “Project Record Copy,” and shall be maintained in a clean and neat condition available for District and Contractor personnel, and shall not be used for any other purpose during the performance of the Work.

The Contractor shall record on the Project Record Copy all deviations in the actual work from the Contract Drawings Reference Drawings or Shop Drawings. This shall include changes to the Work resulting from any Change Orders, or which may be required during assembly, installation, or inspection of the Work.

Information shall be recorded concurrently with construction progress within 24 hours after receipt of information that a change to a Contract Drawing, Reference Drawing, or Shop Drawing has occurred. Work shall not be covered or concealed until the change is recorded.

Preservation:

1. The Contractor shall maintain documents in a clean, dry, legible condition and in good order. Record documents shall not be used for in-the-field purposes.

2. Documents shall be made available at all times for observation by the District and the Engineer.

Making Entries on Drawings:

Exhibit S

Specifications


1. Using an erasable colored pencil (not ink or indelible pencil), Contractor shall clearly describe the change by marking it on the drawing and providing a note as required. These entries shall be dated.

2. Color Coding: GREEN is used when showing information deleted from drawings. RED is used when showing information added to drawings. BLUE and circled in blue is used to show notes. The entry shall be highlighted by a “cloud” drawn around the area or areas affected.

1.2.8.5 As-Built Contract and Shop Drawings Upon Completion of the Work, the Contractor shall revise the Contract and Shop Drawings to accurately reflect As-Built conditions. Those drawings (Contract and Shop) shall conform to the Contract.

1.2.8.6 As-Built Reference Drawings Upon Completion of the Work, the Contractor shall provide the District with one (1) hard copy set of the Reference Drawings, with any As-Built marks done as part of the Work, in conformance with this section.

District-approved, As-Built Drawings (Contract and Shop; and Reference as required) shall be included as a deliverable for Substantial Completion for the contract, and shall conform to Contract Closeout Submittals, Record Drawings, and this section.

1.2.9 Calculations The Engineer shall have the right to review any and all of the Contractor's calculations, including all manual and computerized design calculations. If specified and/or requested by the Engineer, the Contractor shall provide all backup calculations, assumptions, flow charts, computer program documentation, and all other data necessary for proper review of the material by the Engineer.

1.3 PROJECT SCHEDULES 1.3.1 General The Contractor shall prepare and maintain Project schedules. Schedules shall be prepared and maintained in a District approved software format. Schedule submittals shall be posted to the Submittal Exchange web site and one (1) hard copy delivered to the Engineer. Schedule logic shall be included and the critical path calculated and indicated.

Schedules shall be updated to reflect all changes and to show progress, and submitted at least two (2) days prior to each scheduled Progress Meeting. Updates shall indicate actual progress against a baseline schedule established at the beginning of the project. Additionally, the Schedule shall be updated and resubmitted within five (5) working days

Exhibit S

Specifications


of any change known by the Contractor that could cause actual completion dates to exceed the Contract Time specified in the Contract Documents.

1.3.2 Combined Project and Production Schedule The Contractor shall prepare a combined project and production schedule within 20 days following District’s issuance of Notice of Award, but no less than 20 days prior to starting fabrication or construction (approval required prior to starting construction), and maintain a time scaled Critical Path Method (CPM) Schedule showing all significant activities from Contract award to final closeout. This Schedule shall show all major events, activities, milestones, and completion dates required for Completion of the Work.

The combined schedule shall include, as a minimum, the start date, duration time in days and the completion date for the following work items:

1. Planning and design activities, including engineering. 2. Submittal preparation with reference to Specification Section. 3. District response to Submittals. 4. Resubmittals (preparation and review) as applicable. 5. Procurement and receipt of materials. 6. Fabrication, assembly, and shop testing dates for major components. 7. Shipment and delivery of equipment/material to job site. 8. Construction (as a rollup). 9. Construction Phases (as children to the rollup) including installation, field

testing, and acceptance testing. 10. Substantial Completion. 11. Contract dates for Completion.

The Contractor shall assign such forces and perform the Work in such a manner as to assure compliance with the Approved Schedule and the Contract. The Contractor shall inform the Engineer of any Schedule changes.

1.4 CONTRACT CLOSE-OUT SUBMITTALS 1.4.1 Record Drawings After District’s final Approval, submit the following as part of the final As-Built Record Drawings Submittal, which will include all Shop Drawings and marked-up Reference Drawings including any changes made up to the time that the Work is completed and accepted, and all As-Built and field changes, in accordance with this Section:

1. One (1) complete, hard copy set of full-size, reproducible, final drawings (Shop and Reference);

Exhibit S

Specifications


2. One (1) electronic media copy (soft copy) set of all drawings (Shop and Reference as required) on CD, including an enclosed master drawing list (with all reference files included);

3. Post final As-Built Drawings (Shop and Reference as required) to the Submittal Exchange web site.

1.4.2 Record Documents Post record documents to the Submittal Exchange website and furnish one (1) complete set of record documents in hard copy to the Engineer, including, but not limited to, the following:

1. QA/QC Documentation. 2. Certificates of Compliance and Proper Installation. 3. Warranty Documentation.

Furnish duplicate copies of warranty documents that are executed and transferable from Subcontractors, suppliers, and manufacturers as applicable.

Final Documentation Submittal shall be a compilation of documents described above in 1.4.2, items 1 through 3, in order shown above into a three ring binder. Provide four (4) copies. Cover sheet for this binder shall include similar formatting to the following:

ROCKY REACH DAM POWERHOUSE BRIDGE CRANES REFURBISHMENT

NAME OF DOCUMENT (i.e., OPERATIONS AND MAINTENANCE MANUAL, QA/QC Dossier, etc)

(NAME OF CONTRACTOR)

CONTRACT NO. 15-65

(Date)



Exhibit S

Specifications


4.0 LIST OF APPENDICES

Appendix 4.1 – Required Submittals Appendix 4.2 – Contractor Submittal and District Reply Form Appendix 4.3 – Speedy Memo Form Appendix 4.4 – Record Of Conversation Form Appendix 4.5 – Showing How To Properly Identify Embedded Documents, Catalog Cut

Sheets, Etc.

Exhibit S

Specifications


4.1 REQUIRED SUBMITTALS

SECTION NUMBER ACTIVITY/DESCRIPTION

REQUIRED DATE: Calendar days after Notice to

Proceed unless otherwise noted

01 11 00

Resumes detailing work experience : 1. Project Manager. 2. Superintendent 3. Site Quality Representative

Provide with Bid Proposal.

01 11 00 Resumes detailing work experience :

1. Safety Representative. 2. Test Engineers

30 Days Prior to start of on-site Work.

01 30 00 Submittal Schedule Within 20 days after Notice of Award (NOA)

01 25 13 Proposed equivalent material standards Provide with Bid Proposal.

01 30 00 Submittal Schedule – updates Periodically updated

01 30 00 As-Built Record Drawings (which includes Contract and Shop Drawings; and Reference Drawings; updated Bill of Materials, and Calculations)

Required for Substantial Completion

01 30 00 Combined Project and Production Schedule Within 20 days after Notice of Award (NOA)

01 30 00 Critical Path Method Schedule (CPM)

On monthly interval, from Contract award to completion of work two (2) days prior to progress meetings. Additionally as required.

01 30 00 Contract Closeout Within 30 days after completion of work

01 31 19 The Contractor’s official correspondence address and the address, telephone number, and fax number of Contractor’s representative who will be the Project Manager for the Contract

Ten (10) days prior to Post Award Meeting

01 31 19 Contractor’s proposed list of attendees for the Post Award Meeting.

Ten (10) days prior to Post Award Meeting

01 35 24 Company Safety Manual. Within 20 days after Notice of Award

01 35 24 Site Specific Accident Prevention Program. Within 20 days after Notice of Award

Exhibit S

Specifications





01 35 24 Site Specific Safety Plan. Within 30 days prior to mobilization

01 35 24 Accident and Injury Reporting

Verbal notification – Immediately following incident. Written notification – Within 24 hours.

01 35 24 Emergency Notification Procedure Prior to commencement of work

01 35 24 Contractor Site Orientation Prior to commencement of work

01 35 24 Hot Work Permit (HWP) Prior to starting the work in the field (anywhere on site)

01 35 24 Fall Protection Work Plan Within 30 days prior to mobilization

01 35 24 For Contractor crane equipment. Current and signed crane inspection certificate that the crane meets all WAC and OSHA requirements for use.

Prior to starting the work in the field with the crane.

01 35 24 For any crane used as personnel lift. Current and signed crane inspection certificate that the crane meets all WAC and OSHA requirements for such use.

Prior to starting the work in the field with the crane.

01 35 24 Crane Critical Lift Plans.

20 days prior to the start of the work involving a critical lift.

01 35 25 Chemical Hazard Communication Program. 20 days prior to the start of site work

01 35 25 Sample Labels.

20 days prior to the start of the work requiring transfer of chemicals from original container.

01 42 13 Alternate Standards or Codes Provide with Bid Proposal

01 43 33 Installation and testing procedures describing the sequence of operations and the methods to be used for installation.

20 days prior to use of products.

01 43 33 Lesson Plans 21 days prior to scheduled training

Exhibit S

Specifications





01 45 16.13 Contractor Quality Control (CQC) Plan, including an Inspection and Test Plan (ITP)

30 days prior to the start of any work

01 45 16.13 Sample of Non-Conformance Report 30 days prior to the start of any work

01 45 16.13 Field Test Reports Within 48 hours of completion of each field test

01 45 16.13 Test Results Within 48 hours of completion of each test

01 45 16.13 Certification of Compliance

Receipt of signed Certification of Compliance is required for Shipping Release by the District

01 45 16.13 Certification of Proper Installation After installation of equipment

01 50 00 Copies of permits and approvals for construction as required 30 days prior to the start of any on-site activities

01 50 00 Copies of Safety Data Sheets (SDS) for any products brought onto the Site

Prior to mobilization to the site.

01 50 00 Affidavits detailing work experience and physical examination history for operators

30 days prior to the start of any on-site activities

01 50 00

Temporary Utility Submittals:

1. Electric power supply and distribution plans. 2. Water supply and distribution plans. 3. Compressed air supply and distribution plans. 4. Sanitary facility plans. 5. Communications routing plan for telephone and fiber

30 days prior to starting work

Exhibit S

Specifications





01 50 00

Temporary Construction Submittals:

1. Parking area plans. 2. Contractor’s field office and storage yard, storage

buildings, machining/fabrication shop, and any other on-site facilities; proposed layout and use plan.

3. Fencing and protective barrier locations and details. 4. Staging area locations plan. 5. Equipment and material storage, staging, erection, etc. 6. Scaffolding schemes. 7. Traffic and Pedestrian Control and Routing Plans: As

specified herein, and proposed revisions thereto. 8. Transport vehicle wheel loading diagrams. 9. Equipment staging and use plan for powerhouse service

bay floor. Includes details of equipment loadings and calculations and drawings verifying proposed equipment loads do not exceed allowable floor structural capacity. Calculations and drawings shall be stamped by a Structural Engineer licensed in the State of Washington


01 50 00

Temporary Controls Submittals:

1. Dust control plan 2. Waste water control plan 3. Plan for disposal of waste material 4. Spill prevention, containment and countermeasures plan

(SPCC)


01 61 00 Bill of materials (BoMs), packing list, and schedule of shipment and delivery.

30 days prior to shipping

01 61 00 Shipping Release. 20 days prior to shipping any parts to site

01 77 00

Informational Submittals: 1. Record Documents; 2. Approved Shop Drawings; 3. Special bonds, Special Guarantees, and Service

Agreements; 4. Consent of Surety to Final Payment; 5. Releases or Waivers of Liens and Claims; 6. Releases from Agreements; 7. Final Application for Payment; 8. Extra Materials

Prior to application for final payment

01 78 23 Installation Instructions Submitted and approved prior to start of any work

Exhibit S

Specifications





01 78 23 O&M manuals Submitted and Approved before commissioning

01 78 43 List of recommended spare parts Provide with Bid Proposal

01 78 43 Updated list of recommended spare parts After Approval of Shop Drawings

01 78 43 Inventory of spare parts Prior to shipping

01 78 43 Final spare parts list After Approval of Contractor equipment designs

01 91 14 Startup procedures for shop and field test Inspection Test Plans (ITPs)

At least 20 days prior to test

01 91 14 Shop and Field Inspection Test Plans (ITPs) At least 30 days prior to test

01 91 14 Field and shop functional and performance test results Within 48 hours of completion of each test

02 41 19 Equipment removal and demolition work plan. 30 days prior to starting work

02 82 13.01 Site Safety and Health Plan Within 30 days prior to mobilization

02 82 13.01 Qualifications of the asbestos abatement contractor, his onsite supervisor, and workers

Within 30 days prior to mobilization

02 82 13.01 Air sample results Within 24 hours after completion of the sampling period.

02 83 33.13 Site Safety and Health Plan Within 30 days prior to mobilization

02 83 33.13 Proof of Certification of independent testing lab

At least 20 days prior to any testing work performed by lab.

02 83 33.13 Test Results for worker blood level testing Within 48 hours of completion of each test

02 83 33.13 Qualifications - Evidence of worker qualifications to perform lead based paint removal and abetment work.

Within 30 days prior to mobilization

05 05 23 Shop and field Welding Procedures (WPS) and Procedure Qualification Records (PQR)


Exhibit S

Specifications





05 05 23 NDT procedure specifications prepared in accordance with ASME BPVC SEC V


05 05 23

Welding Data (Shop and Field):

1. Show on Shop Drawings or a weld map complete information regarding base metal specification designation, location, type, size, and extent of welds with reference called out for WPS and NDE numbers in tails of combined welding and NDE symbols as indicated in AWS A2.4

2. Clearly distinguish between shop and field welds 3. Indicate, by welding symbols or sketches, details of

welded joints and preparation of base metal. Provide complete joint welding details showing bevels, groove angles, and root openings for welds

4. Welding and NDE symbols shall be in accordance with AWS A2.4

5. Welding terms and definitions shall be in accordance with AWS A3.0

6. Submit welding data together with Shop Drawings as a complete package


05 05 23 Weld repair procedures 20 days prior to starting work

05 05 23 Stress-Relief Time Temperature Charts Within 30 days after stress relieving

05 05 23 Qualification of Welders 30 days prior to starting work

05 05 23 Certification of Welding Inspectors 30 days prior to starting work

05 05 23 Testing agency personnel credentials 30 days prior to starting work

05 05 23 CWI reports Within five (5) days of the inspection

05 05 23 Welding documentation Within 30 days of completion of the work

05 05 24

High Strength Bolts:

1. Certificates of Compliance 2. Manufacturer’s Inspection Test Reports 3. Certificate of Mill Test Reports for Bolts and Nuts


Exhibit S

Specifications





05 50 00 Shop Drawings:

1. Metal fabrications, including welding and fastener information


05 50 00 Ladders: Letter of certification that ladder meets OSHA 29 CFR 1910.27 requirements


05 50 00 Hot-Dip Galvanizing: Certificate of compliance 20 days prior to starting work

05 50 00 Passivation method for stainless steel members 20 days prior to starting work

05 56 00

Informational Submittals:

1. Certificates of Compliance that products meet chemical and mechanical requirements of standards specified

2. Certificates of Compliance that castings meet the design requirements for the equipment

3. Qualifications of the individuals performing inspection, nondestructive examination, and repairing

4. Manufacturer’s inspection test and examination reports


05 56 00 Descriptive report of defects and repair procedures for casting defects

20 days prior to starting casting repair work

05 58 10

Informational Submittals:

1. Certificates of Compliance that products meet chemical and mechanical requirements of standards specified

2. Certificates of Compliance that castings meet the design requirements for the equipment

3. Qualifications of the individuals performing inspection, nondestructive examination, and repairing

4. Manufacturer’s inspection test and examination reports


05 58 10 Descriptive report of defects and repair procedures for forging defects

20 days prior to starting forging repair work

09 90 04 Work Plan 20 days prior to starting work

09 90 04 QA/QC Plan 20 days prior to starting work

09 90 04 Inspection and Test Plan 20 days prior to starting work

Exhibit S

Specifications





09 90 04

Product Data Sheets:

1. For each product, furnish a Product Data Sheet (PDS), the manufacturer’s technical data sheets, and paint colors available (where applicable). The PDS form is appended to the end of this section (Appendix 4.3).

2. For each paint system, furnish a Paint System Data Sheet (PSDS). The PSDS form is appended to the end of this section (Appendix 4.2).

3. Furnish copies of paint system submittals to coating applicator.

4. Indiscriminate submittal of manufacturer’s literature is not acceptable


09 90 04 Detailed chemical and gradation analysis for each proposed abrasive material

Twenty (20) days prior to starting work

09 90 04 Samples: Reference Panel Ten (10) days prior to starting work

09 90 04 Test/inspection reports

Within forty-eight (48) hours of completion of each field test

09 90 04 Manufacturer’s written verification that submitted products are suitable for the intended use

Twenty (20) days prior to starting work

09 90 04 Factory Applied Coatings: Manufacturer’s certification Five (5) days prior to shipping to Site

09 90 04 Coating Manufacturer’s Certificate of Compliance

Receipt of signed Certification of Compliance is required for shipping release by the District

09 90 04 Applicator’s experience and certification Twenty (20) days prior to starting work

26 08 00

Submit prior to performing inspections or tests:

1. Schedule for performing inspection and tests. 2. List of references to be used for each test. 3. Sample copy of equipment and materials inspection

form(s).

Thirty (30) days prior to performing inspections or tests

26 08 00 Test reports, inspection reports and certificates for each electrical item tested (as part of shop and field tests)

Within 48 hours after completion of test

Exhibit S

Specifications





26 08 00

Operation and Maintenance Data:

1. In accordance with Section 01 45 16.13, Contractor Quality Control

2. After test or inspection reports and certificates have been reviewed by Engineer and returned, insert a copy of each in Operation and Maintenance Manual

Prior to application for final payment

41 05 13.13 Manufacturer’s inspection test and examination reports to certify that products meet chemical and mechanical requirements of standards specified.

As soon as practical but not less than 20 days prior to start of work.

41 22 10.13 Procedures: Work Plan; QA/QC Plan; Inspection and Test Plan.(For Mechanical Work Items)


41 22 10.13

Mechanical Drawings to demonstrate fully that all parts will conform to the provisions and intent of this Section and related Sections, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 10.13 for listing of drawings required)


41 22 10.13

Equipment and Material Lists (Mechanical)

1. Equipment and material lists shall be provided for all items, pieces, parts and assemblies to provide a complete listing of all components that make up the refurbished crane system.

2. Bills of Material (BOM) shall be provided for each assembly drawing with bill of material item number corresponding with item number indicated on assembly drawings.

3. BOM shall include quantity, manufacturer, manufacturer’s part number and description.


41 22 10.13

Catalog Data

1. Provide product specifications, descriptive literature, and performance data for items of standard manufacture.

2. Catalog data shall be submitted for items of standard manufacture, which will consist of the manufacturer’s published catalog; including but not limited to product specifications, descriptive literature and performance data


Exhibit S

Specifications





41 22 10.13

Engineering Data to demonstrate fully that all parts will conform to the provisions and intent of the Specifications, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 10.13 for listing of engineering data required)


41 22 10.13

Reports and Documentation to demonstrate fully that all parts will conform to the provisions and intent of the Specifications, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 10.13 for listing of reports and documentation data required)


41 22 11.13 Procedures: Work Plan; QA/QC Plan; Inspection and Test Plan.(For Electrical Work Items)


41 22 11.13

Electrical Drawings to demonstrate fully that all parts will conform to the provisions and intent of this Section and related Sections, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 11.13 for listing of drawings required)


41 22 11.13

Equipment and Material Lists (Electrical)





Exhibit S

Specifications





41 22 11.13

Catalog Data 1. Provide product specifications, descriptive literature, and

performance data for electrical items of standard manufacture; including but not limited to manufacturer’s data sheets for motors, brakes, limit switches, circuit breakers, ACVF drives, contactors and similar electrical components, etc.

2. Catalog data shall be submitted for items of standard manufacture, which will consist of the manufacturer’s published catalog; including but not limited to product specifications, descriptive literature and performance data

41 22 11.13

Engineering Data to demonstrate fully that all parts will conform to the provisions and intent of the Specifications, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 11.13 for listing of engineering data required)


41 22 11.13

Reports and Documentation to demonstrate fully that all parts will conform to the provisions and intent of the Specifications, and to the requirements related to installation, operation, and maintenance (see Specifications Section 41 22 11.13 for listing of reports and documentation data required)


Exhibit S

Specifications


4.2 SAMPLE: CONTRACTOR SUBMITTAL AND DISTRICT REPLY FORM

CONTRACTOR SUBMITTAL & DISTRICT REPLY FORM Submittal No.: 1565-XXXX-S-XXXX-0

TO: P.U.D. No. 1 of Chelan County Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment Project Manager, Steve Wiest ATTN: Donna Olman 327 N. Wenatchee Ave Wenatchee, WA 98801

Project: Contract 15-65 Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment

Date Submitted:

FROM: Approved Submittal Schedule Date:

Submittal Type: Shop Drawing Administrative Sample No. of Copies:

Quality Control Contract Closeout “Or-Equal”/Substitute

CONTRACTOR SUBMITTAL: DISTRICT REPLY:

No.

CPUD REF-if

app

Spec &

Para No.

Description of Item (Type Size, Model No, etc.) Drawing or Brochure No.

Contract Variation N-or-Y Status* Action**

Reviewed by & Date

1.

2.

3.

4.

Contractor Comments: Contractor hereby certifies that (i) contractor has complied with the requirements of Contract Documents in preparation, review, and submission of designated Submittal and (ii) the Submittal is complete and in accordance with the Contract Documents and requirements of laws and regulations and governing agencies. By:__________________________________________________ CONTRACTOR (Authorized Signature)

District Comments: Review is for general conformance with the design concept and contract documents. Markings or comments shall not be construed as relieving the Contractor from compliance with the contract documents. The Contractor remains responsible for details and accuracy, for confirming and correlating all quantities and dimensions for fabrication processes; for techniques of assembly; and performing the work safely. Status*: Action**:

ANR – Approval Not Required NR – No Action Required APP – Approved REV – Revise and Resubmit for Approval AAR – Approved as Revised RSR – Revise and Submit for Record NOT APP – Not Approved SR – Submit for Record

Exhibit S

Specifications


4.3 SAMPLE: SPEEDY MEMO

SPEEDY MEMO Speedy Memo Number: 1565-XXXX-MXXXX-0

Date:

To:

From:


Regarding:

Description/Request:

Requested Due Date:

Attachments: By:

Copy: Date:

Response Assigned To (Names(s) and/or Organization(s)):

Response A:

Attachments: By:

Copy: Date:

CCPUD Action Required:

Follow Up Variance Field Order / Change Order DWG/Spec

Revision Other:

Action Completed:

By: Date:

Exhibit S

Specifications


4.4 SAMPLE: RECORD OF CONVERSATION

RECORD OF CONVERSATION

Check one: Phone Call Personal Contact

Date: Time: ROC No. 1565-XXXX-RXXXX-0


Person(s) Talked With:

Company / Phone Number:

Conversation Summary:

Significant Decisions:

Required Actions/Follow-up:

Signature: Date:

Distribution:

Exhibit S

Specifications


4.5 SAMPLE: SHOWING HOW TO PROPERLY IDENTIFY EMBEDDED DOCUMENTS, CATALOG CUT SHEETS, ETC.


Exhibit S

Specifictions

Bid No. 15-65 Coordination and Meetings – 01 31 19 Page 1

SECTION 01 31 19

COORDINATION AND MEETINGS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 COORDINATION ................................................................................................... 2 1.2 PROJECT SITE COORDINATION ............................................................................. 2 1.3 POST-AWARD MEETING ....................................................................................... 2 1.4 QUALITY CONTROL COORDINATION MEETING ........................................................ 3 1.5 SAFETY MEETINGS .............................................................................................. 3 1.6 PROGRESS MEETINGS ......................................................................................... 3 1.7 PRECONSTRUCTION CONFERENCE ........................................................................ 4 1.8 WEEKLY CONSTRUCTION PROGRESS MEETINGS .................................................... 4 1.9 RECORD DRAWINGS REVIEW MEETING ................................................................. 5


Exhibit S

Specifictions


SECTION 01 31 19

COORDINATION AND MEETINGS

1.0 GENERAL

1.1 COORDINATION Contractor shall submit to District and Engineer:

1. The Contractor’s official correspondence address. 2. The address, telephone number, and fax number of Contractor’s representative

who will be the project manager for the Contract.

Throughout the duration of the Contract, submit to the District and Engineer in writing the names, addresses, telephone numbers, e-mail addresses, and fax numbers of Contractor’s and Subcontractor’s representatives.

Expenses: For attendance at all meetings described in this Section, all participants will be responsible for their own expenses without additional compensation by the District.

1.2 PROJECT SITE COORDINATION

District and other contractors may need access to and across the powerhouse generator floor during on-site construction. Contractor shall plan for and accommodate such activities as a normal part of Contractor’s Work. Contractor shall fully coordinate its activities with the District and other contractors. This includes promptly bringing any conflicts or coordination problems to the District’s attention.

Contractor shall be responsible for coordinating the manufacture, testing, inspection, delivery, and storage of all products furnished under this Contract. Contractor shall be responsible for delivery, on-site storage, and handling of all equipment and material to the Project Site.

Contractor shall be responsible for the coordination of its Work to the work of other trades, contractors, and with the District.

1.3 POST-AWARD MEETING 1.3.1 Schedule The post-award meeting will be held at the District’s office in Wenatchee, Washington no later than 20 calendar days after the District’s issuance of the Notice of Award of this Contract.

Exhibit S

Specifictions


1.3.2 Meeting Agenda The meeting agenda will be prepared by the District in advance of the meeting. Agenda will include a review of the Specification requirements, major activities, Contractor’s proposal, submittal schedule, list of submittals, and overall project schedule. In addition, requirements for Contractor personnel to comply with the latest District policies on “No Smoking”, “Violence in the Workplace”, and “Fitness for Duty” while working on District property will be reviewed.

1.3.3 Meeting Participants The Contractor shall ensure that the Contractor and representatives for the major Subcontractors, and others (as may be required by the District) shall participate in the post-award meeting. Contractor shall submit post-award meeting attendee list for review by Engineer, at least 10 calendar days prior to post-award meeting.

1.4 QUALITY CONTROL COORDINATION MEETING In accordance with Section 01 45 16.13 Contractor Quality Control.

1.5 SAFETY MEETINGS In accordance with Section 01 35 24, Safety.

1.6 PROGRESS MEETINGS Progress meetings shall be conducted bi-weekly over the course of the Work, or more frequently as directed by the District. 1.6.1 Meeting Agenda The meeting agenda will be prepared by the Engineer in advance of the meeting and will include, but not limited to review of the following:

1. Previous meeting minutes 2. Unresolved issues 3. Cost and schedule issues 4. Submittals 5. Work in progress, problems, difficulties, or delays 6. Scheduled activities for the current and subsequent week 7. Methods being employed for the Work 8. Workmanship, quality issues, and other deficiencies in the Work 9. Incidents, accidents, and injuries 10. Observations and decisions

Exhibit S

Specifictions


1.6.2 Meeting Participants Contractor shall ensure that the Contractor and representatives from principal subcontractors and others as may be required by the District, shall participate in the periodic progress meetings.

1.7 PRECONSTRUCTION CONFERENCE 1.7.1 General A preconstruction meeting shall be held at approximately 60 calendar days prior to Contractor’s mobilization to Project Site. The preconstruction conference will be held at the location, date, and time to be designated by the District.

1.7.2 Agenda The matters to be discussed at the preconstruction meeting include:

1. Installation schedule and progress reports to be submitted by Contractor 2. Communication and general correspondence procedures between the parties 3. The names and titles of all persons authorized by the Contractor to represent

and execute documents with samples of all authorized signatures 4. The names, addresses, and telephone numbers of all those authorized by the

Contractor to act for it in emergencies 5. Site access and security requirements 6. Specification requirements for site Work 7. Submittals related to site Work 8. Other administrative and general matters as needed 9. Emergency telephone numbers for doctors, hospital, ambulance service, etc. 10. Site layout and location of field office 11. Safety regulations and site specific safety plans

1.7.3 Meeting Participants Contractor shall ensure that the Contractor and representatives from principal Subcontractors and others, as required by the District, shall participate in the preconstruction meeting. The Contractor shall submit preconstruction meeting attendee list for review by the Engineer, at least 20 calendar days prior to the meeting.

1.8 WEEKLY CONSTRUCTION PROGRESS MEETINGS 1.8.1 General During construction, progress meetings shall be held weekly over the course of the Work, or more frequently as directed by the District.

The District shall have the final determination of the need for additional meetings and the meeting locations.

Exhibit S

Specifictions


1.8.2 Meeting Agenda The meeting agenda will be prepared by the District in advance of the meeting and will include, but not be limited to, review of the following:

1. Previous meeting minutes 2. Unresolved issues 3. Cost and schedule issues 4. Work in progress, problems, difficulties, or delays 5. Site improvement coordination 6. Scheduled activities for the current and subsequent week 7. Methods being employed for the Work 8. Workmanship, quality issues, and other deficiencies in the Work 9. Incidents, accidents, and injuries 10. Observations and decisions

All matters bearing on the progress and performance of the Work since the preceding progress meeting will be discussed and resolved; including, without limitation, any previously unresolved matters; deficiencies in the Work or the methods being employed for the Work; and problems, difficulties, or delays which may be encountered; in order that the Work may be completed on schedule and within cost.

1.8.3 Meeting Participants Contractor shall ensure that the Contractor and representatives from principal Subcontractors and others, as required by the District, shall participate in the weekly construction progress meeting.

1.9 RECORD DRAWINGS REVIEW MEETING A Record Drawing review meeting will be held at the District’s office or project office to discuss and summarize the changes to Contract Drawings, to discuss the punch list items, and to discuss contractual matters.

Upon completion of the project, the Contractor shall submit Project Record Drawings, including manufacturers’ reproducible Record Drawings reflecting all field changes concerning the document package addressed in Section 01 11 00 Summary of Work, Section 01 30 00 Administrative Requirements, and Section 01 77 00 Contract Closeout, to the District before final payment will be made. Drawing format shall be in accordance with Section 01 30 00 Administrative Requirements.

Exhibit S

Specifictions





Exhibit S Specifications

Bid No. 15-65 Safety – 01 35 24 Page 1

SECTION 01 35 24

SAFETY

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 3 1.3 SAFETY PLAN ...................................................................................................... 4

1.4 FALL PROTECTION PLAN ...................................................................................... 4 1.5 ACTIVITY HAZARD ANALYSIS ................................................................................ 5

1.6 CRITICAL LIFT PLAN ............................................................................................. 6 1.7 SAFETY MEETINGS .............................................................................................. 7 1.8 ACCIDENT AND INJURY REPORTING ....................................................................... 7

1.9 EMERGENCY NOTIFICATION PROCEDURE .............................................................. 7 1.10 ACCIDENT PREVENTION PROGRAM ....................................................................... 8

1.11 HOT WORK PERMIT (HWP) ................................................................................. 8 2.0 PRODUCTS (NOT USED).................................................................................... 8 3.0 EXECUTION ......................................................................................................... 9

3.1 GENERAL ............................................................................................................ 9 3.2 WORK AREA ENVIRONMENT ................................................................................. 9

3.3 SAFE CLEARANCE (TAG OUT) PROCEDURES ......................................................... 9

3.4 FIRE PREVENTION ............................................................................................. 10

4.0 APPENDICES .................................................................................................... 11 4.1 APPENDIX A - CONTRACTOR ACCIDENT PREVENTION PROGRAM

ORIENTATION/CHECKLIST .................................................................................. 11 4.2 APPENDIX B – NON-ELECTRICAL HOT WORK POLICY ........................................... 18 4.3 APPENDIX C - HOT WORK PERMIT ...................................................................... 22 4.4 APPENDIX D – PERSONAL PROTECTIVE EQUIPMENT ............................................. 23



SECTION 01 35 24

SAFETY

1.0 GENERAL

Safety requirements shall be in compliance with the requirements of General Conditions GC 59 Safety Requirements, and the safety requirements specified herein. In addition to the requirements of these sections, Work requiring the disturbing or removal of hazardous substances shall be in compliance with the requirements of General Conditions paragraph, Hazardous Substances and Environmental Protection, the requirements of Section 02 82 13.01 Class III Asbestos Abatement, and the requirements of Section 02 83 33.13 Lead Based Paint Removal and Disposal.

The District's goal is zero (0) injuries and accidents and the District expects the Contractor to have the same goal.

The Contractor is solely responsible for the safety of its employees and maintaining safe working conditions at the Work site.

Safety precautions shall be implemented by the Contractor to protect those individuals working at the Project site during the construction period.

District reserves the right to immediately stop any work or activity that is deemed to be inherently unsafe or in violation of established safe work practices. Costs relating to lost time and productivity due to Work stoppage for safety reasons are the sole responsibility of the Contractor and shall not be grounds for additional consideration, compensation to the Contractor, or the time for completion of the Contract.

Contractor shall perform weekly safety site inspections with the District’s representative to identify and correct hazards and unsafe working conditions.

Contractor shall provide all scaffolding and work platforms, lighting, and safety equipment, including hard hats, safety glasses, hearing protection, respirators, first-aid supplies, etc., required to perform the Work properly and safely.

1.1 REFERENCES

The following is a list of standards which may be referenced in this section:

Washington Administrative Code (WAC) WAC 296-24 General Safety and Health Standards WAC 296-62 General Occupational Health Standards



Washington Administrative Code (WAC) WAC 296-155 Safety Standards for Construction Work WAC 296-155 Part C-1 Fall Protection Requirements for Construction WAC 296-155-24605 Fall Protection Requirements for Construction, General

Requirements WAC 296-155 Part L Cranes, Rigging, and Personnel Lifting WAC 296-800 Safety and Health Core Rules WAC 296-800-140 Accident Prevention Program WAC 296-800-160 Personal Protective Equipment (PPE) WAC 296-800-16070 Make sure your employees are protected from drowning WAC 296-800-170 Employer – Chemical Hazard Communication WAC 296-809 Confined Space WAC 296-820 Core Rules WAC 296-841 Respiratory Hazards

1.2 SUBMITTALS

All Safety related submittals, Company Safety Manual, Site Specific Accident Prevention Program, and any other safety written programs as required by WISHA shall be approved by District prior to starting the work in the field. Contractor shall submit the following:

1. Contractor site specific Accident Prevention Program, including Emergency Notification Procedure, shall be submitted to the District for review within 20 calendar days after District’s issuance of Notice of Award

2. Contractor shall submit a site specific Safety Plan, with Emergency Notification Procedure, to the District’s Engineer for review 30 days prior to mobilization.

3. Contractor shall submit a site specific Fall Protection Plan to the District’s Engineer for review 30 days prior to mobilization.

4. Prior to use of a Contractor provided crane on the site, submit a current, signed inspection certificate stating that the crane meets all applicable WAC, OSHA and WISHA requirements for the intended use. The certificate shall be provided by the crane’s manufacturer, stamped by a Professional Engineer licensed in Washington State, or prepared by an independent certifying agency acceptable to the District.

5. Prior to use of a crane as a personnel lift, submit current, signed certification that the crane meets all WAC, OSHA and WISHA requirements for such use. Certification shall be provided by the crane’s manufacturer, stamped by a Professional Engineer licensed in Washington State, or prepared by an independent certifying agency acceptable to the District.

6. Prior to use of a crane for any non-routine crane lift that requires detailed planning and additional or unusual safety precautions, submit a Critical Lift Plan



to the District’s Engineer for review. The plan shall be submitted no later than 20 days prior to the start of the work involving the critical lift.

1.3 SAFETY PLAN

At all times Work is being performed on site, Contractor shall have and use a written Safety Plan that conforms to all applicable State safety requirements. Contractor’s written safety plan shall contain as a minimum:

1. Name of the Contractor employee designated as safety representative and made responsible for coordinating the Safety Plan and rescue operations.

2. Procedures to ensure that all Work is performed in compliance with District, Chelan County, State, and Federal OSHA safety regulations.

3. Activity Hazard Analysis Procedures for identifying unsafe conditions and taking appropriate corrective action.

4. Procedure to inform workers of the actions to be taken should an accident or emergency situation occur, including evacuation routes, locations of “safe areas” to account for all Contractor employees, and how to inform new employees that join the workforce at any time during the Contract.

5. Schedule for holding weekly safety meetings for Contractor personnel. 6. Requirements for discussing and reviewing in advance the planned activities for

major portions of the Work with Contractor’s employees, addressing safety issues related to the Work, and ensuring safe work practices are being used during the performance of the Work.

7. Locations of on-site safety equipment, e.g. eyewash stations, first-aid kits, fire extinguishers, Stokes stretcher, etc.

8. Requirements for Contractor personnel working in proximity to water to wear life jackets, in compliance with WAC 296-800-16070.

9. Requirements for Contractor personnel to comply with WAC 296-809 confined space entry regulations in permit required spaces.

10. Requirements for Contractor personnel to comply with the latest District policies on “No Smoking”, “Violence in the Workplace”, and “Fitness for Duty” while working on District property. The policies will be provided to Contractor at the post award meeting; additional copies will be provided upon request to the District.

11. Methods and equipment for prompt evacuation of injured personnel from the work area.

1.4 FALL PROTECTION PLAN

For any work activities where fall hazards exist, the Contractor shall have and use a written Fall Protection Plan that conforms to all applicable state safety requirements (e.g. see WAC 296-155 Part C-1 for a list of required contents). Contractor’s written fall protection plan shall as a minimum:



1. Identify all fall hazards in the work area. 2. Describe the method(s) of fall arrest or fall restraint to be provided to meet the

WAC requirements, e.g. attachment point above waist height and protection on ladders.

3. Describe the method(s) and equipment to be used to retrieve personnel whose falls have been arrested by fall arrest equipment.

4. Describe the correct procedures for the assembly, maintenance, inspection, and disassembly of the fall protection system to be used.

5. Describe the correct procedures for the handling, storage, and securing of tools and materials.

6. Describe the method of providing overhead protection for workers who may be in, or pass through the areas below the work sites.

7. Describe the method for prompt, safe removal from the work areas of injured workers, including locations of equipment on hand, e.g. hoists, Stokes stretchers, etc.

8. Be made available on the job site for inspection as necessary. 9. Ensure that employees are trained and instructed in the items described above,

prior to entering areas where fall hazards exist. 10. Provide for Contractor’s periodic inspection of fall protection devices and

systems to ensure compliance with WAC 296-155-24605. 11. Provide for Contractor’s training and documentation of training to ensure that

employees are familiar with the methods, equipment, and requirements of the Plan.

12. Provide for "retraining" when the Contractor has reason to believe that any affected employee who has already been trained does not have the understanding and skill required. Circumstances where retraining is required include, but are not limited to, situations where: changes in the workplace render previous training obsolete; or changes in the types of fall protection systems or equipment to be used render previous training obsolete; or inadequacies in an affected employee's knowledge or use of fall protection systems or equipment indicate that the employee has not retained the requisite understanding or skill.

1.5 ACTIVITY HAZARD ANALYSIS

Before beginning each work activity presenting hazards or whenever a change in the Contractor’s staff results in new personnel who have not been previously oriented to the potential work activity hazards, the Contractor shall prepare an activity hazard analysis. The activity hazard analysis shall define the activities being performed and identify the work sequences, the specific anticipated hazards, site conditions, equipment, materials, and the control measures to be implemented to eliminate or reduce each hazard to an acceptable level of risk.

The activity hazard analysis shall be in a format acceptable to the District and shall be submitted as part of the site specific safety plan. Updates to the activity hazard analysis

http://www.leg.wa.gov/wac/index.cfm?fuseaction=section&section=296-155-24510



shall be submitted to the District for review at least 5 days prior to the start of each phase of work for which the revision is required.

Work shall not begin until the activity hazard analysis procedures for the work activity has been accepted by the District and discussed with all engaged in the activity including the Contractor, subcontractors, and the District.

The activity hazard analysis will be reviewed at weekly safety meetings and updated as necessary when procedures, scheduling, or hazards change.

1.6 CRITICAL LIFT PLAN

The Contractor shall prepare and sign weight handling critical lift plans before making any critical lift. Critical lifts include the following:

1. Lifts involving hazardous materials; 2. Hoisting personnel with a crane or hoist; 3. Lifts where the center of gravity could change; 4. Lifts the operator considers to be critical; 5. Lifts over 75% of the rated capacity of the rigging used; 6. Lifts over 75% of the capacity of the crane or hoist (or lifts over 50% of the

capacity of a barge-mounted mobile crane's hoists) at any radius of lift; 7. Lifts over 75% of the load bearing capacity of the ground, outriggers, pads, and

floats used, or whenever foundation treatment is required to achieve a stable foundation of sufficient bearing capacity for the lift.

8. Lifts without the use of outriggers using rubber tire load charts; 9. Lifts involving more than one crane or hoist; 10. Lifts involving non-routine or technically difficult rigging arrangement (to include

lifts involving multiple lift rigging); 11. Lifts out of the operator’s view; 12. Load Tests.

The plan shall be developed by a qualified person and shall include the crane operator, lift supervisor, and the rigger and shall be signed by all personnel involved in the lift. The plan shall include the following:

1. The specific make and model of the cranes, the line, boom, and swing speeds; 2. The exact size and weight of the load to be lifted and all crane and rigging

components that add to the weight. The manufacturer's maximum load limits for the entire range of the lift, as listed in the load charts, shall also be specified;

3. The plan shall specify the lift geometry and procedures, including the crane position, height of the lift, the load radius, and the boom length and angle, for the entire range of the lift;

4. Site drawing shall be included to identify placement/location(s) of crane, adjacent equipment and/or facilities, etc.



5. The plan shall designate the crane operator, lift supervisor and rigger and include their qualifications;

6. The plan will include a rigging plan that shows the lift points and describes rigging procedures and hardware requirements;

7. The plan will describe the ground conditions, outrigger or crawler track requirements, and, if necessary, the design of mats, necessary to achieve a level, stable foundation of sufficient bearing capacity for the lift;

8. For floating crane or derricks, the plan shall describe the operating base (platform) condition and any potential maximum list / trim. The amount of list and trim shall be within the crane manufacturer's requirements;

9. The plan will list environmental conditions under which lift operations are to be stopped;

10. The plan will specify coordination and communication requirements for the lift operation;

11. For tandem or tailing crane lifts, identify the requirements for an equalizer beam if applicable.

1.7 SAFETY MEETINGS

Safety meetings shall be conducted to review past activities, plan for new or changed operations, establish safe working procedures for anticipated hazards, and provide pertinent safety and health training and motivation.

Meetings shall be conducted at least once a month for all supervisors on the project location and at least once a week for all workers by supervisors or foremen.

Meetings shall be documented, including the date, persons in attendance, subjects discussed, and names of individual(s) who conducted the meeting. Documentation shall be maintained and copies furnished to the District on request.

The District shall be informed of all scheduled meetings in advance and be invited to attend.

1.8 ACCIDENT AND INJURY REPORTING

Accidents involving equipment or employee(s) resulting in injury to employee or damage to equipment occurring on the Project site shall be reported to the District orally immediately after such incident, followed by a detailed written incident report within 24 hours of occurrence. Failure to report accidents or injuries to the District may result in immediate shutdown of Work.

1.9 EMERGENCY NOTIFICATION PROCEDURE

1. The Contractor shall be responsible for developing and implementing an Emergency Notification Procedure. Contractor shall submit the Emergency Notification Procedure for District review. This procedure shall be used to notify



all Contractor employees in designated Work areas in the event of an emergency.

2. The Contractor shall provide emergency notification equipment and train its employees, including affected District personnel on the use of this equipment. Contractor shall demonstrate the Emergency Notification Procedure to the District prior to commencing Work on site.

3. Contractor-supplied emergency notification equipment shall be maintained in good working order and tested monthly during the Work.

1.10 ACCIDENT PREVENTION PROGRAM

Contractor shall have a written Accident Prevention Program that conforms to all applicable Federal, State, or local safety requirements at all times Work is being performed on site. Washington Administrative Code Sections 296-800-140 and 296-155-110(3) requires employers to develop an Accident Prevention Program.

1.10.1 Contractor Accident Prevention Program Orientation

1. The District has developed an Accident Prevention Program Orientation Checklist (see 4.1 Appendix A of this section) pursuant to these regulations. The checklist is not intended to be all-inclusive. Contractor shall complete the checklist prior to commencement of Work and maintain documentation of completion, as well as documentation of Contractor and employee safety plans, inspections, and meetings. Contractor shall be responsible for reviewing checklist information and procedures with its employees.

2. Contractor shall be responsible for observing and educating its employees with regard to any and all safety regulations, procedures and equipment requirements applicable to, and consistent with, the type of work being performed.

1.11 HOT WORK PERMIT (HWP)

Contractor shall comply with the District's policy for non-electrical hot work, (see 4.2 – Appendix B of this section) attached, this policy is considered a minimum standard and does not relieve the Contractor of responsibility for safety while performing non-electrical hot work.




3.0 EXECUTION

3.1 GENERAL

Contractor shall discuss and review in advance the planned activities for major portions of the Work with its employees and address safety issues related to the Work and ensure safe work practices are being used during the performance of the Work.

The latest District policies on “No Smoking,” “Violence In The Workplace,” and “Fitness For Duty” shall apply to all Contractor employees working on District property. The policies will be provided to Contractor at the post award meeting; additional copies will be provided upon request to the District.

3.2 WORK AREA ENVIRONMENT

Contractor shall maintain a neat, clean, and safe work environment complying with all applicable regulations, laws, and codes during all site Work. Where there is a conflict in regulations, codes or laws, the most stringent shall apply.

Contractor shall keep the Work area free from accumulations of waste material or rubbish at all times. Upon completion of the Work, the Contractor shall remove all rubbish, tools, equipment, surplus materials, and chemicals from the site. All laydown, storage, staging and work areas shall be completely cleaned and restored to the original condition that existed prior to beginning the Work.

During disassembly, scraping, blasting, grinding, welding, brazing, painting and other work that could generate airborne contaminants, smoke, fumes or other irritants, Contractor shall provide air ventilation, cleaning, dust collection, containment or other applicable systems and equipment to prevent personnel hazard or irritation. Contractor shall verify the effectiveness of all engineering controls and PPE by performing an exposure assessment when personnel are exposed to contaminants. Contractor shall verify proper operation of ventilation equipment at the beginning of each shift. Contractor shall continue to monitor personnel exposed to contaminants as required in WAC 296-62.

3.3 SAFE CLEARANCE (TAG OUT) PROCEDURES

Any Work performed at the project site by the Contractor which requires taking equipment out of service shall require a Clearance Permit. Contractor shall follow District Clearance Policies and Procedures for obtaining equipment clearances.

Only the Powerhouse Control Room Operators will issue clearances at the request of the District’s designated Project Construction Representative on behalf of the Contractor. Contractor’s personnel will sign-on to the clearances as discussed in the District’s Dispatching and Operating Safety Manual. Contractor personnel shall not



violate the clearance procedure. District clearances will be taken prior to the issuance of Contractor clearance.

A copy of the District’s Dispatching and Operating Safety Rules and Instructions, which includes the Clearance Procedures, will be provided to the Contractor. All Contractors' clearance holders will be given training in these policies and procedures. Clearances will be issued only to those individuals who have successfully completed the training.

3.4 FIRE PREVENTION

The Contractor shall be responsible for fire prevention during the performance of the Work.

Proper fire fighting equipment shall be present in locations as prescribed by Washington Administrative Code 296-24 Part G.

Contractor shall provide appropriate and approved flammable liquid storage cabinets to be used for storage of all solvents, resins, and other flammable liquids.

The Contractor shall be responsible for all damage from fire due directly or indirectly to its own activities, the activities of its employees, and the activities of its Subcontractors and their employees.



4.0 APPENDICES 4.1 APPENDIX A - CONTRACTOR ACCIDENT PREVENTION PROGRAM

ORIENTATION/CHECKLIST



Contractor Safety Orientation Checklist Orientation Presented by:__________________________ Date: ___________

Company Contracted: ________________________________________________

Contract Title (Bid/SA#, Location/Project name, e.g.): __________________________

District Project Manager: _________________________________________________

The Chelan County PUD (“District”) has developed the following checklist to promote a general understanding of safety standards, guidelines and procedures that must be followed while working on District property. As used herein, the word “Contractor” includes consultants. Contractors must complete the checklist prior to commencement of work and maintain documentation of completion, as well as documentation of Contractor-employee safety plans, inspections, and meetings. Accident prevention programs submitted by the contractor must meet the requirements of WAC 296-800-140.

This orientation will be required annually and if necessary repeated if new information and/or work location changes. This orientation does not address all procedural items that a Chelan County PUD employee overseeing a project would typically review with the contractor.

Contractors are responsible for reviewing checklist information and procedures with their employees. The checklist is not designed to cover every safety issue applicable to Contractors’ work. Contractors are responsible for observing and educating their employees with regard to any and all safety regulations, procedures and equipment requirements applicable to employment in general, as well as those specifically applicable to their type of work. The Contractor is solely responsible for the safety of the Contractor’s employees and the work site.

Initials are required for each section. If section(s) do not apply write NA

CHECK LIST

___________ INTRODUCTIONS

The Contractor shall be introduced to the applicable facility supervisors, safety and maintenance personnel.

___________ CONTROL ROOM

The Contractor shall be made aware of the location and the function of the

Control Room. Contractor shall provide the Control Room an emergency phone

number list and list of on-site employees. A copy of the contract work plan

(accurate) will be provided to the Control Room.

Please route original document once completed to the Safety/HR Dept. Admin; retain a copy for your records if needed.



___________ EMERGENCY NUMBERS

Contractors working at Hydro plants should notify the Hydro Facility Control Room after calling the emergency number 911 or 9911. Hydro Facility Control Room phone numbers are:

Rocky Reach Dam: 509-662-8705 or Extension 6000 from a plant telephone

Rock Island Dam: 509-661-4007 or Extension 5000 from a plant telephone

Chelan Dam: 509-682-2612 or Extension 4227 from a plant telephone.

System Operations 509-661-4000

___________ MEDICAL FACILITIES

Discuss the location of the nearest first aid station or medical facility:

Confluence Health Wenatchee Valley Hospital aka “The Clinic”

820 N. Chelan Avenue Wenatchee, WA 98801 509-663-8711

Confluence Health Central Washington Hospital

1201 S. Miller Street Wenatchee, WA 98801 509-662-1511

Cascade Medical Center 871 Commercial Street Leavenworth, WA 98826 509-548-5815

Lake Chelan Community Hospital 503 E. Highland Avenue Chelan, WA 98816 509-682-3300

___________ EMERGENCY RESPONSE PLAN (ERP)

Contractors will be made aware of the facility’s ERP. The ERP deals with major emergencies that may arise such as fire or a major accident. Discuss assembly areas, evacuation routes and alternate evacuation routes. In the event of an emergency, contractors will be notified by District staff or audible alarm and they should report the emergency meeting area immediately. Once all employees and contractors are accounted for, they will be able to leave the site should the situation warrant.

Contractors shall also make the District aware of any company specific emergency response plan or signals (audible or visual) that could affect District workers in the area.

___________ CHECK-IN / CHECK-OUT

The Contractor shall be instructed on proper check-in/check-out procedures.

___________ PARKING

The Contractor will be shown where to park vehicles. Coordinate special arrangements (i.e. work at spillway) with appropriate plant supervision.



___________ VEHICLES, TOOLS & EQUIPMENT

Vehicles must be kept in safe operation condition. Only qualified equipment operators are to operate equipment

Tools, electrical cords, rigging equipment and machinery shall be in good condition and inspected before use.

___________ JOB SAFETY ANALYSIS

A job safety analysis (tailgate) is required daily to ensure hazards are identified and mitigated.

___________ SAFETY EQUIPMENT (PPE)

All safety equipment will be supplied by the contractor. Unless agreed upon

Chelan County PUD will not loan or provide any safety and health equipment.

Approved hard hats are required but not provided by the District for outside

contractor employees. Contractor must supply their employees with hard hats

and enforce the wearing of these items while working on District construction

projects. Other PPE such as special footwear and protective clothing may be

required depending on the task and activities being performed.

___________ INCIDENT REPORT

Any injury, property damage, safety concern or close call must be immediately reported to a Chelan County PUD representative as practical.

___________ FIRE EXTINGUISHERS

The Contractor will be made aware of the location of District fire extinguishers. Contractors must provide fire extinguishers as required by regulations and per contract.

___________ FLAMMABLES

Flammable liquids shall be stored in and dispensed from approved containers. Flammables and combustibles must be separated by a distance of no less than 20 feet. Oxygen cylinders must be separated from fuel gas cylinders by a distance of no less than 20 feet or by a five foot fire wall unless said cylinders are in use.

___________ HOUSEKEEPING

Proper housekeeping and maintaining a neat work area is required. This includes removal of trash and rubbish daily, and removal of all unused chemicals, paints, etc. from the site when project is completed.

___________ LADDERS/FALL PROTECTION

Ladders must be in good condition and must be made secure near the top.

Scaffolding shall be of substantial construction with guardrails and toe boards

installed.

Fall protection must be provided when employees are exposed to a fall greater

than 10 feet. On walking/working surfaces, fall protection must be provided at 4

feet. Where fall protection is required, a fall protection plan must be provided

that meets the requirements of WAC 296-155, Part C-1.



___________ OVERHEAD WORK

When overhead work is necessary, precautions must be taken to prevent fall of

persons and materials. The area underneath the work operation shall be

barricaded off and labeled with appropriate warning signs.

DISTRICT PERMITS/CLEARENCES

Permits/clearances must be obtained for the following operations BEFORE work begins:

___________ ENERGY ISOLATION (Lockout / Tag out)

Required for work on any equipment that may have live or stored energy that

could cause injuries or property damage if started accidentally or released. Do

not shut off or make connections to live electric, gas, air, water, or process lines

without the prior authorization Affected workers will require certification by

training and a test.

___________ CONFINED SPACE PERMIT

Permit required for any workers who enter permit required confined spaces.

Confined spaces must be cleaned, purged, and ventilated before employees are

allowed to enter them. Life lines, harnesses, and supplied air respirators may be

required. An attendant will be required for all permit confined space entries. All

work in confined spaces must meet the requirements of WAC 296-809 and

employees must be properly trained in accordance with this regulation.

Contractors entering confined spaces must submit a confined space program.

List all permit-required confined spaces here:

__________________________________________________________

__________________________________________________________

___________ HOT WORK PERMIT

Required for all open flame, spark-producing, or heat producing activities on-site.

This includes, but is not limited to: welding, cutting, grinding, soldering, brazing,

and heat producing chemicals. Control Room must be notified before work

begins.

Other permits may be required for special procedures or unusual work

conditions. Your District contact will coordinate permit requests for the specific

area where the work is being performed

___________ SAFETY BARRICADES AND SIGNAGE



Safety barricades must be in place at open man holes, floor holes, catch basins,

and excavations. Appropriate lights must be installed if holes are to be left open

after daylight hours.

___________ SPILL PREVENTION

Spill prevention and District procedures for spill clean-up, including notification of

Chelan County PUD personnel, will be reviewed for contractors who would be

using any petroleum-based products or hazardous materials on District property.

The contractor should ensure that the spill is contained before leaving the area to

report the spill. Contractors are responsible for providing spill containment kits.

___________ HAZARDOUS MATERIALS (WASTE)

Waste that is generated on District property that is designated “Dangerous

Waste” per WAC 173-303 needs to be stored and labeled properly by the

contractor. The contractor needs to work with Environmental to ensure proper

transfer of the waste at the point of generation. Unused hazardous material

product need to be removed at the end of the job by the contractor.

___________ RIGHT-TO-KNOW

WAC’s Right-to-Know (Hazard Communication) – This program is a WAC

requirement (WAC-296-800-170) requiring employers to ensure all employees,

including all contractors on-site, are aware of any hazards that they may be

exposed to in the workplace. Contractors will be made aware of recognized

chemical hazards and the location of MSafety Data Sheets (SDS). Contractors

must provide to the Project Manager prior to the start of work SDS Sheets for all

products brought to District Facilities and must make the District aware of when

and where hazardous products are being used. SDS’s must be current, legible

and in English. All chemical containers must be properly labeled.

___________ SUBSTATION/SWITCHYARD TRAINING/ORIENTATION (If applicable)

Anyone entering a District substation for any reason is required to have this

training on an annual basis. Contact Safety and Health Dept. to become

authorized.

___________ REGULATORY COMPLIANCE

All federal, state, local and District safety, health and environmental regulations

and rules must be observed by all employees of outside contractors. Contractor

supervisors shall ensure that all of their employees are aware of and comply with

the rules and regulations.

VIOLATORS WILL NOT BE PERMITTED TO WORK AT DISTRICT FACILITIES

Contractor Owners and employees attending:



PRINT NAME SIGNATURE

Orientation given by: __________________________ Date: _____________________

Please Note: Original must be forwarded to the Safety/HR Admin.



4.2 APPENDIX B – NON-ELECTRICAL HOT WORK POLICY

4.2.1 Purpose

The intended purpose of this policy is to provide a safe work environment for employees, visitors, and contractors on District property when hot work is performed. Hot work is defined as any operation involving open flames or producing heat or sparks. Potential health, safety, and property hazards can result from fumes, gases, sparks, hot metals, and radiant energy produced during hot work. These and other hazards can be reduced or eliminated through the implementation of effective controls outlined in this policy.

4.2.2 Scope

This policy applies to all District employees, contractors, and subcontractors involved in welding, cutting, torching, brazing of metals, grinding, or any portable gas procedures in areas other than those designated specifically for that purpose. This procedure also applies to anyone working with heat-producing chemicals.

4.2.3 Responsibilities

It is the responsibility of the Contractor to ensure that all individuals involved in hot work on District property to implement controls that will eliminate or greatly reduce the hazards generated by the work.

It is the responsibility of each supervisor whose employees engage in hot work to ensure that the guidelines in this policy are implemented, hazards are controlled, and necessary procedures and equipment are utilized to minimize exposure to hazards generated.

It is the responsibility of the District to provide necessary equipment to control the hazards generated by the work when said work is being performed by District employees.

It is the responsibility of the District’s Safety and Health Division to provide training to supervisors and District personnel involved in the planning of a job that requires hot work.

It is the responsibility of the person performing the work to complete HWPs prior to commencing with said work and to notify plant operators, system operations, or facility management accordingly.



4.2.4 General Cutting and Welding Controls

If possible, perform all hot work in designated shops or areas designed for hot work. When this is not possible, work areas must be properly analyzed and prepared before hot work is to be performed. The following controls will be implemented:

Cutting and welding operations are restricted to properly trained individuals only.

All hot work equipment must be inspected before use and be in good condition.

Fire extinguishers must be readily available (see paragraph 4.2.7, Fire Protection/Fire Watch of this section for further details).

Wooden floors beneath the hot work must be wet down, covered with damp sand, or protected with fire blankets.

Combustible materials must be moved at least 35 feet from where the hot work is to be performed. If this is not feasible, combustible items must be protected with metal guards, flameproof curtains or fire blankets. Ordinary tarpaulins or cloths are not acceptable protection.

Cover floor and wall openings located within 35 feet of the hot work area to prevent hot sparks from entering and falling beneath to a lower level. Ensure all floor openings are barricaded to prevent falls to a lower level.

Use fire-resistant curtains/blankets and/or tinted shields to prevent fire, employee burns, and ultraviolet exposure.

Smoke alarms should be disabled when necessary to prevent false alarms from sounding and unnecessary evacuation of the facility.

4.2.5 Heat-Producing Chemicals

Some chemicals produce heat and can spontaneously combust. The MSDS should always be reviewed before working with any chemical. When mixing heat-producing chemicals in quantities larger than 1 (one) gallon, a HWP must be issued.

4.2.6 Ventilation and Atmospheric Testing

Hot work shall not be conducted in the presence of flammable gases, vapors, liquids, or dusts (where an explosive concentration can develop). Atmospheric testing prior to work commencement and continuously thereafter must be conducted if the atmosphere in the work area has the potential to become hazardous (i.e., confined spaces).

Ventilation of the work site shall be adequate for the work being performed.

4.2.7 Fire Protection/Fire Watch

A person other than the operator of the equipment should perform fire watch duty. This includes remaining at the work site for at least 30 minutes after hot work operations have ended. In addition, the following steps shall be taken:

A fire extinguisher rated not less than 2A:20BC must be available in work areas where hot work is being performed.



A fire extinguisher rated not less than 2A:10BC must be attached to all portable cutting and welding carts.

If a building or area is equipped with a sprinkler system, the system must be operational when hot work is being performed.

4.2.8 Personal Protective Equipment

Personal Protective Equipment (PPE) specifically designed for hot work will be provided to, and utilized by, employees performing the hot work including, but not limited to, leather coats and sleeves, welding hoods, welding gloves, respirators, safety goggles, and face shields. Supervisors should consult the Safety and Health Division if questions arise regarding employee exposure and the PPE necessary to protect employees from over-exposure. See Appendix D, PPE of this section for additional details.

4.2.9 Confined Spaces

Any hot work done in confined spaces, whether designated permit entry or non-permit entry, will require that permit entry required procedures are followed. Hot work in any confined space exposes employees to atmospheric hazards and requires that the space be designated a permit entry confined space. Consult the District Confined Space Policy or Safety and Health Division with any questions.

4.2.10 Compressed Gas Cylinder Storage and Handling

The safe storage and handling of compressed gas cylinders is an important part of cutting and welding operations. The following steps will be followed:

Oxygen and fuel gas cylinders not in use should be stored properly with protective valve caps in place.

Except when in use, oxygen and fuel gas cylinders should be stored at least 20 feet apart or separated by a fire wall at least 5 feet high.

Cylinder carts equipped with a cylinder restraint (chain, strap) must be used for the transport of all compressed gas cylinders.

All cylinders must be secured when in storage or in use. Securing devices should be designed to prevent the tipping over of the cylinder.

Regulators must be compatible with the cylinder and its contents. Regulators are gas specific. Employees should ensure the correct regulator is being used.



4.2.11 Hot Work Permits

No hot work can be performed without the completion of a HWP except in those shops that have areas designed to accommodate hot work operations (CM Shop, fabrication shops inside plants and facilities, etc.) No HWP shall be valid for more than 24 hours. The procedure for completing and posting a HWP is as follows:

The foreman or person performing the hot work must complete a HWP before beginning any operation that produces open flame, heat or sparks. This includes, but is not limited to, brazing, welding, cutting, grinding, soldering, thawing, or working with heat guns or heat-producing chemicals. After completing the permit and ensuring proper precautions have been taken, the person performing the hot work must contact plant operators, system operations, or facility management. Each permit must be job specific. The HWP is a two-part document. The top copy is removed and returned to the appropriate supervisor when the work is completed. The bottom copy of the permit is to be displayed in plain view in the area where the hot work is being performed. When work is complete, the copy at the work site should be retained with the work packet, if applicable. If no work packet has been issued, the bottom copy should be returned to the appropriate supervisor. For confined space work, the copy should be retained with the confined space permit.

When the permit has expired or the work has been completed, contact plant operators, system operations or facility management and inform them the work is complete or that the HWP has expired and a new one has been issued.

Contractors shall have access to the District’s hot work policy. Before beginning any hot work on District property, the contractor’s representative should complete the HWP and contact the plant operator or facility management before beginning any hot work. The HWP must be displayed at the job site. When work is complete or the permit expires, the contractor will turn in the HWP to the District’s project manager assigned to the project. Contractor personnel are expected to adhere to all of the guidelines set forth in this policy and to make all reasonable efforts to protect the health and safety of all District employees and visitors.

There are no exceptions for outdoor work (i.e. switchyards, by-pass, etc.). The same procedure shall apply.

4.2.12 Training

District employees engaged in hot work operations will receive training and have developed the skills necessary to work in a safe and professional manner.

The Safety and Health Division will provide training to any employee on the topic of personal and fire safety as it relates to hot work.

District personnel with the responsibilities of completing HWPs will be trained in their completion and the guidelines of this policy by the Safety and Health Division.



4.3 APPENDIX C - HOT WORK PERMIT



4.4 APPENDIX D – PERSONAL PROTECTIVE EQUIPMENT

Generation Operational Standard

#10 - Personal Protective Equipment

Purpose: To prevent occupational diseases and injuries that may be avoided through the use of appropriate protective equipment.

This standard supports District Administrative Policy #701 and the Safety and Health Divisions PPE Standard. Procedure: Personal Protective Equipment (PPE) appropriate to the hazards in the workplace must be worn at all times to protect employees and contractors from hazards where or when they exist. Safety glasses, hard hats, shirts with sleeves, full length trousers and substantial leather footwear will be the minimum requirements where the typical job hazards dictate that protection per WAC 296-800-160. Hazard assessments will indicate the types of tasks and a list of crafts most susceptible to those tasks and those groups will be required to wear all PPE.

1. Safety Glasses

Eye protection must conform to the American National Standards Institute (ANSI), Standard Z87.1-2010.

Prescription safety glasses are recommended for employees who must routinely wear safety glasses in lieu of fitting safety glasses over their personal glasses. CCPUD requires polycarbonate lenses and side protection from either permanent side shields or wrap around style lenses providing full coverage.

2. Hard Hats

Hard hats designed to protect the head from impact and penetration from falling/flying objects and from limited electric shock and burn shall meet the requirements and specifications established in ANSI Z89.1

http://www.ncsu.edu/ehs/www99/right/handsMan/worker/ppe/prescr.html



3. Footwear:

At a minimum, sturdy leather boots with a 5 inch top measured from the ground are required at Generation facilities with the exception of Administration offices, areas open to public access, or designated areas. Cold weather work (ice and snow) and working in water will be exceptions to the all leather portion of the foot wear standard.

The need for sturdy leather footwear with toe protection for others will be established based on hazard assessments, the frequency of exposure, or a JSA review.

When toe protection footwear is required, it shall meet or exceed the ASTM I75 C75 with toe protection (steel or composite material) standard.

4. Hearing Protection:

Hearing protection is required for all employees that have an exposure of 85 dBA or above.

5. Face Shields:

Grinding requires a minimum of safety glasses and a face shield as well as hearing protection.

Caustic chemicals require goggles and a face shield as well as protective gloves and protective clothing. For more detailed information, always refer to the manufacturer’s MSDS.

Electrical welding requires a welding helmet with the appropriate shade. Gas welding requires appropriate shaded eye protection. Employees shall wear protective clothing that covers the body anywhere welding slag may land as a result of the activity being performed.

Respiratory protection per CCPUD “respiratory protection program” shall be followed. To view the “respiratory protection program” click here http://intranet/home/safety/TotalSafetyandHealthPlan.htm

6. Personal Flotation Devices

Personal floatation devices (PFDs) must be worn whenever an employee is working in the water, working over the water, or working in close proximity to water more than 5 feet deep.

Employees working behind a guardrail do not have to wear a PFD. However, PFD’s are required while leaning over or working through a guardrail.

All personnel on District boats must wear a PFD that is worn properly (buckled, zipped, etc.)

http://intranet/home/safety/TotalSafetyandHealthPlan.htm



Personnel attached to fall arrest systems (harnesses and lanyards/SLR) while working over water are not required to wear a PFD.

Employees shall wear an approved PFD or be protected by a safety belt, harness and lanyard, safety nets, or guardrails that prevent the employee from falling in the water.

VISITORS

District Representative will be responsible for escorting visitor and ensuring PPE requirements are followed. Minimum Requirements:

Safety glasses, hard hats, hearing protection, shirts with sleeves, full length trousers and substantial footwear will be the minimum PPE requirements. Clothing

Full length trousers and shirts with sleeves are required at all times during tours. Footwear:

Enclosed footwear will be required at all times during tour. Footwear must provide support to the ankle during transition while climbing and descending stairways.

Open toe footwear, high/low heels, sandals, flip flops, clogs; etc will not be allowed.

The need for sturdy leather footwear with toe protection may be established based on a hazard assessment or a JSA review.

Safety Glasses (Provided by the District)

Eye Protection will be required at all times during tours. All eye protection must conform to (ANSI), Standard Z87.1-2010.

Eye protection that provides coverage over personal prescription glasses will also be available for visitors.

CCPUD requires polycarbonate lenses and side protection from either permanent side shields or wrap around style lenses providing full coverage.

Hard Hats (Provided by the District)

Hard Hats will be required at all times during tours. Hard hats shall meet the requirements and specifications established in ANSI Z89.1

No personal hats and/ or headwear that may obstruct from proper fit will be allowed under hard hats.

Hearing Protection: (Provided by the District)

http://www.ncsu.edu/ehs/www99/right/handsMan/worker/ppe/prescr.html



Hearing protection is required for all visitors that have an exposure of 85 dBA or above.

Other PPE: (Provided by the District)

Includes but not limited to Face Shields, Goggles, Personal floatation devices (PFDs), Respiratory PPE, etc will be based on hazard assessment of the tour.

Contact information:

Rock Island Safety & Health Coordinator, extension #4065

Rocky Reach Safety & Health Coordinator, extension #4589

Effective Date: March 31, 2008

Date of Amendments: March 31, 2008, June 16, 2008, February 23, 2010, September 14, 2010, Sept, 24, 2014, October 20, 2014


Exhibit S

Specifications

Bid No. 15-65 Hazard Communication Program – 01 35 25 Page 1

SECTION 01 35 25

HAZARD COMMUNICATION PROGRAM

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 PURPOSE ........................................................................................................... 2 1.2 SCOPE ............................................................................................................... 2 1.3 REFERENCES ...................................................................................................... 2 1.4 DEFINITIONS ....................................................................................................... 2 1.5 SUBMITTALS ....................................................................................................... 3 1.6 HAZARD COMMUNICATION PROGRAM .................................................................... 4 1.7 CONTRACTOR EMPLOYEE TRAINING AND INFORMATION .......................................... 4

2.0 PRODUCTS (NOT USED).................................................................................... 5 3.0 EXECUTION ......................................................................................................... 5

3.1 SAFETY DATA SHEETS ......................................................................................... 5 3.2 CONTAINER LABELING.......................................................................................... 5 3.3 DISPOSAL OF CHEMICAL PRODUCTS ..................................................................... 6 3.4 PROHIBITED PRODUCTS ....................................................................................... 6

4.0 ATTACHMENTS .................................................................................................. 6 4.1 DISTRICT SAFETY STANDARD – HAZARD COMMUNICATION PROGRAM ...................... 6

Exhibit S

Specifications


SECTION 01 35 25

HAZARD COMMUNICATION PROGRAM

1.0 GENERAL

1.1 PURPOSE The purpose of this section is to ensure that all Contractor and District employees are informed of the hazards of all chemicals they may use or could expect to encounter in the workplace, and that information concerning the classified hazards is transmitted to employers and employees. The requirements of this section are intended to be consistent with requirements for employer chemical hazard communication as outlined in WAC 296-800-170, the provisions of the United Nations Globally Harmonized System of Classification and Labeling of Chemicals (GHS), Revision 3 under OSHA 29 CFR 1910.1200, and Washington State Department of Occupational Safety and Health (DOSH) WAC 296-901. The transmittal of information is to be accomplished by means of a comprehensive hazard communication program, which shall include container labeling and other forms of warning, safety data sheets and employee training.

1.2 SCOPE

This standard applies to all District operational areas, facilities, and worksites and is applicable to all District employees and contractors.

1.3 REFERENCES The following is a list of standards which may be referenced in this section:

Washington Administrative Code (WAC) WAC 296-24 General Safety and Health Standards WAC 296-62 General Occupational Health Standards WAC 296-155 Safety Standards for Construction Work WAC 296-800 Safety and Health Core Rules WAC 296-800-170 Employer – Chemical Hazard Communication WAC 296-901 Hazard Communication

1.4 DEFINITIONS 1. Carcinogen - means a substance or agent that is known to or likely to cause

cancer. 2. Hazardous Chemical - Any chemical that could cause physical/health hazards.

Exhibit S

Specifications


3. Hazard Statement – a statement assigned to a hazard class and category that describes the nature of the hazard(s) of a chemical, including, where appropriate, the degree of hazard.

4. Hazard Warning - Any words, pictures, symbols or combination thereof that appear on a label or other appropriate form of warning which convey the hazard(s) of the chemical(s) in the container(s).

5. Health Hazard - means a chemical for which there is statistically significant evidence based on at least one study conducted in accordance with established scientific principles that acute or chronic health effects may occur in exposed employees.

6. Other Definitions - To the extent not otherwise provided herein, the definitions set forth in WAC 296-901 shall be incorporated herein by reference.

7. Physical Hazard - means a chemical for which there is scientifically valid evidence that it is a combustible liquid, a compressed gas, explosive, flammable, an organic peroxide, an oxidizer, pyrophoric, unstable (reactive) or water-reactive.

8. Pictogram: a symbol plus other graphic elements on a white background with a red frame or border that is intended to convey specific information about health, physical and environmental hazards of the chemical. There are currently nine (9) pictograms under GHS; however, only eight (8) are required under the final Hazard Communication Standard. The environmental pictogram is not required as environmental hazards are not within OSHA’s jurisdiction.

9. Precautionary Statement – a phrase that describes recommended measures to be taken to minimize or prevent adverse effects resulting from exposure to a hazardous chemical, or improper storage or handling of a hazardous chemical.

10. Safety Data Sheet (SDS) - means written or printed material concerning a hazardous chemical that is prepared in accordance with WAC 296-901.

11. Signal words – a single word used to indicate the relative level of severity of hazard and alert the reader to a potential hazard on the label. The signal words used are: a. “Danger” – used for more severe hazards; and b. “Warning” – used for less severe hazards.

1.5 SUBMITTALS 1.5.1 Written Chemical Hazard Communication Program The Contractor shall submit a site specific written Chemical Hazard Communication Program. The Chemical Hazard Communication Program must, at a minimum, include:

1. A list of hazardous chemicals known to be brought to the District’s work site by the Contractor.

2. Procedures for making sure all containers are properly labeled. 3. A description of how to obtain and maintain safety data sheets (SDSs).

Exhibit S

Specifications


4. A description of how to train and inform employees about hazardous chemicals in their workplace.

5. A description of how to inform Contractor’s employees and the District about: a. Chemical hazards used to perform the Work. b. The hazards associated with chemicals contained in unlabeled pipes or

equipment in employee work areas.

1.5.2 Safety Data Sheets (SDS)

Contractor shall submit to the District copies of SDS’s for all products that they will use during the completion of the project, per the contract requirements.

1.5.3 Sample Labels Whenever the Contractor must transfer a chemical from its original container to a second container, the second container shall be properly labeled. The Contractor shall submit sample secondary container labels for District Approval.

1.6 HAZARD COMMUNICATION PROGRAM

The Contractor shall develop, implement, and maintain a site specific hazard communication program which describes how the criteria specified in WAC 296-901-14012, 296-901-14014, and 296-901-14016 for labels and other forms of warning, safety data sheets, and employee information and training will be met.

The Contractor shall coordinate requirements and details of its site specific hazard communication program with those of the District. A copy of the District’s hazard communication program is attached in Part 4 of this section.

1.7 CONTRACTOR EMPLOYEE TRAINING AND INFORMATION The Contractor shall provide site specific training to employees on the hazardous chemicals present in their work area, and whenever a new chemical hazard the employees have not previously been trained about is introduced into their work area.

This training may include, but not be limited to the following: 1. Any location/operations in their work area where hazardous chemicals are

present. 2. Methods and observations that may be used to detect the presence or release

of a hazardous chemical in the work area, i.e., monitoring methods and/or devices, visual appearance or odor of hazardous chemicals when being released.

3. Physical and health hazards of the chemicals in the work area, including the likely physical symptoms or effects of overexposure, and procedures to follow in the event of overexposure.

Exhibit S

Specifications


4. Steps employees can take to protect themselves from the chemical hazards in the workplace, including engineering controls, safe work practices, operational/ emergency procedures, and the use of personal protective equipment.


3.0 EXECUTION

3.1 SAFETY DATA SHEETS

The District will maintain SDS information for all hazardous chemicals in use throughout the District. SDSs of chemicals used or stored at District facilities are accessible via the Dolphin SDS Database on the CCPUD Intranet site at http://rtk.complyplus.com/frame.asp.

The Dolphin SDS Database program can be used to generate a list of all chemical products used or stored at District facilities. Contact the District’s Project Manager for assistance generating a list.

3.2 CONTAINER LABELING Contractor employees receiving chemical containers delivered/brought on to District job sites are responsible for verifying that all containers are clearly labeled, in English, with the following information:

1. Name of the product; 2. Name, address, and phone number of manufacturer or importer; 3. Identity of the hazardous chemical(s) using either the chemical or common

name; and 4. Appropriate hazard warnings, using statements or pictograms, which give

general information about the relevant health and physical hazards of the chemicals. This includes health effects information, such as information about organs most likely to be affected by the chemicals.

As of June 1, 2015, all chemical container labels are required to have the following information (in accordance with OSHA’s adoption of the Globally Harmonized System of Classification and Labeling of Chemicals):

1. Pictogram; 2. Signal word; 3. Hazard and precautionary Statement(s); 4. The product identifier (product name); and 5. Name, address, and telephone number of the chemical manufacturer, importer,

or other responsible party.

http://rtk.complyplus.com/frame.asp

Exhibit S

Specifications


See paragraph 1.4 for the definition of pictograms, signal words, and hazard and precautionary statements and Appendix C of the District’s Hazard Communication Program Safety Standard, attached, for illustrations of pictograms. Contractor employees transferring a chemical from its original container to another container are responsible for labeling the second container with either an extra copy of the original manufacturer label or with labels that contain:

1. Product name and manufacturer; 2. Appropriate hazard warnings (word, pictograms, or combination thereof); and 3. Date when secondary container was filled.

Secondary container labels shall be acceptable to the District. If a Contractor label is provided in lieu of an original manufacturer label, the Contractor shall submit a sample of the Contractor provided secondary container labels to the District for Approval.

3.3 DISPOSAL OF CHEMICAL PRODUCTS Any unused chemical product brought on-site by the Contractor shall be disposed of by the Contractor. Disposal of chemical wastes shall be in accordance with all applicable federal, state, and local regulatory requirements.

3.4 PROHIBITED PRODUCTS See Appendix D of the attached District Safety Standard – Hazard Communication program for items that are prohibited from being brought onto District property.

4.0 ATTACHMENTS

4.1 DISTRICT SAFETY STANDARD – HAZARD COMMUNICATION PROGRAM

Safety Standard

Title: Hazard Communication Program

Bid No. 15-21 Hazard Communication Program Standard Revision Date: November 2014 Page 7

TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 ROLES/RESPONSIBILITIES 5.0 CONTAINER LABELING 6.0 SAFETY DATA SHEETS (SDS) 7.0 EMPLOYEE TRAINING AND INFORMATION 8.0 DISPOSAL OF CHEMICAL PRODUCTS 9.0 USE OF CHEMICAL PRODUCTS BY CONTRACTORS 10.0 LIST OF HAZARDOUS CHEMICALS 11.0 APPLICABLE STATE REGULATIONS/GUIDELINES 12.0 APPENDICES

APPENDIX A – DEFINITIONS APPENDIX B – SELECTION/PURCHASING OF CHEMICAL PRODUCTS APPENDIX C – LABELING REQUIREMENTS APPENDIX D – RESTRICTED CHEMICALS/INGREDIENTS

1.0 Purpose

The purpose of the Hazard Communication Program Safety Standard is to ensure employees and contractors are informed of the hazards of chemicals they may use or could expect to encounter in their work. This standard is in accordance with Hazard Communication Standards and the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) under OSHA 29 CFR 1910.1200 and Washington State Department of Occupational Safety and Health (DOSH) WAC 296-901-140.

2.0 Scope

This standard applies to all District operational areas, facilities, and worksites and is applicable to all District employees and contractors.

3.0 Definitions

See Appendix A.

Safety Standard



4.0 Roles/Responsibilities The District’s Safety & Health Division is responsible for providing oversight of the Hazardous Communication Program. This includes:

a. Providing guidance in the: i. Evaluation and selection of chemicals to be used on District property (See

Appendix B); ii. Storage, handling, and use of chemicals; and iii. Waste disposal and recordkeeping.

b. Maintaining the District’s Safety Data Sheets (SDS) in the Dolphin Database. c. Contacting chemical manufacturer(s) or vendor(s) to request a copy of a SDS for

a chemical and/or to obtain additional chemical information as needed. d. Facilitating the general orientation and PureSafety Hazard Communication

training. e. Assisting supervisors and employees as needed to ensure proper

implementation of this program. f. Working collaborative with District Procurement and Contract Services to:

i. Recommend language to be inserted into Small Works and bid documents and boiler plates as needed.

ii. Review Small Works and bid documents as requested to ensure compliance with the District’s Hazard Communication Program.

g. Evaluating the overall effectiveness of the program and updating the written program.

District Supervisors/Superintendents, in conjunction with the Safety and Health Division, are responsible for:

a. Ensuring the program is understood and followed by employees under their charge.

b. Ensuring employees receive site-specific Hazard Communication training. c. Monitoring compliance within their work area to ensure chemical products are

labeled, handled, used and stored appropriately. d. Adhering to the process outlined in Section 5.0, Container Labeling, regarding

the selection of chemical products to be used.

District Construction/Project Managers are responsible for:

Safety Standard



a. Reviewing contracts to ensure the aspects of the Hazard Communication Program have been addressed and are carried out.

b. Overseeing projects and communicating between construction, contractors, project managers and the Safety and Health Division regarding all chemical products to be used throughout the duration of the project. See Section 9.0, Use of Chemical Products by Contractors.

c. Forwarding copies of the SDS to the Safety and Health Division.

Procurement and Contract Services Department is responsible for: a. Routing Small Works and bid documents to other departments, i.e., Safety &

Health, Licensing and Natural Resource Compliance, Engineering Services, etc., for review as needed language regarding hazardous substances and/or hazardous materials handling and disposal.

b. Disseminating to the project manager the inventory list of hazardous chemicals and SDS submitted by the contractor if a precondition of Notice to Proceed.

c. Insert language provided by Safety and Health in Small Works and bid documents and boiler plates as needed.

All employees receiving/purchasing chemical products, including, but not limited to those assigned to work in the Warehouse/Tool Rooms are responsible for:

a. Inspecting products received upon arrival to ensure: i. They are in good condition. Any product/containers which arrive damaged

may be rejected. ii. All labels on the containers are in English, legible, and in accordance with

the requirements outlined in this standard (see Section 5.0, Container Labeling).

iii. All products received are accompanied by a SDS. iv. Contacting suppliers to request a copy of a SDS if necessary.

Note:

• If an SDS is not available (received with the product or located in Dolphin), the product cannot be used until a SDS has been obtained.

• For assistance in locating a SDS, contact the Safety and Health Division.

b. Verifying that the current SDS for the product is in the District's SDS program. c. Forwarding SDSs that need to be added to the District's SDS Database (i.e., not

currently in the database, new revision, etc.) to the Safety and Health Division, requesting that it be added to the database.

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d. Notify the individual who requested the product that the product has arrived and determine if the product needs to be routed to the project or stored until needed.

e. If the product will be stored, reviewing the SDS to determine how to properly store the product, i.e., appropriate storage area, special containment needs, temperature control, etc.

All District employees are responsible for: a. Complying with all aspects of the Hazard Communication Program, including

ensuring that any new products to be used have been approved and that a copy of the SDS is available in the SDS Database.

b. Requesting approval for any new chemical products to be used (see Appendices B and D).

c. Reviewing, understanding and following the information provided on the SDS for all chemical products prior to use.

d. Labeling all secondary containers.

5.0 Container Labeling

Employees receiving chemical containers delivered/brought in to District job sites are responsible for verifying that all containers are clearly labeled, in English, with the following information:

a. Name of the product; b. Name, address, and phone number of manufacturer or importer; c. Identity of the hazardous chemical(s) using either the chemical or common

name; and d. Appropriate hazard warnings, using statements or pictograms, which give

general information about the relevant health and physical hazards of the chemicals. This includes health effects information, such as information about organs most likely to be affected by the chemicals.

As of June 1, 2015, all chemical container labels will be required to have the following information (in accordance with OSHA’s adoption of the Globally Harmonized System of Classification and Labeling of Chemicals):

a. Pictogram; b. Signal word; c. Hazard and precautionary Statement(s); d. The product identifier (product name); and e. Name, address, and telephone number of the chemical manufacturer, importer,

or other responsible party.

Safety Standard



See Appendix A for the definition of pictograms, signal words, and hazard and precautionary statements and Appendix C for illustrations of pictograms. All employees transferring a chemical from its original container to another container are responsible for labeling the second container with either an extra copy of the original manufacturer label or with labels that contain:

a. Product name and manufacturer; b. Appropriate hazard warnings (word, pictograms, or combination thereof); and c. Date when secondary container was filled.

Contact the:

a. Tool Rooms/Warehouses and/or the Safety and Health Division to obtain secondary container labels.

b. Safety and Health Division for assistance with labeling chemicals and/or re-labeling containers with damaged, fading, and/or illegible labels.

6.0 Safety Data Sheets (SDS)

SDS information for all hazardous chemicals in use throughout the District will be: a. Available either through the Dolphin SDS Database and/or as a printed copy at

the work location where the product is in use. b. Retained for the period of product usage plus 30 years.

Revised versions of product SDS will be uploaded into the Dolphin SDS Database as they become available. This is important as the contents and/or ingredients of a product may be changed at the manufacturer’s discretion. This in turn may affect the chemical’s physical and health hazards as well as the first aid treatment, PPE requirements, storage, handling, spill response, and disposal recommendations.

7.0 Employee Training and Information

All new District employees attend a general orientation conducted by the Safety & Health Division. The orientation may include, but not be limited to, the following:

a. An overview of the requirements contained in the Hazard Communication Standard/Right to Know.

b. The location and availability of the District’s Hazard Communication Program Safety Standard.

c. How to identify hazardous chemicals present in the workplace. d. Physical and health risks of hazardous chemicals. e. How to reduce or prevent exposure to hazardous chemicals through use of safe

work practices and personal protective equipment.

Safety Standard



f. How to read labels and review SDS's to obtain hazard information. g. Chemical label requirements for secondary containers. h. How to obtain a SDS using the Dolphin SDS Database and/or copies available at

the work location where the SDS is needed. When the general orientation training is complete, employees sign the training roster indicating they have received and understand the information as outlined above pertaining to the Hazard Communication Program. Site-specific training is provided to employees on hazardous chemicals in their work area at the time of their initial assignment, and whenever a new chemical hazard the employees have not previously been trained about is introduced into their work area. This training may include, but not be limited to the following:

a. Any location/operations in their work area where hazardous chemicals are present.

b. Methods and observations that may be used to detect the presence or release of a hazardous chemical in the work area, i.e., monitoring methods and/or devices, visual appearance or odor of hazardous chemicals when being released.

c. Physical and health hazards of the chemicals in the work area, including the likely physical symptoms or effects of overexposure, and procedures to follow in the event of overexposure.

d. Steps employees can take to protect themselves from the chemical hazards in the workplace, including engineering controls, safe work practices, operational/ emergency procedures, and the use of personal protective equipment.

8.0 Disposal of Chemical Products Products, such as paints, cleaners, oils, batteries, and pesticides, that contain hazardous ingredients may be regulated and require special handling for disposal. Improper disposal of regulated waste may include pouring product down the drain, on the ground, into storm sewers, and disposing of the product in the trash. The dangers of such disposal methods might not be immediately obvious, but improper disposal of these wastes can pollute the environment and pose a threat to human health.

At the District, a variety of methods are available for disposing of chemical products. Consult the SDS for information pertaining to acceptable methods of disposal. Consult the Environmental Compliance Technician to determine which satellite accumulation container to use.

Safety Standard



9.0 Use of Chemical Products by Contractors

The District will: a. Provide contractors and their employees copies of SDS's (or make them

available at a central location) for any product containing potentially hazardous chemicals that the contractors and their employees may be exposed to while working on District property.

b. Inform contactors of: i. Any precautionary measures that need to be taken to protect individuals

during normal operating conditions or in foreseeable emergencies; and ii. An explanation of the labeling system that is used at the workplace.

Contractors are required to:

a. Provide the District with copies of SDS’s for all products that they will use during the completion of the project, per the individual contract requirements.

b. Notify the Project Manager and seek authorization if, during the completion of the project, additional products are needed.

10.0 List of Hazardous Chemicals SDSs of chemicals used or stored at District facilities are accessible via the Dolphin SDS Database on the CCPUD Intranet site at http://rtk.complyplus.com/frame.asp. The Dolphin SDS Database program can be used to generate a list of all chemical products used or stored at District facilities. Contact the Safety and Health Division for assistance generating a list as needed.

11.0 Applicable State Regulations/Guidelines

WAC 296-901 - Globally Harmonized System of Classification and Labeling of Chemicals (GHS)

http://rtk.complyplus.com/frame.asp

http://www.lni.wa.gov/safety/rules/chapter/901/

Safety Standard



12.0 APPENDICIES

APPENDIX A - DEFINITIONS

a. Carcinogen - means a substance or agent that is known to or likely to cause cancer.

b. Hazardous Chemical - Any chemical that could cause physical/health hazards.

c. Hazard Warning - Any words, pictures, symbols or combination thereof that appear on a label or other appropriate form of warning which convey the hazard(s) of the chemical(s) in the container(s).

d. Health Hazard - means a chemical for which there is statistically significant evidence based on at least one study conducted in accordance with established scientific principles that acute or chronic health effects may occur in exposed employees.

e. Safety Data Sheet (SDS) - means written or printed material concerning a hazardous chemical that is prepared in accordance with WAC 296-901.

f. Physical Hazard - means a chemical for which there is scientifically valid evidence that it is a combustible liquid, a compressed gas, explosive, flammable, an organic peroxide, an oxidizer, pyrophoric, unstable (reactive) or water-reactive.

g. Other Definitions - To the extent not otherwise provided herein the definitions set forth in WAC 296-901 shall be incorporated herein by reference.

• Signal words – a single word used to indicate the relative level of severity of hazard and alert the reader to a potential hazard on the label. The signal words used are:

o “Danger” – used for more severe hazards; and

o “Warning” – used for less severe hazards.

• Hazard Statement – a statement assigned to a hazard class and category that describes the nature of the hazard(s) of a chemical, including, where appropriate, the degree of hazard.

• Pictogram: a symbol plus other graphic elements on a white background with a red frame or border that is intended to convey specific information about health, physical and environmental hazards of the chemical. There are currently 9 pictograms under GHS; however, only eight are required under the final Hazard Communication Standard. The environmental pictogram is not required as environmental hazards are not within OSHA’s jurisdiction.

• Precautionary Statement – a phrase that describes recommended measures to be taken to minimize or prevent adverse effects resulting from exposure to a hazardous chemical, or improper storage or handling of a hazardous chemical.

Safety Standard



APPENDIX B – SELECTION/PURCHASING OF CHEMICAL PRODUCTS Chemical Selection/Approval Guidance Before any new (non-stocked) chemical is purchased, the purchaser must: 1. Contact the Warehouse to determine if the desired or a similar suitable chemical product is

currently in stock. 2. Evaluate the chemical/product options available in order to obtain the least hazardous and

most environmentally friendly chemical(s) available that meet the needs of the project. This is best accomplished by reviewing the current Safety Data Sheet(s) (SDS) to determine if the chemical contains any ingredients on the restricted chemical/ingredient list (see Appendix D).

3. If the product or another suitable chemical product is not in stock, approval must be obtained from the Safety and Health Division before the product can be purchased by submitting the SDS to the Safety and Health Division.

4. A response will be issued within 5 business days of receipt of the request. 5. If approval for purchase is granted, the SDS will be added to the Dolphin database by the

designated Dolphin Database Administrator (HR/Safety & Health Administrative Assistant).

Purchasing Guidance 1. Chemicals should be purchased by submitting a purchasing request. 2. No chemical products may be purchased using a P-card except in emergency situations.

Emergency situations are defined as any situation when approval is not feasible, such as emergency work that must be completed to protect District resources.

3. Individuals purchasing products containing hazardous chemicals shall obtain a copy of the current SDS at the time the order is placed.

4. If it is necessary to purchase chemical(s) using a P-card, the purchaser must: A. Obtain a copy of the SDS at the time the product is purchased; and then B. Forward the SDS to the designated Dolphin Database Administrator (HR/Safety & Health

Administrative Assistant) with a note indicating that the chemical product was purchased using a P-card during an emergency.

5. The Dolphin Database Administrator will: A. Add the SDS to Dolphin; and B. Notify the IH Team that the SDS has been added to Dolphin and needs reviewed.

6. If a chemical has been purchased for a special project and the project has been cancelled, it is the responsibility of the planner, project manager, etc., to insure the chemical is returned to the vendor. A restocking fee may apply; however, this is more economical and environmentally responsible than disposal. Any disposal costs for cancelled projects will be charged to the original project.

Safety Standard



APPENDIX C – LABELING REQUIREMENTS

Pictograms will be required to on all labels effective June 1, 2015.

Health Hazard

Flame Exclamation Mark

• Carcinogen • Mutagenicity • Reproductive Toxicity • Respirator Sensitizer • Target Organ Toxicity • Aspiration Toxicity

• Flammables • Pyrophorics • Self-Heating • Emits Flammable Gas • Self-Reactives • Organic Peroxides

• Irritant (skin and eye) • Skin Sensitizer • Acute Toxicity (harmful) • Narcotic Effects • Respiratory Tract Irritant • Hazardous to Ozone Layer (Non-

Mandatory) Gas Cylinder

Corrosion Exploding Bomb

• Gas Under Pressure

• Skin Corrosion/Burns • Eye Damage • Corrosive to Metals

• Explosives • Self-Reactives • Organic Peroxides

Flame over Circle

Skull and Crossbones Environment (Non mandatory)

• Oxidizers • Aquatic Toxicity (fatal or toxic) • Aquatic Toxicity

Safety Standard



APPENDIX D - RESTRICTED CHEMICALS /INGREDIENTS

Use of the following chemicals/ingredients are restricted and not allowed unless approved in writing by the District’s Safety and Health Division and all applicable requirements of WAC 296-62 (click here) are followed:

• Asbestos (WAC 296-62-077 through 296-62-07755 - click here) - includes chrysotile, amosite, crocidolite, tremolite asbestos, anthophyllite asbestos, actinolite asbestos, and any of these minerals that have been chemically treated and/or altered.

• Air Contaminants (WAC 296-62-07517 through 296-62-07660 - click here) o Benzine o Formaldehyde o Lead o Methylenedialine (MDA) o Trichlorothane o Thiram

• Atmospheres and Ventilation (WAC 296-62-11015 through 296-62-13635 - click here) Note: Mercury is cited as measurements of pressure and working with equipment containing Mercury – but not as a chemical under 296-62.

• Carcinogens (WAC 296-62-073 through 296-62-07316 - click here) o Methylene Chloride (CH2Cl2) – synonyms include MC, Dichloromethane (DCM),

Methylene dichloride, Methylene bichloride, Methane dichloride (CAS: 75-09-2; NCI-C50102)

o Tetrachloroethylene o Trichloroethylene o Other Halogenated/Chlorinated Solvents/Oils

Note: Use of Carcinogenetic chemicals must follow WAC 296-62-07312 Report Guidelines.

• Physical Agents (WAC 296-62-090 through 296-62-09560 - click here) - Ionizing/Non-Ionizing Radiation, Pressure, Vibration, Temperature Radiant and Temperature Humidity.

Products with any of the following physical or health hazards must be used in accordance with safe and healthy work practices:

• Coating removal products that generate hazardous waste such as Peel Away 1, Jasco Paint Stripper, or other chlorinated paint stripper. The recommended alternative is to use a lead binding agent such as Blast-Tox, Strip-Tox, or equivalent.

• Mercury or mercury containing equipment.

• Welding fumes:







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o Hexavalent Chromium (WAC 296-62-08003 through 296-62-08029 - click here)

o Manganese

If there are no effective substitutes for a specific restricted chemical/ ingredient, special work procedures must be developed and followed in accordance to WAC 296-62 (click here). The work procedure must be submitted and approved by the District’s Safety and Health Division. Special work procedures may include:

• Engineer controls (containment, ventilation, equipment, etc.)

• Administrative procedures (facility controls, personnel exposure limits, etc.)

• Personal protective equipment (respiratory, clothing, etc. This may include medical surveillance)

• Waste handling and recordkeeping

• Impact on dangerous waste generator status rating (small, medium or large)

• Transportation and disposal costs

• Long-term storage expenditures – cradle to grave

• Establishment of a regulated area prior to chemical usage

• Exposure evaluation process (WAC 296-841-20005)

• Laboratory validated approved sampling process

• Continuous onsite environmental and personnel monitoring activities

• State and Federal agency notification

• Medical surveillance of individuals exposed at or above limits (TWA, PEL, STEL)

• Employee training and recordkeeping

• Air sampling (collection, analysis, employee notification and recordkeeping).

Note: If approved for use by the Safety and Health Division, the one-time use approval is only valid for the specific project for which the special work procedure was developed. All subsequent use will require the submittal of an additional request for use and development of another project specific special work procedure.




Exhibit S

Specifications

Bid No. 15-65 References – Codes and Standards – 01 42 13 Page 1

SECTION 01 42 13

REFERENCES – CODES & STANDARDS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 ALTERNATIVE STANDARDS OR CODES ................................................................... 2 1.2 STANDARDS AND CODES ...................................................................................... 2 1.3 APPLICABILITY ..................................................................................................... 4


Exhibit S

Specifications


SECTION 01 42 13

REFERENCES – CODES & STANDARDS

1.0 GENERAL

All supplied equipment/materials shall be designed, fabricated, and tested in accordance with these Specifications, and the latest applicable industry standards and codes. Any deviations from the following standards or additional standards referenced elsewhere in these Specifications shall be clearly stated as exceptions in the proposal. Unless otherwise specified, the latest edition of each standard shall be used.

1.1 ALTERNATIVE STANDARDS OR CODES Contractor may submit for approval by Engineer an alternative standard or code, which Contractor believes most closely, approximates the specified standard or code. Contractor shall include the designation of the specified standard or code, the designation and originating authority of the proposed alternative standard or code, and the text of the proposed alternative in the English language. Contractor shall also indicate the material parts and/or systems to which the alternative standard or code shall be applied. Use of alternative standards or codes is not permitted without Approval by the District; the list of any alternatives proposed shall be submitted with the Contractor’s Bid. Engineer may Approve the use of alternate equivalent recognized international standards; however the requirements regarding properties, workmanship, quality and testing specified in the listed standards shall apply for all equivalent standards proposed.

1.2 STANDARDS AND CODES 1.2.1 General Standards The following general standards and codes are applicable to the Project. Additional specific standards are listed in applicable sections of the equipment to be manufactured and installed.

Organization Abbreviation Aerospace Standard AS

(The) Aluminum Association AA

American Concrete Institute ACI

Anti-Friction Bearing Manufacturers Association AFBMA

American Galvanizers Association AGA

Exhibit S

Specifications


Organization Abbreviation American Gear Manufacturers Association AGMA

American Institute of Steel Construction AISC

American Iron and Steel Institute AISI

American Ladder Institute ALI

American National Standards Institute ANSI

American Petroleum Institute API

American Society of Civil Engineers ASCE

American Society of Mechanical Engineers ASME

American Society for Non-Destructive Testing ASNT

American Society for Quality Control ASQC

ASTM International ASTM

American Welding Society AWS

Code of Federal Regulations CFR

Canadian Electrical Association CEA

Crane Manufacturers Association of America CMAA

Environmental Protection Agency EPA

Institute of Electrical and Electronic Engineers IEEE

Instrumentation, Systems, and Automation Society ISA

International Building Code IBC

International Electrotechnical Commission IEC

InterNational Electrical Testing Association NETA

Insulated Cable Engineers Association ICEA

Military Standard MIL

National Electrical Code NEC

National Electrical Manufacturing Association NEMA

National Fire Protection Association NFPA

National Institute for Certification in Engineering Technologies NICET

National Institute of Standards and Technology NIST

Occupational Safety and Health Administration OSHA

The Society for Protective Coatings SSPC

Society of Automotive Engineers SAE

Exhibit S

Specifications


Organization Abbreviation State of Washington – Washington Administrative Code WAC

State of Washington – Revised Code of Washington RCW

Underwriters Laboratories Inc. UL

1.3 APPLICABILITY Each standard forms an integral part of this Document. If a conflict between standards, or a standard and this Document occurs, then the one shall govern which has the most restrictive requirements unless otherwise stated in writing by District. Contractor shall comply with any new or revised laws, standards, and codes that apply to the Work by Contractor. Throughout the duration of this Contract, Contractor shall remain appraised of any revisions to laws, standards and codes, which apply to the Work by Contractor. Contractor shall immediately notify Engineer of any revisions to laws, standards and codes that affect the Work by Contractor. Notwithstanding the provision of any standard or code applicable to the Work, Contractor shall be exclusively responsible for proper design, manufacture, installation, inspection and testing of the work to assure that it meets all requirements of the Contract.





Bid No. 15-65 Manufacturers’ Field Services – 01 43 33 Page 1

SECTION 01 43 33

MANUFACTURERS’ FIELD SERVICES

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 DEFINITIONS ....................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 2 1.3 QUALITY ASSURANCE .......................................................................................... 2

1.4 SAFETY .............................................................................................................. 3 2.0 PRODUCTS (NOT USED).................................................................................... 3

3.0 EXECUTION ......................................................................................................... 3 3.1 FULFILLMENT OF SPECIFIED MINIMUM SERVICES .................................................... 3 3.2 MANUFACTURER’S CERTIFICATION OF COMPLIANCE ............................................... 4

3.3 MANUFACTURER’S CERTIFICATION OF PROPER INSTALLATION ................................. 4 3.4 TRAINING ............................................................................................................ 4



SECTION 01 43 33

MANUFACTURERS’ FIELD SERVICES

1.0 GENERAL

1.1 DEFINITIONS

1.1.1 Person-Day

One person for 8 hours within regular Contractor working hours.

1.2 SUBMITTALS

General: Submit all items in accordance with Section 01 30 00 Administrative Requirements.

The Contractor shall submit installation procedures that describe the sequence of operations and the methods to be used for installation; including tolerances on alignment and other dimensions wherever they are critical. See Section 01 78 23 Operation and Maintenance Data, for additional requirements.

The Contractor shall submit a testing procedure to the Engineer. Included as a part of this procedure shall be a complete list of all electrical instruments, mechanical equipment, and inspection tools that will be required during installation, covering preoperational and acceptance testing as defined in Section 01 91 14 Equipment Testing and Commissioning, and individual equipment sections.

The Contractor shall submit training schedule in accordance with requirements of this Specification, not less than 30 days prior to start of equipment installation and revise as necessary for acceptance.

The Contractor shall submit lesson plan in accordance with requirements of this Specification, proposed lesson plan not less than 30 days prior to scheduled training and revise as necessary for acceptance.

1.3 QUALITY ASSURANCE

Authorized representative of the manufacturer shall be factory trained, and experienced in the technical applications, installation, operation, and maintenance of respective equipment, subsystem, or system, with full authority by the equipment manufacturer to issue the certifications required of the manufacturer. Additional qualifications may be specified in the individual specification section.



The representative shall be subject to acceptance by District No substitute representatives will be allowed unless prior written approval by the District has been given.

1.4 SAFETY

The Contractor’s representative shall comply with all applicable ordinances and regulations including, but not limited to, federal, state, and municipal laws that are in force in the locality of the Work. Also see General Conditions paragraph GC 59 Safety Requirements and Section 01 35 24 Safety.


3.0 EXECUTION

3.1 FULFILLMENT OF SPECIFIED MINIMUM SERVICES

Furnish manufacturers’ services, when required by an individual specification section, to meet the requirements of this section.

Where time is necessary in excess of that stated in the Specifications for manufacturers’ services, or when a minimum time is not specified, time required to perform specified services shall be considered incidental.

Schedule manufacturers’ services to avoid conflict with other onsite testing or other manufacturers’ onsite services.

Determine, before scheduling services, that conditions necessary to allow successful testing have been met.

Only those days of service approved by Engineer will be credited to fulfill specified minimum services.

When specified in individual specification sections, manufacturer’s onsite services shall include:

1. Assistance during product (system, subsystem, or component) installation to include observation, guidance, instruction of Contractor’s assembly, erection, installation or application procedures.

2. Inspection, checking, and adjustment as required for product (system, subsystem, or component) to function as warranted by manufacturer and necessary to furnish Manufacturer’s Certificate of Proper Installation.

3. Providing, on a daily basis, copies of manufacturers’ representative’s field notes and data to Engineer.



4. Revisiting the Site as required to correct problems and until installation and operation are acceptable to Engineer.

5. Resolution of assembly or installation problems attributable to or associated with respective manufacturer’s products and systems.

6. Assistance during functional and performance testing, and crane startup and evaluation.

7. Training of District’s personnel in the operation and maintenance of respective product as required.

3.2 MANUFACTURER’S CERTIFICATION OF COMPLIANCE

In accordance with Section 01 45 16.13 Contractor Quality Control.

3.3 MANUFACTURER’S CERTIFICATION OF PROPER INSTALLATION

In accordance with Section 01 45 16.13 Contractor Quality Control.

3.4 TRAINING

3.4.1 General

Furnish manufacturers’ representatives for detailed classroom and hands-on training to District’s personnel on operation and maintenance of specified product (system, subsystem, and component) and as may be required in applicable Specifications.

Furnish trained, articulate personnel to coordinate and expedite training, to be present during training coordination meetings with the District, and familiar with operation and maintenance manual information specified in Section 01 78 23 Operation and Maintenance Data.

Manufacturer’s representative shall be familiar with facility operation and maintenance requirements as well as with specified equipment.

Furnish complete training materials, to include operation and maintenance data, to be retained by each trainee.

3.4.2 Training Schedule

List specified equipment and systems that require training services and show:

1. Respective manufacturer 2. Estimated dates for installation completion 3. Estimated training dates

Allow for multiple sessions when several shifts are involved.



Adjust schedule to ensure training of appropriate personnel as deemed necessary by the District, and to allow full participation by manufacturers’ representatives. Adjust schedule for interruptions in operability of equipment.

Coordinate with Section 01 31 19 Coordination and Meetings, and Section 01 91 14 Equipment Testing and Commissioning.

3.4.3 Lesson Plan

When manufacturer or vendor training of District personnel is specified, prepare a lesson plan for each required course containing the following minimum information:

1. Title and objectives 2. Recommended attendees (such as, managers, engineers, operators,

maintenance) 3. Course description, outline of course content, and estimated class duration. 4. Format (such as, lecture, self-study, demonstration, hands-on) 5. Instruction materials and equipment requirements 6. Resumes of instructors providing training

3.4.4 Prestartup Training

Coordinate training sessions with the District’s operating personnel and manufacturers’ representatives, and with submission of operation and maintenance manuals in accordance with Section 01 78 23 Operation and Maintenance Data.

Complete at least 14 days prior to beginning of equipment startup.

3.4.5 Post-startup Training

If required in Specifications, furnish and coordinate training of District’s operating personnel by respective manufacturer’s representatives.


Exhibit S

Specifications

Bid No. 15-65 Contractor Quality Control – 01 45 16.13 Page 1

SECTION 01 45 16.13

CONTRACTOR QUALITY CONTROL

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCE SPECIFICATIONS, CODES AND STANDARDS ......................................... 3 1.2 DEFINITIONS ....................................................................................................... 3 1.3 SUBMITTALS ....................................................................................................... 3 1.4 DISTRICT’S QUALITY ASSURANCE ......................................................................... 4 1.5 CONTRACTOR QUALITY CONTROL (CQC) PLAN ..................................................... 4 1.6 QUALITY CONTROL PHASING ................................................................................ 5 1.7 INSPECTION AND TESTS ....................................................................................... 7 1.8 MEASUREMENT AND TEST EQUIPMENT .................................................................. 9 1.9 SOURCE QUALITY CONTROL............................................................................... 10 1.10 SHOP TESTS ..................................................................................................... 10 1.11 FIELD TESTS ..................................................................................................... 11 1.12 CONTROL OF NON-CONFORMANCES ................................................................... 12 1.13 QUALITY RECORDS ............................................................................................ 13 1.14 WITNESS AND HOLD POINTS .............................................................................. 13 1.15 QC COORDINATION MEETING ............................................................................. 13 1.16 CERTIFICATE OF COMPLIANCE ............................................................................ 14 1.17 CERTIFICATE OF PROPER INSTALLATION .............................................................. 14

2.0 PRODUCTS (NOT USED).................................................................................. 15 3.0 EXECUTION (NOT USED) ................................................................................. 15 4.0 LIST OF APPENDICES ..................................................................................... 15

4.1 NON-CONFORMANCE REPORT ............................................................................ 16 4.2 CERTIFICATE OF COMPLIANCE ............................................................................ 18 4.3 CERTIFICATE OF PROPER INSTALLATION .............................................................. 19 4.4 INSPECTIONS ELEMENTS – SUMMARY MATRIX ..................................................... 20

Exhibit S

Specifications


SECTION 01 45 16.13

CONTRACTOR QUALITY CONTROL

1.0 GENERAL

The Contractor is responsible for quality control and shall establish and maintain an effective quality control system for the Work. The quality control system shall consist of plans, procedures, and organization necessary to maintain an adequate inspection system and perform such inspections as will ensure that the Work conforms to the Contract Documents.

The Contractor shall develop a Contractor Quality Control (CQC) Plan for all phases of the Work in accordance with ANSI/ASQC E1 and E2. The requirements of this section apply to the Contractor and all Subcontractors.

The CQC Plan shall clearly establish the authority and responsibility of those responsible for the administration, inspections, tests and plan execution.

Organizational charts showing the relationship(s) among the Contractor’s and Subcontractor’s management, engineering, purchasing, and quality assurance/quality control shall be submitted to the District. Contractor shall maintain the CQC Plan organizational chart to reflect the actual organization and lines of authority throughout the duration of the Contract.

Persons performing quality functions shall be qualified (e.g., by training, education, or experience) and have sufficient and well defined authority to enforce quality requirements, to identify, initiate, recommend, and provide solutions to quality problems and to verify the effectiveness of the solutions.

The Contractor shall monitor quality control of suppliers, manufacturers, material, equipment, services, site conditions and workmanship to produce Work of specified quality.

The Contractor shall comply with specified standards as a minimum quality for the Work except when more stringent tolerances or specific requirements in these Contract documents indicate higher quality or more precise workmanship.

The Contractor shall comply with manufacturer’s instructions and procedures, where applicable.

Exhibit S

Specifications


The Contractor shall maintain complete inspection records and make them available at all times to District and Engineer. District reserves the right to audit Contractor facilities for purpose of verifying compliance with District Approved CQC Plan.

Rework caused by failure to follow Approved CQC Plan shall be at Contractor’s expense.

Additional specifications and standards for special processes are specified in other sections of this document. Specifications for special processes located in other sections of this document are “in addition to” those specified in this section. They do not relieve Contractor from compliance with this section.

Should conflicts arise between different or overlapping standards and the technical Specifications, District reserves the right to determine the applicable standard.

1.1 REFERENCE SPECIFICATIONS, CODES AND STANDARDS The following is a list of standards which may be referenced in this section:

American National Standards Institute (ANSI)/ American Society for Quality Control (ASQC)

ANSI/ASQC E1 Quality Program Guidelines for Project Phase of Non-nuclear Power Generation Facilities

ANSI/ASQC E2 Guide to Inspection Planning

Code of Federal Regulations (CFR)

National Institute of Standards and Technology (NIST)

1.2 DEFINITIONS 1.2.1 Contractor Quality Control (CQC) The means by which Contractor ensures that the construction, including work performed by Subcontractors and suppliers, complies with the requirements of the Contract.

1.3 SUBMITTALS The Contractor shall submit to the District for review and approval 30 days before beginning any Work the following:

Exhibit S

Specifications


1. CQC Plan 2. Site specific Inspection and Test Plan 3. Sample Non-Conformance Report form

1.4 DISTRICT’S QUALITY ASSURANCE All Work is subject to District’s quality assurance inspection and testing at all locations and at all reasonable times before acceptance to ensure strict compliance with the terms of the Contract Documents.

District’s quality assurance inspections and tests are for the sole benefit of District and do not:

1. Relieve Contractor of responsibility for providing adequate quality control measures;

2. Relieve Contractor of responsibility for damage to or loss of the material before acceptance;

3. Constitute or imply acceptance; or 4. Affect the continuing rights of District after acceptance of the completed Work.

The presence or absence of a quality assurance inspector does not relieve Contractor from any Contract requirement.

Promptly furnish all facilities, labor, and material reasonably needed for performing such safe and convenient inspections and tests as may be required by Engineer.

District may charge Contractor for any additional cost of inspection or test when Work is not ready at the time specified by Contractor for inspection or test, or when prior rejection makes re-inspection or retest necessary. Quality assurance inspections and tests will be performed in a manner that will not unnecessarily delay the Work.

1.5 CONTRACTOR QUALITY CONTROL (CQC) PLAN The Contractor shall furnish for review by the District, in accordance with Section 01 30 00 Administrative Requirements, and not later than 30 calendar days before start of any Work, the Contractor Quality Control (CQC) Plan.

The CQC plan shall include, as a minimum, the following to cover all Work including work by Subcontractors, fabricators, and suppliers:

a. The name, qualifications (in resume format), duties, responsibilities, and authorities of each person assigned a CQC function.

b. Organizational chart

Exhibit S

Specifications


c. Procedures for scheduling, reviewing, certifying, and managing submittals, including those of Subcontractors, fabricators, suppliers and purchasing agents.

d. An Inspection and Test Plan (ITP). The Contractor shall submit separate ITPs for work performed in the shop and work to be performed in the field.

e. Control, verification, and acceptance testing procedures for each specific test to include the test name, specification paragraph requiring test, feature of work to be tested, test frequency, and person responsible for each test. Laboratory facilities will be subject to approval by the District.

f. Reporting procedures, including proposed reporting formats. g. The CQC Plan shall also contain procedures for Control of Inspection

Records, Traceability of Materials, Test Procedures, Packaging and Shipping Procedures, Storage and Handling Instructions, Witness and Hold Points, and Procedures for Control of Nonconforming Items.

h. The CQC Plan shall include an Inspection Elements Summary Matrix similar to that shown in Appendix 4.4. The Inspection Elements Summary Matrix shall include all scheduled and completed documentation, inspections and tests meeting all Contract requirements, including preliminary Witness and Hold Points as detailed in the draft Inspection Elements Summary Matrix, as a minimum.

1.5.1 Acceptance of Plan The CQC Plan shall be subject to approval and verification by District.

After acceptance of the CQC Plan, the Contractor shall notify the District in writing a minimum of seven (7) calendar days prior to any proposed change. Proposed changes are subject to acceptance by the District.

1.6 QUALITY CONTROL PHASING CQC shall include at least three (3) phases of control to be conducted by CQC System Manager for all definable features of Work, as follows:

1.6.1 Preparatory Phase Notify District at least 48 hours in advance of beginning any of the required action of the preparatory phase.

This phase shall include a meeting conducted by the CQC System Manager and attended by the superintendent, other CQC personnel (as applicable), and the foreman responsible for the definable feature. The CQC System Manager shall instruct applicable CQC staff as to the acceptable level of workmanship required in order to meet Contract requirements.

Exhibit S

Specifications


Document the results of the preparatory phase meeting by separate minutes prepared by the CQC System Manager and attached to the QC report.

Perform prior to beginning Work on each definable feature of Work:

1. Review applicable Contract Specifications. 2. Review applicable Contract Drawings. 3. Verify that all materials and/or equipment have been tested, submitted, and

approved. 4. Verify that provisions have been made to provide required control inspection

and testing. 5. Examine the Work area to verify that all required preliminary Work has been

completed and is in compliance with the Contract. 6. Perform a physical examination of required materials, equipment, and sample

Work to verify that they are on hand, conform to approved Shop Drawing or submitted data, and are properly stored.

7. Review the appropriate activity hazard analysis to verify safety requirements are met.

8. Review procedures for constructing the Work, including repetitive deficiencies. 9. Document construction tolerances and workmanship standards for that phase

of the Work. 10. Check to verify that the plan for the Work to be performed, if so required, has

been accepted by Engineer.

1.6.2 Initial Phase Accomplish at the beginning of a definable feature of Work:

1. Notify District at least 48 hours in advance of beginning the initial phase. 2. Perform prior to beginning Work on each definable feature of Work:

a. Review minutes of the preparatory meeting. b. Check preliminary Work to verify compliance with Contract requirements. c. Verify required control inspection and testing. d. Establish level of workmanship and verify that it meets minimum acceptable

workmanship standards. Comparison with sample panels is appropriate. e. Resolve all differences. f. Check safety to include compliance with and upgrading of the safety plan

and activity hazard analysis. Review the activity analysis with each worker. 3. Separate minutes of this phase shall be prepared by the CQC System Manager

and attached to the QC report. Exact location of initial phase shall be indicated for future reference and comparison with follow-up phases.

4. The initial phase should be repeated for each new crew to work on site, or any time acceptable specified quality standards are not being met.

Exhibit S

Specifications


1.6.3 Follow-up Phase Perform daily checks to verify continuing compliance with Contract requirements, including control testing, until completion of the particular feature of Work.

Daily checks shall be made a matter of record in the CQC documentation and shall document specific results of inspections for all features of Work for the day or shift.

Conduct final follow-up checks and correct all deficiencies prior to the start of additional features of Work that will be affected by the deficient Work. Constructing upon or concealing nonconforming Work will not be allowed.

1.6.4 Additional Preparatory and Initial Phase Additional preparatory and initial phases may be conducted on the same definable features of Work as determined by District if the quality of ongoing Work is unacceptable; or if there are changes in the applicable QC staff or in the on-site production supervision or work crew; or if work on a definable feature is resumed after a substantial period of inactivity, or if other problems develop.

1.7 INSPECTION AND TESTS

1.7.1 General Requirements All materials, products and components used by the Contractor as part of the Work shall be subjected to such tests and inspections as may be necessary to verify compliance with the requirements of the Contract Documents. The District may, at the District’s option, provide material testing for verification of field quality assurance. All other required testing shall be the responsibility of the Contractor.

All expenses for the Contractor required tests shall be fully borne by Contractor. Contractor shall prepare and provide all labor, material and equipment necessary for performing specified or required tests. Contractor shall submit the test results to District and Engineer for review within 48 hours after completion of the tests.

Inspections shall be performed in accordance with the Approved Contractor Quality Control Plan and Inspection and Test Plan. Inspection results shall be part of the quality documentation. Follow-up inspections shall be conducted after correction of all deficiencies. Satisfactory follow-up inspections shall be completed and documented prior to beginning subsequent Work that may be affected by the unsatisfactory Work. Contractor shall not build upon or conceal non-conforming Work.

Contractor shall perform tests as specified or required to verify that the control measures are adequate and the Work meets the requirements of the Contract and applicable standards and codes.

Exhibit S

Specifications


Approval of assemblies, tests and test procedures, etc., and acceptance of pertinent test certificates, inspection or waiving of inspections and tests shall in no way relieve Contractor of its contractual obligations for furnishing the Work in accordance with the provisions of these Contract Documents.

1.7.2 Tests

The Contractor shall perform tests specified or required to verify that control measures are adequate to provide a product which conforms to Contract requirements. A list of tests to be performed shall be furnished as a part of the Inspection and Test Plan contained in the CQC plan. The Contractor shall perform the following activities and record and provide the following data:

1. Verify that testing procedures comply with Contract requirements. 2. Verify that facilities and testing equipment are available and comply with testing

standards. 3. Check test instrument calibration data against certified standards. 4. Verify that recording forms and test identification control number system,

including all of the test documentation requirements, have been prepared.

Results of all tests taken, both passing and failing tests, shall be recorded on Quality Control Record Sheets for the date taken. Specification paragraph reference, test procedure number or reference standard, location where tests were taken, description of test, name of testers and witnesses, and the sequential control number identifying the test shall be recorded.

Contractor shall perform checks and tests in accordance with the following:

1. Manufacturer’s and/or Contractor’s standard practices and recommendations 2. Reference and applicable testing standards 3. Mutual agreement of Contractor and Engineer based upon conditions or

circumstances that may arise during the Work.

Contractor shall evaluate test results and advise Engineer immediately of any discrepancy between test results and test limits or the failure of any item to meet the test criteria.

Contractor at its expense shall furnish, set up, and operate test equipment and facilities in Contractor’s shops or on site. If facilities for conducting required tests are unavailable, Contractor may conduct tests elsewhere or have them performed by an independent agency subject to approval by Engineer.

Exhibit S

Specifications


Contractor shall protect all material and equipment during and after testing and checking to provide that subsequent testing of other equipment or systems does not disturb, damage, or otherwise interfere with functional capability of material and equipment.

In the event that test results do not fulfill the requirements specified in these Specifications or that any defects attributable to Contractor are found in test results, Contractor shall issue a Non-Conformance Report (NCR) with a recommended disposition to replace, repair, adjust, or correct and retest at its own expense to the satisfaction of Engineer. Repair methods or procedures shall be subject to the approval of Engineer. Repairs shall be retested with results that meet the contract requirements. Even in such an event, Contractor shall be responsible for maintaining the Project schedule and Milestone Completion Dates.

1.7.3 Inspection and Test Plans Contractor shall submit for review and Approval by the District not later than 20 calendar days before the start of any off-site work, an Inspection and Test Plan (ITP). The ITP shall list all required Inspections and Tests, references to test methods, applicable standards and procedures, acceptance criteria, and results; in addition, the ITP shall include items listed in the Inspection Elements – Summary Matrix (Appendix 4.4). Separate ITPs shall be submitted for shop and field test programs. The District will review the ITP and establish Witness Points for those tests, inspections, and operations to be witnessed by District. The Contractor shall incorporate the Witness Points into the ITP and resubmit to District. The ITP shall be revised as necessary if the planned tests change. Any changes to the ITP shall be resubmitted for approval. Any work done by the Contractor prior to Approval of the ITP shall be repeated at Contractor’s cost at the discretion of the Engineer.

1.8 MEASUREMENT AND TEST EQUIPMENT

Measurement and test equipment (meters, gauges, torque wrenches, sensors, etc.) supplied or used by Contractor for taking or recording of data shall:

1. Have accuracy equal to or greater than stated acceptance criteria tolerances for test or work being performed.

2. Have current calibration with traceability to National Institute of Standards and Technology (NIST). Calibration records shall be maintained as required by ANSI/ASQC E2 and submitted if requested by Engineer.

3. Have traceability to national standards in the country of use, subject to approval by Engineer, where such equipment is supplied and used in facilities outside the United States.

Exhibit S

Specifications


1.9 SOURCE QUALITY CONTROL

1.9.1 General All materials and components shall be tested by the Contractor’s suppliers in accordance with the CQC Plan, Inspection and Test Plan (ITP), and these Specifications. Contractor shall provide all procedures, equipment, materials, and labor for source quality control testing.

Testing shall be performed by personnel experienced in the type of test being performed under the direct supervision of Contractor’s test engineers. Qualifications of test personnel shall be submitted for District approval.

1.10 SHOP TESTS

1.10.1 General All materials, components, and assemblies shall be completely shop tested in accordance with the CQC Plan, Inspection and Test Plan (ITP), and these Specifications. Contractor shall provide all procedures, equipment, materials, and labor for shop testing.

Contractor shall give full cooperation to District's inspection at the shop. During manufacture, Contractor shall request District's observation of those in-progress tests, which are impossible to be checked if the manufacture is advanced or completed.

Shop tests shall be performed by personnel experienced in the type of test being performed under the direct supervision of Contractor’s Test Engineers.

1.10.2 Shop Test Procedures Contractor shall prepare and maintain complete detailed procedures for all shop inspections and tests. Tests and procedures identified in the specific equipment sections shall be prepared or translated to the English language and submitted for review and approval. Other procedures shall be available for inspection at Contractor’s facilities and submitted upon request. Procedures shall include, as a minimum, the following:

1. Table of Contents 2. Purpose 3. Precautions 4. References 5. Test Equipment 6. Prerequisites 7. Step-by-Step Procedures

Exhibit S

Specifications


8. Acceptance Criteria 9. Data or Record Sheets 10. Drawings or Data, as applicable 11. Sign-off for Performance and Witness

Step-by-step procedures shall be in sufficient detail to perform the test without reference to documentation or information not contained in the procedure or the need for interpretation as to intent or methods.

1.10.3 Inspection and Test Documentation The results of all inspections and tests shall be fully documented. Results for tests identified in these Specifications shall be included in complete test reports and submitted to Engineer for review and approval. Approval of test results is a requirement for shipping release.

1.11 FIELD TESTS

1.11.1 General All components and assemblies installed at site shall be completely tested in accordance with the CQC Plan, Inspection and Test Plan (ITP), Acceptance Test Plan in Section 01 91 14 Equipment Testing and Commissioning, and these Specifications. Contractor shall provide all procedures, oversight, and documentation for field testing.

Field tests shall be performed by personnel experienced in the type of test being performed.

1.11.2 Field Test Procedures Contractor shall prepare and submit for review and approval field test procedures for all field tests. Procedures shall include, as a minimum, the following:

1. Table of Contents 2. Purpose 3. Precautions 4. References 5. Test Equipment 6. Prerequisites 7. Step-by-Step Procedures 8. Acceptance Criteria 9. Data or Record Sheets 10. Drawings or Data, as applicable 11. Sign-off for Performance and Witness

Exhibit S

Specifications



1.11.3 Field Test Reports Within 48 hours of completion of each field test, Contractor shall submit one (1) copy of the test results to Engineer, unless specified otherwise. After completion of all field tests for an assembly, Contractor shall furnish two (2) copies of a complete report of all field tests performed. The report shall include a description (at a minimum) of the following:

1. Item Tested 2. Test Instrumentation 3. List of Test Personnel 4. Calibrations of Measuring Equipment 5. Test Procedure 6. Tabulations of Measurements 7. Sample Calculations, as appropriate 8. Test Results, including final adjustments and settings 9. Conclusions and/or Remarks

To the fullest extent possible, all data gathered electronically shall be in a form easily imported to Microsoft Excel. Contractor shall furnish an electronic copy of all original and manipulated test data to the District.

1.12 CONTROL OF NON-CONFORMANCES As a part of its Quality Control and Quality Assurance Plan, the Contractor shall:

1. Define a procedure for preventing nonconforming materials and equipment that do not meet standards, criteria or Specifications from being inadvertently used for this Project.

2. Nonconforming materials and equipment that do not meet Contract standards, criteria or Specifications inadvertently used for this Project shall be resolved as a price deduction, repair, return to source, scrap, or rework at the discretion of the District.

3. Any request for approval for deviations or nonconformance to the Contract documents or Quality Control Plan shall be made to the Engineer in writing.

4. A Nonconformance Report (NCR) shall be written and submitted to the District for each nonconforming item. The NCR shall 1) describe the system or part in nonconformance, 2) make reference to the controlling plan, specification, or procedure in violation, 3) include the Contractor’s recommended disposition,

Exhibit S

Specifications


and 4) signatures of the Contractor’s Quality and Engineering personnel. Use the NCR form included at the end this section (Appendix 4.1).

1.13 QUALITY RECORDS

Contractor shall maintain written quality records for the quality checks and verifications for the Work. The records shall be controlled by the Contractor to provide easy access for record retrieval and maintenance. All records shall be made available to the District for inspection or the District’s use and shall be submitted to the District upon request.

Contractor shall establish and maintain a record system that provides for the identification of materials and correlation to manufacturing, testing, and inspection.

Reports for all tests and inspections shall be written and submitted. All reports shall show the approved procedure, latest revision, the results, the date, the identification of the inspector or tester and the item examined.

1.14 WITNESS AND HOLD POINTS

Witness points require receipt in writing of notification to the District at least five (5) working days in advance of the scheduled time of performance. The District or designee may witness the event; however, the Contractor may proceed without their presence. The District may require activities performed without proper notification to be repeated for the District’s observation at the Contractor’s expense.

Hold Points are those tests, inspections, and operations which require witnessing by District and beyond which operations shall not proceed without written consent of District. Contractor’s failure to stop at a Hold Point may be cause for rejection of those items for which notification was not provided, or Contractor may be requested to repeat the operation at its expense. Hold Points require receipt of notification as may be appropriate for District to arrange for inspection. Contractor shall provide at least five (5) working days’ notice for Hold Points.

1.15 QC COORDINATION MEETING

Before start of construction, and prior to acceptance by the District of the Quality Control Plan, the Contractor shall meet with the Project Manager or Authorized Representative and discuss the Contractor's quality control system. During the meeting, a mutual understanding of the system details shall be developed, including the forms for recording the CQC operations, control activities, testing, administration of the system for both on-site and off-site work, and the interrelationship of Contractor's Management and control with the District's Quality Assurance inspection. Minutes of the meeting will be prepared by the District and signed by both the Contractor and the Project Manager.

Exhibit S

Specifications


The minutes shall become a part of the Contract file. There may be occasions when subsequent conferences will be called by either party to reconfirm mutual understandings and/or address deficiencies in the CQC system or procedures which may require corrective action by the Contractor.

1.16 CERTIFICATE OF COMPLIANCE When specified in individual Specification sections, submit certificate prior to shipment or use of material or equipment. Use the form included at the end of this section (Appendix 4.2). Contractor’s representative officially responsible for assuring that all requirements of these Contract Documents are met shall sign the Certification of Compliance. Receipt of the signed Certificate of Compliance is required for shipping release by the District.

District may permit use of certain materials or assemblies prior to sampling and testing if accompanied by accepted Certification of Compliance.

Certificate shall be signed by manufacturer and/or Contractor certifying that material or equipment provided conforms to or exceeds the requirements of the Specifications. Attach supporting reference data, affidavits and certifications as appropriate.

Material or equipment used on the basis of a Certification of Compliance may be sampled and tested at any time. The fact that material or equipment is used on the basis of a Certificate of Compliance shall not relieve Contractor of responsibility for incorporating material or equipment in the Work which conforms to requirements of the Contract Documents. Material or equipment not conforming to such requirements may be subject to rejection whether in-place or not.

District reserves the right to refuse permission for use of material or equipment on the basis of a Certification of Compliance.

1.17 CERTIFICATE OF PROPER INSTALLATION When specified in individual Specification sections, submit certificate after installation of material or equipment. Use the form at the end of this section (Appendix 4.3).

Certificate shall be signed by manufacturer and/or Contractor certifying that material or equipment specified and installed conforms to or exceeds the requirements of the Specifications and has been inspected by an authorized field representative. Attach supporting reference data, affidavits and certifications as appropriate.

Exhibit S

Specifications





Appendix 4.1 – Non-Conformance Report Appendix 4.2 – Certificate of Compliance Appendix 4.3 – Certificate of Proper Installation Appendix 4.4 – Inspections Elements – Summary Matrix

4.1 NON-CONFORMANCE REPORT NON-CONFORMANCE REPORT

XXX NCR No. NCR Number 1565-XXX-C0000-0.doc Initiator: XXX Date: Contractor/Subcontractor/Vendor: Unit No.: Part Name:

Shop Field Other Part Location:

XXX REASON Deviation from Spec Spec Violated: Related Ref. Doc: dated: Deviation from Dwg Dwg Violated: CPUD: Vendor: Code Violated Name/Sec/Para: Other, describe: Item No.:

Condition Details:

Attachments: Condition details by: Date: Disposition assigned to XXX Engineer: Date:

XXX DISPOSITION 1 Action: Accept As Is Scrap Rework Revise Return to Vendor DCN Required Disposition Details:

Attachments: XXX Disposition by: Date: DISPOSITION 1 STATUS

APP CPUD Engineer signature: Date: NOT APP QA/QC Manager signature: Date:

REASON FOR NOT APP:

XXX DISPOSITION 2 (if D1 becomes NOT APP) Action: Accept As Is Scrap Rework Revise Return to Vendor DCN Required Disposition Details:

Attachments: XXX Disposition by: Date: DISPOSITION 2 STATUS

APP CPUD Engineer signature: Date:

NOT APP QA/QC Manager signature: Date: REASON FOR NOT APP:

INSPECTION/ VERIFICATION:

Signature: Date: Acceptable Not Acceptable

REINSPECTION/ RE-VERIFICATION:

Signature: Date: Acceptable Not Acceptable New NCR No.: Supersedes NCR No.: New IR No.:

REVIEWED AND CLOSED

CPUD Engineer signature: Date:

QA/QC Manager signature: Date:

NON-CONFORMANCE REPORT CORRESPONDENCE

NCR NO.: 1565-XXX-C0000-0.doc

0 - Description/Request:

Requested Due Date: By: Attachments:

Copy: VENDOR

:

CPUD: Date:

A - Response: CPUD:


Copy: VENDOR

:

CPUD: Date:

B - Response: VENDOR:

Requested Due Date: By:

Attachments:

Copy: VENDOR

:

CPUD: Date:

C - Response: CPUD:


Copy: VENDOR:

CPUD: Date:

D - Response: VENDOR:


Copy: VENDOR:

CPUD: Date:

Exhibit S

Specifications


4.2 CERTIFICATE OF COMPLIANCE Contract: No. 15-65 Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment

Contractor:___________________________________________________________

Equipment/System:____________________________________________________

_____________________________________________________________________

The Manufacturer(s) and Fabricator(s) of materials and products incorporated into the Work and furnished as specified in the Contract Documents hereby certify that: 1. All materials and products incorporated into the Work provided by manufacturers

and fabricators are as specified in the Contract Documents. 2. All materials and products incorporated into the Work provided by manufacturers

and fabricators are in accordance with all codes, and standards as specified in the Contract Documents.

3. All materials and products incorporated into the Work provided by manufacturers and fabricators have been subjected to all material and/or factory tests specified in the Contract Documents, and that the results of those tests are within all limits and acceptance criteria as specified.

4. Copies of material certification and factory test results are attached.

Manufacturer/Fabricator Information Name of Manufacturer or

Fabricator:

Street Address:

City/State/Zip: Phone Number:

Authorized Representative: Name and Title: Signature/Date:

Comments:

Exhibit S

Specifications


4.3 CERTIFICATE OF PROPER INSTALLATION Contract No. 15-65 Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment

Contractor:___________________________________________________________

Equipment/System:____________________________________________________

_____________________________________________________________________

The Manufacturer and Fabricator of materials and products incorporated into the Work and furnished as specified in the Contract Documents hereby certify that: 1. Authorized representative(s) have provided technical support during installation,

alignment, functional and performance testing of all materials and products as specified in the Contract Documents.

2. Authorized representative(s) have performed final inspection of all materials and products as specified and that installation, alignment and operation of materials and products is in accordance with the Manufacturer/Fabricator.

3. Authorized representative(s) certify that installation of materials and products meet all Manufacturer/Fabricator requirements for proper installation.

4. Copies of documentation demonstrating proper installation are attached.

Manufacturer/Fabricator Information Name of Manufacturer or

Fabricator:

Street Address:

City/State/Zip: Phone Number:

Authorized Representative: Name and Title: Signature/Date:

Comments:

Exhibit S

Specifications


4.4 INSPECTIONS ELEMENTS – SUMMARY MATRIX

Name of Project: 15-65 Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment Notes: 1) Indicate specification reference with criteria. 2) Results and Inspector’s name can be placed in last two columns. Responsible party:

PLAN SECTION NO. AND INSPECTION CRITERIA

Description: 15-65 Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment

Identification of Item to be Inspected

Inspection Schedule/Date

Inspection Conditions

Characteristics to be Inspected Acceptance Criteria Inspection Method/Test Extent of

Inspection

Factory/ Source Inspection

Witness/ Hold Point Results Inspector

DIVISION 5 METALS

A) Material Documentation and Certfication

Submittal, Shop, and Field

Material verification Applicable Material Specification, (ASTM, ASME, IEEE, etc.)

Specification Section 41 05 13.13 Specification Section 41 22 10.13 Specification Section 41 22 11.13

Witness

B) Dimensional Inspection

Shop and Field Position, alignment, dimensions, straightness

Specifications Sections

Visual Dimensional Witness

C) Welding - WPS Submittal Documents – in accordance with Contract

Specification Section 05 05 23


Hold (before first welding)

D) Welding – Trolley Frame

Field Field Welds Specification Section 05 05 23


Hold (before paint)

E) Welding – Drum Shell

Shop Shop Welds Specification Section 05 05 23


Witness (before paint)

F) Welding – Bridge Structure

Field Field welds Specification Section 05 05 23

Specifications Section 05 05 23

Witness

G) Welding – General Shop and Field All Welds Specification Section 05 05 23


H) Fasteners – High-strength bolts, nuts and washers

Submittal, Shop and Field

Material verification Specifications Section 05 05 24


Exhibit S

Specifications







Inspection



I) Metal Fabrications Walkways & Handrails

Shop Galvanizing (Hot-dip) Specifications Section 05 50 00


Witness

J) Castings – General

Submittal Material Verification Specifications Section 05 56 00


K) Castings – Repair Shop Weld repair Specifications Section 05 56 00


Witness

L) Forgings – General

Submittal Material Verification Specifications Section 05 58 10


M) Forgings – Repair Shop Weld repair Specifications Section 05 58 10


Witness

DIVISION 9 FINISHES

A) Painting – General Submittal Field and shop paint systems



B) Painting – Trolley Frame

Field Surface preparation Specifications Section 09 90 04


Witness

C) Painting – Bridge structure

Field Surface preparation Specifications Section 09 90 04


Witness

DIVISION 26 - ELECTRICAL AND DIVISION 41 MATERIAL PROCESSING AND HANDLING EQUIPMENT (Electrical Work)

A) Motors Shop – Supplier Electrical Tests Specification Section 41 22 13.16 NEMA MG1

Specification Section 41 22 13.16 NEMA MG1

Witness

B) Panel Boards Field Visual and Mechanical Inspection



Witness

C) Panel Boards Field Electrical Tests Specification Section 26 08 00


Witness

D) Dry Type Transformers

Field Visual and Mechanical Inspection



Witness

E) Low Voltage Cables




Witness

F) Low Voltage Cables

Field Electrical Tests Specification Section 26 08 00


Hold

Exhibit S

Specifications







Inspection



G) Circuit Breakers Field Visual and Mechanical Inspection



Witness

H) Grounding Systems




Witness

I) Grounding Systems

Field Electrical Tests Specification Section 26 08 00


Witness

J) Low Voltage Surge Arrestors




Witness

K) Control Panels Shop – Supplier UL508 Specification Section 41 22 11.13

Specification Section 41 22 13.16

Witness

L) Control Panels Shop – Supplier Operational acceptance test



Witness

M) Load Cells Shop – Supplier Electrical test Specification Section 41 22 13.16


Witness

N) Electrical System Shop Operational acceptance test



Witness

O) Electrical System Field Operational acceptance test



Hold

P) Material Documentation and Certification


Material verification Applicable Material Specification, (NEMA, IEEE, etc.)


Witness

Q) Component Certificates of Conformance

Submittal Component verification Applicable Equipment Manufacturer’s Standard (IEEE, NEMA, UL, etc. )


Witness

DIVISION 41 MATERIAL PROCESSING AND HANDLING EQUIPMENT (Mechanical Work)

A) Material Documentation and Certification


Material verification Applicable Material Specification, (ASTM, ASME, etc.)

Specification Section 41 05 13.13 Specification Section 41 22 10.13

Witness

B) Dimensional Inspection

Shop, and Field Alignment, overall dimensions, materials, construction


Visual

Exhibit S

Specifications







Inspection



C) Component Certificates of Conformance

Submittal Component verification

Applicable Equipment Manufacturer’s Standard (ABMA, AGMA, etc.


Witness

D) Hooks Shop – Supplier Proof test Specification Section 41 22 10.13


Witness

E) Wire Rope Shop – Supplier Pull test – To Failure Specification Section 01 91 14


Witness

F) Load Test Field Specification Sections 01 91 14 41 22 10.13

Specification Sections 01 91 14 41 22 10.13

Hold

END OF SECTION 01 45 16.13


Bid No. 15-65 Construction Facilities and Temporary Controls – 01 50 00 Page 1

SECTION 01 50 00

CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 2

1.3 MOBILIZATION FOR ON-SITE WORK ....................................................................... 4 1.4 PROJECT WORK AREAS AND ACCESS ................................................................... 4

1.5 VEHICULAR TRAFFIC ............................................................................................ 5 1.6 POWERHOUSE FLOORS ........................................................................................ 6 1.7 PROJECT SITE WORKING HOURS .......................................................................... 8

1.8 PROJECT SECURITY ............................................................................................ 8 1.9 DRAWINGS AND MANUALS .................................................................................. 10

2.0 PRODUCTS (NOT USED).................................................................................. 11 3.0 EXECUTION ....................................................................................................... 11

3.1 TEMPORARY UTILITIES ....................................................................................... 11

3.2 PROTECTION OF WORK AND PROPERTY .............................................................. 12 3.3 TEMPORARY CONTROLS .................................................................................... 13

3.4 RIGGING AND LIFTING EQUIPMENT ...................................................................... 15

3.5 LAYDOWN AREAS FOR STOCKPILING, STAGING OR STORAGE BUILDINGS ............... 15

3.6 CONTRACTOR EQUIPMENT ................................................................................. 16 3.7 ACCESS ROADS ................................................................................................ 18

3.8 PARKING AREAS ................................................................................................ 18 3.9 CARE OF DRAINS ............................................................................................... 18 3.10 CLEANING DURING CONSTRUCTION .................................................................... 19 3.11 DISPOSAL ......................................................................................................... 19



SECTION 01 50 00

CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

1.0 GENERAL

1.1 REFERENCES


Occupational Safety and Health Administration (OSHA)

United States Environmental Protection Agency (EPA)

National Fire Prevention Association (NFPA) 241 Standard for Safeguarding Construction, Alteration, and

Demolition Operations

American Concrete Institute (ACI)

American Society of Mechanical Engineers (ASME) B30.9 Slings B30.10 Hooks B30.20 Below-the-Hook Lifting Devices B30.23 Personnel Lifting Systems

1.2 SUBMITTALS

1.2.1 Informational Submittals

Provide copies of permits and approvals for construction beyond those already obtained by the District, if any, as required by Laws and Regulations and governing agencies.

Submit and post copies of SDSs for any new chemicals brought onto the site which were not included in the original submittal of SDS information.

Affidavits detailing work experience and physical examination history for Contractor crane, lift truck, and manlift operators and riggers.



1.2.2 Temporary Construction Facilities

Submit construction facilities and temporary controls site plan which provides details on the following items:

Temporary Utility Submittals:

1. Electric power supply and distribution plans. 2. Water supply and distribution plans. 3. Compressed air supply and distribution plans. 4. Sanitary facility plans. 5. Communications routing plan for telephone and fiber.

Temporary Construction Submittals:

1. Parking area plans. 2. Contractor’s field office and storage yard, storage buildings,

machining/fabrication shop, and any other on-site facilities; proposed layout and use plan.

3. Fencing and protective barrier locations and details. 4. Staging area locations plan. 5. Equipment and material storage, staging, erection, etc. 6. Scaffolding schemes. 7. Traffic and Pedestrian Control and Routing Plans: As specified herein, and

proposed revisions thereto. 8. Transport vehicle wheel loading diagrams. 9. Equipment staging and use plan for powerhouse service bay floor. Includes

details of equipment loadings and calculations and drawings verifying proposed equipment loads do not exceed allowable floor structural capacity. Calculations and drawings shall be stamped by a Structural Engineer licensed in the State of Washington.

10. Equipment staging and use plan for intake deck. Includes details of equipment loadings and calculations and drawings verifying proposed equipment loads do not exceed allowable deck structural capacity. Calculations and drawings shall be stamped by a Structural Engineer licensed in the State of Washington.

Temporary Controls Submittals:

1. Dust control plan. 2. Waste water control plan. 3. Plan for disposal of waste materials. 4. Spill Prevention, Containment and Countermeasures Plan (SPCC).



1.3 MOBILIZATION FOR ON-SITE WORK

Mobilization shall include, but not be limited to, these principal items:

1. Obtaining required permits beyond those already obtained by District, if any. 2. Moving Contractor’s field office and equipment required for operations onto site. 3. Installing temporary construction power, wiring, and lighting facilities. 4. Providing onsite communication facilities, including telephones and internet. 5. Providing onsite sanitary facilities and potable water facilities as specified and

as required by laws and regulations, and governing agencies. 6. Arranging for and erection of Contractor’s work and storage yard. 7. Posting OSHA required notices and establishing safety programs and

procedures. 8. Having Contractor’s superintendent at site full time.

Use area designated for Contractor’s temporary facilities as shown on Contract Drawings unless otherwise requested by Contractor in construction facilities and temporary controls site plan submittal and Approved by the District.

1.4 PROJECT WORK AREAS AND ACCESS

1.4.1 Project Site Coordination

Contractor shall be responsible for coordinating the manufacture, testing, inspection, storage and delivery of all products furnished under this Contract. Contractor shall notify the Rocky Reach Dam Control Room at extension 6000 upon entering and leaving the Project site.

1.4.2 Access by District Personnel

Clear access shall be maintained for District personnel and equipment through all Project Work areas. District crews may require access to the Work area for normal District operations or emergencies. Contractor shall coordinate their use of the site with use of the site by others, subject to Approval by the District.

1.4.3 Access by Contractor Personnel

The Project site is located adjacent to the Rocky Reach Powerhouse, located on the Columbia River approximately 5 miles north of Wenatchee, Washington. Access to the Contractor’s work areas shall be from US Hwy 97A onto the Chelan County entrance to the Rocky Reach Hydroelectric Project. The physical address for the Rocky Reach Project is: Rocky Reach Hydroelectric Project, 5000 Highway 97A North, Wenatchee, Washington. This will include all Contractor vehicles, all private vehicles of Contractor and Contractor's employees, and all delivery vehicles of equipment and materials.



Private vehicles are restricted to designated parking areas adjacent to the Project site as shown on Contract Drawings.

1.4.4 Access by Public to the Visitors Center, Museum, and Park Grounds

The Rocky Reach Dam Visitors Center is located on the west bank of the dam adjacent to the entrance to the forebay deck as shown on the Drawings. Visitor services, which include public access to the Rocky Reach parks grounds, Visitors Center, the forebay deck, the service bay intake deck, and the powerhouse (via the powerhouse entrance located at the service bay intake deck), are open to the public from March 1 through October 31, daily from 9 a.m. to 4 p.m. Public access to these areas is from US Hwy 97A onto the main entrance to the Rocky Reach Hydroelectric Project.

Whenever it is necessary to cross, close, or obstruct roads, parking areas, or other areas open to the public; the Contractor shall provide and maintain suitable and safe detours, flaggers, or other temporary measures to accommodate public travel in and out of areas open to the public.

1.5 VEHICULAR TRAFFIC

1.5.1 Construction Access and Entrances

The Contractor shall maintain control of the entrances to work areas by restricting access through such measures as signage and flagging or by other means as directed by the District.

1.5.2 Access Restrictions for District Roadways

Hauling of materials and equipment will be permitted on the Project’s roadways subject to a load limitation equivalent to the Standard Highway HS20 loading; at least one lane shall be kept open for vehicle traffic at all times on these roadways

The Contractor shall protect the various portions of the Project’s structures from damage by traffic and also keep the areas in use cleaned up and orderly at all times during use. Vehicle speeds, special precautions, and safety measures shall be As Directed by the District.

1.5.3 Use of Decks

Deck space at the Project site is limited. Contractor shall maintain single-vehicle access (9-foot 9-inch width) across the forebay, service bay, and powerhouse intake decks. Any deck blockages shall be scheduled at least seven (7) days prior to the blockage, and shall be Approved in writing. At the end of each day’s work all deck blockages shall be cleared, unless Approved by District.



Access for emergency vehicles shall be continuously provided. Contractor shall be allowed to block the deck for reasonable periods as may be necessary to facilitate the Work. Vehicle access shall be provided a minimum of two (2) 1-hour periods per day corresponding to the beginning and/or end of District work shifts.

District shall have first priority to deck access and maintains the right to revise or restrict Contractor’s use of deck areas at any time, if necessary, for District operations. If the District requires access to the deck that affects a pre-approved blockage or causes removal of a Contractor pre-approved deck blockage, Contractor shall be entitled to a time extension for any delay greater than four (4) hours attributable to the District’s use of the deck, conditional upon Contractor’s compliance with all requirements of the Contract documents for obtaining such time extension including but not limited to General Conditions Paragraph GC-41, Delays and Extensions of Time.

Use of the intake deck must be coordinated with District and other Contractors at the site. Access to and use of the decks other than for a deck blockage, shall be requested at least three (3) days prior to the use. Contractor shall submit a description of the activity including weights and dimensions of lifting equipment, sketch of the proposed location, and a detailed schedule of the activity. The deck cannot be completely blocked to foot traffic at any time.

Contractor shall protect the various portions of the hydro project’s structures from damage, prevent material from falling through the deck openings, and keep the areas in use cleaned up and orderly at all times during the Work.

Contractor shall engineer all crane picks on the intake deck to assure that loads imposed on intake structure do not exceed deflections or stresses allowed by the latest edition of ACI 318 or AISC.

1.5.4 Access Routing Plan

Show sequences of construction affecting use of access roadways, time required for each phase of the Work, provisions for decking over openings and phasing of operations to provide necessary access, and plans for signing, barricading, and striping to provide passages for pedestrians and vehicles.

1.6 POWERHOUSE FLOORS

1.6.1 General

Storage of equipment and materials will be permitted only in designated staging areas outside of the powerhouse and in designated erection areas within the powerhouse as Approved by the District. Staging and erection areas are shown on the Contract Drawings.



Staging of equipment and materials on the powerhouse service bay floor shall not exceed the maximum allowable floor loading capacity. See the Reference Drawings for additional details on the generator and service bay floor load capacities. For loads heavier than the maximum allowable floor loading capacity, the Contractor shall provide an engineering analysis that shows the existing structure can safely support the load; or how and by what additional temporary structures, the applied load will be adequately distributed and supported to ensure the existing structure will not be overloaded. 1.6.2 Protection of Floors and Powerhouse

The Contractor shall maintain the District installed plywood floor coverings that are on the powerhouse floor. The existing coverings are made of ¾” tongue and groove plywood, with steel connecting plates. Materials which are damaged and no longer provide floor protection, or are unsafe, shall be replaced with like materials at Contractors expense. Contractor shall provide, install, and maintain protective coverings and equipment as needed, to protect floors and District installed plywood floor coverings from any damage that might result from Contractor’s operations in performance of the Work. In locations without existing plywood floor coverings, the Contractor shall install plywood floor coverings of similar design as necessary to protect floor surfaces from any damage that might result from Contractor’s Work activities. Contractor shall submit details of additional floor covering design and materials for District Approval. The Contractor shall provide cribbing material for supporting parts removed from the crane during disassembly and reassembly. Timbers shall be sized to distribute load so that the maximum load capacity of the floor is not exceeded and to ensure floor coverings and finishes are not damaged. Timbers shall be stress graded and rated for use as cribbing. Contractor shall preserve and store cribbing for major components. Contractor shall protect the various portions of the hydro project’s structures from damage, prevent material from falling through the floor openings, and keep the areas in use cleaned up and orderly at all times during the Work.

1.6.3 Use of Floors in the Powerhouse

Floor space at the Project site is limited. Contractor shall maintain clear access for District personnel and equipment through all project work areas. Access for emergency vehicles shall be continuously provided. The powerhouse floor cannot be completely blocked to foot traffic at any time.

District shall have first priority to floor space and access and maintains the right to revise or restrict Contractor’s use of powerhouse floor areas at any time if necessary for District operations. If the District requires use of the powerhouse floor areas that are designated for Contractor staging and erection, Contractor shall be entitled to a time



extension for any delay greater than four (4) hours attributable to the District’s use of the floor areas, conditional upon Contractor’s compliance with all requirements of the Contract documents for obtaining such time extension including but not limited to General Conditions Paragraph, Delays and Extensions of Time.

Use of the powerhouse floor areas must be coordinated with District and other Contractors at the site. Contractor shall submit an equipment staging and use plan for work areas on powerhouse floor. The plan shall include details and drawings to show how the Contractor will use work areas, store materials and stage equipment. The plan will also outline routes of access through work areas.

Contractor shall engineer all crane picks on the powerhouse floor areas to assure that loads imposed on the structure do not exceed deflections or stresses allowed by the latest edition of ACI 318 or AISC.

1.7 PROJECT SITE WORKING HOURS

1.7.1 District Project Personnel Working Hours

The working hours of the Project staff and maintenance crews are Mondays through Fridays, excluding District holidays, from 7:00 a.m. until 3:30 p.m. A powerhouse operator is at the Project site during these times, but is not available to assist Contractor.

1.7.2 Contractor’s Working Hours

At the Preconstruction Meeting, Contractor’s schedule of working hours and days shall be reviewed. The Contractor shall furnish notification of any change of schedule of regular work hours, overtime work hours, and shifts of work crews and personnel at the Site. Contractor shall provide to District this notification a minimum of 72 hours prior to any schedule change to allow suitable scheduling of District personnel and inspection. Contractor shall not work on District holidays without prior District Approval.

1.8 PROJECT SECURITY

1.8.1 General

Contractor and Subcontractors shall abide by all District security policies and procedures, as specified in General Conditions paragraph, Security, as well as additional requirements including, but not limited, to the following:

1. Obey all security signs, instructions, fenced/locked/barred barriers, and requests and inquiries by security guards.

2. All Contractor workers with access to generation plants, switchyards, substations, System Operation Control, and Information Technology (IT) systems are subject to background screening.



3. Identification badges issued by District shall be worn conspicuously by each Contractor employee at all times when on the District’s premises.

4. Each Contractor employee shall occupy only their immediate Work area. Any Contractor employee found occupying areas not directly related to the Work areas designated for this Contract may be permanently removed from the site at the discretion of the District.

5. Each Contractor employee is subject to search each time they enter or leave the site and during the performance of their work.

6. Portions of the Project site are secured. Contractor shall coordinate activities with the District to gain access to secured areas.

7. Contractor shall be responsible to secure their Work areas for safety and to protect against damage and theft.

8. Prior to Work at the site, each Contractor employee shall attend up to two (2) hours of security, safety, and plant orientation meetings provided by the District.

9. Provide and maintain additional temporary security fences as necessary to protect the Work and Contractor-furnished products not yet installed.

The security measures affect all Contractor and Subcontractor vehicles and personnel. There will be delays when entering the Project due to locked gates, vehicle inspections, and personnel checks. Inspections and checks may include inspection of tool boxes, brief cases, lunch boxes, and other containers.

1.8.2 Vehicle Access

Project access roads are secured with locked gates. All Contractor, Subcontractor, and private vehicles that pass through the locked gates will be subject to being searched.

Privately owned vehicles will be restricted to designated parking areas on the Project. Only Contractor’s Work vehicles and equipment that are essential to the conduct of the Work will be allowed in the Work areas.

All Contractor and Subcontractor vehicles shall display Approved identification of such size and color to allow District personnel and security guards to identify the vehicle.

1.8.3 Identification of Employees

The District will issue to each Contractor and Subcontractor employee a photo identification badge/card. The Contractor shall be responsible for requiring each employee engaged in the Work to display identification at all times. All prescribed identification shall immediately be delivered to the District for cancellation upon the release of the employee. Employees who fail to submit to photographing will not be allowed on the Project site. See General Conditions paragraph, Security.



1.8.4 Delivery of Equipment and Materials

Deliveries of equipment and materials to secured areas of the Project site shall arrive during the District’s normal working hours. The Contractor shall coordinate deliveries with the District a minimum of 24 hours in advance of the scheduled delivery time. Delivery vehicles will not be allowed to cross the river over the Rocky Reach Dam Project roadways or decks.

1.8.5 Site Investigations and Conditions Affecting the Work

The Contractor acknowledges that it has taken steps reasonably necessary to ascertain the nature and location of the Work, and that it has investigated and satisfied itself as to the general and local conditions which can affect the Work or its cost, including, but not limited to:

1. Conditions bearing upon transportation, disposal, handling, and storage of materials;

2. The availability of labor, water, electrical power, roads, and decks; 3. Uncertainties of weather, river stages, or similar physical conditions at the

Project site; 4. The conformation and conditions of the ground and equipment and facilities to

be replaced and/or rehabilitated; 5. The character of equipment and facilities needed preliminary to and during work

performance; 6. The amount of work space at the Project site, accessibility, lighting, etc.

Any failure of the Contractor to take the actions described and acknowledged in this paragraph will not relieve the Contractor from responsibility for estimating properly the difficulty and cost of successfully performing the Work, or for proceeding to successfully perform the Work without additional expenses to the District.

The District assumes no responsibility for any conclusions or interpretations made by the Contractor based on the information made available by the District. Nor does the District assume responsibility for any understanding reached or representation made concerning conditions that can affect the Work by any of its officers or agents before the execution of this Contract, unless the understanding or representation is expressly stated in these Contract Documents.

1.9 DRAWINGS AND MANUALS

Existing plant drawings and manuals required for the Work will be available for viewing at the Project site during normal project day shift working hours, from 7:00 a.m. to 3:30 p.m., Monday through Friday, excluding District holidays. Drawings and manuals shall not be removed from the office.




3.0 EXECUTION

3.1 TEMPORARY UTILITIES

3.1.1 General

All utilities that are required for use in performance of the Work at the Project site under this Contract shall be Contractor furnished unless otherwise specified.

3.1.2 Power

Electric power will be made available to Contractor from the existing operable electrical outlets without cost to Contractor. Only those outlets and services designated for use by Contractor may be used. All others are reserved for use by District.

All other temporary power that Contractor requires for construction shall be the responsibility of Contractor. Contractor shall be responsible for connection to District’s power source at identified locations and for distribution of this power. Contractor shall provide all equipment required for Contractor’s use and for personnel safety and protection of the power supply system.

Contractor shall make its own determination as to the suitability and capacity of each power source. All temporary equipment and wiring for power and lighting shall be in accordance with all applicable provisions of all governing codes. All temporary wiring shall be maintained in a safe manner and utilized so as not to constitute a hazard to persons or property.

At the completion of the construction work, all temporary wiring, lighting, and other temporary electrical equipment devices shall be removed.

3.1.3 Lighting

Contractor shall provide temporary lighting to meet applicable safety requirements to allow erection, application, or installation of materials and equipment, and observation or inspection of the Work.

3.1.4 Compressed Air

Contractor will be allowed to use plant air, but the District makes no warranties as to the suitability of plant supplied compressed air for use by the Contractor. Contractor shall make its own determination as to the suitability and capacity of plant air supplied and shall be responsible for connection to District’s air source at identified locations and for distribution of this compressed air to points of use.



Contractor shall provide all equipment required for Contractor’s use and for personnel safety and protection of the air supply system.

If plant supplied compressed air is not adequate for the Contractor’s intended use, the Contractor shall supply all equipment to provide any compressed air that may be required to perform the Work.

3.1.5 Water

Contractor shall have access to non-potable plant service water for construction purposes without cost to Contractor. Water supply is limited. Only those outlets designated for use by Contractor may be used. All others are reserved for use by District.

Contractor shall be responsible for connection to District’s water source at identified locations and for distribution of this water to points of use. Contractor shall provide all required equipment required for Contractor’s use and for personnel safety and protection of the water supply system.

Contractor shall furnish drinking water with suitable containers, cups, and trash receptacles for use of employees. Drinking water dispensers shall be conveniently located in all areas where Work is in progress.

3.1.6 Sanitary Provisions

See General Conditions, Paragraph GC-62, Sanitary Provisions. The existing sanitary facilities in Rocky Reach Powerhouse will not be available for use by the Contractor.

3.1.7 Communication Service

District will provide and install telephone and internet service to each of Contractor’s office trailers. Use of these services is subject to District Policy. Cellular phones may be used, however service in the area is limited.

3.1.8 Fire Protection

See Section 01 35 24 Safety.

Furnish and maintain on Site adequate firefighting equipment capable of extinguishing incipient fires. Comply with applicable parts of NFPA 241.

3.2 PROTECTION OF WORK AND PROPERTY

See General Conditions paragraph GC-59, Protection of Property.



Contractor shall immediately report to the District any damage to District equipment or facilities caused either directly or indirectly by Contractor in the performance of the Work. Contractor shall respond appropriately only to minimize a safety or hazardous condition; otherwise the damage is not to be disturbed until District has been notified. Damage to District property caused by Contractor shall be corrected at Contractor’s expense.

3.3 TEMPORARY CONTROLS

3.3.1 Air Pollution Control

3.3.1.1 General

See General Conditions Paragraph GC-60, Dust and Smoke Control.

In addition, Contractor shall minimize air pollution from its construction operations. Burning of waste materials, rubbish, or other debris will not be permitted on or adjacent to site. Contractor shall conduct operations of dumping and of carrying waste material away to cause a minimum of dust. Contractor shall provide and maintain temporary dust-tight partitions, bulkheads, or other protective devices during construction to permit normal operation of existing facilities and to eliminate dust, smoke, or fumes from contamination of the balance of the powerhouse. Contractor shall construct partitions of plywood, insulating board, plastic sheets, or similar material. Contractor shall construct partitions in such a manner that dust, smoke, metal filings, etc. from demolition and cutting will not enter other parts of existing building or facilities. Contractor shall remove temporary partitions as soon as the need for them no longer exists.

3.3.1.2 Air Purity Control in the Powerhouse

Contractor shall take all necessary measures to effect maximum control of all dust and fumes created by its operations under this contract. To the maximum extent possible, all dust, smoke and fumes shall be removed by vacuum cleaning, unless otherwise approved. Prior to commencement of field operations, Contractor shall submit to District a dust and fume control plan. As a minimum the air purity program shall include the following:

1. Provision of exhaust ducts which shall discharge outside the powerhouse structure where mechanical ventilation is used. Exhaust shall contain no dust, smoke, or hazardous emissions.

2. Controlled operation of power-driven tools. 3. Furnishing and removal of oiled sawdust or other approved dust preventatives

in areas which cannot be properly rendered free from excessive dusting by vacuum cleaning or other methods.



4. Vacuum cleaning (or other acceptable method) of spaces within the powerhouse where dust accumulates.

5. Gasoline and diesel internal combustion engine powered equipment will not be permitted to operate inside the powerhouse.

6. All doors shall be kept closed when not being used. Depending upon Contractor's equipment and methods of operation, additional provisions for satisfactory dust control will be required and shall be included in the proposed dust-control program. Decisions of District as to the adequacy and extent of the dust control program and prosecution of the Work shall be final. The dust, smoke and fume control in the powerhouse shall be considered as incidental to the work and no separate payment will be made therefore.

3.3.2 Invasive Species Control

See General Conditions Paragraph GC-67, Invasive Species Control.

3.3.3 Water Pollution Control

The Contractor shall at all times control and contain all wastes and wastewater generated from their operations. Do not cause or permit action to occur which would cause an overflow to existing waterway.

Prior to commencing excavation and construction, Contractor shall obtain Engineer’s approval of Contractor-prepared, activity-specific Spill Prevention, Containment and Countermeasures (SPCC) Plan. A SPCC Plan shall be prepared by Contractor and accepted by Engineer prior to performance of any Work activity which could potentially lead to a discharge of pollutants and/or contaminants. The plan shall show procedures intended to handle and dispose of sewage, groundwater, and storm water flow, including dewatering pump discharges. The SPCC Plan shall also contain detailed plans showing procedures intended to prevent unauthorized discharges into the environment, and containment and countermeasure plans which will be employed by Contractor in the event an accidental or otherwise unauthorized discharge occurs. Prevention Plans shall include Best Management Practices for the handling water flow, and for the handling, containment and control of fuel and lubricants. See GC-69 Hazardous Substances and Environmental Protection

Comply with procedures outlined in U.S. Environmental Protection Agency manuals entitled, “Guidelines for Erosion and Sedimentation Control Planning” and “Implementation, Processes, Procedures, and Methods to Control Pollution Resulting from All Construction Activity,” and “Erosion and Sediment Control-Surface Mining in Eastern United States.”



Do not dispose of volatile wastes such as mineral spirits, oil, chemicals, or paint thinner in storm or sanitary drains. Disposal of wastes into streams or waterways is prohibited. Drains obstructed by Contractor shall be cleared and cleaned by the Contractor. Provide acceptable containers for collection and disposal of waste materials, debris, and rubbish.

3.4 RIGGING AND LIFTING EQUIPMENT

Contractor shall supply all lifting devices, rigging and other means for proper, safe, convenient and expeditious disassembling, and assembling of the cranes. Contractor shall furnish all lifting equipment to handle crane parts and equipment during the disassembly and erection of each crane. All rigging and lifting equipment must, as a minimum, meet the requirements of the following codes and standards:

American Society of Mechanical Engineers (ASME) B30.9 Slings B30.10 Hooks B30.20 Below-the-Hook Lifting Devices B30.23 Personnel Lifting Systems

Contractor is exclusively responsible for inspections of the Contractor supplied lifting equipment, and to meet inspection frequency as required by Contractor’s safety program.

3.5 LAYDOWN AREAS FOR STOCKPILING, STAGING OR STORAGE BUILDINGS

The Contractor shall prepare laydown areas at or within the locations shown on the Contract Drawings unless otherwise Approved in writing by the District or through approval of Construction Facilities and Temporary Controls Site Plan Submittal.

At the Contractor’s option, the Contractor may install one office trailer at the Project site. The Contractor shall coordinate location of their office trailers and Contractor parking with the District. Electrical service will be installed by the District. Internet access can also be made available via the District’s fiber optic network. No wireless devices may be connected to the District’s network.

Construction shanties, sheds, and temporary facilities provided by Contractor shall be maintained in good condition and neat appearance.

All storage, staging, field fabrication and field office operations shall be confined to the Approved staging areas. Staging areas shall be kept clean and orderly.



Storage of equipment and materials will be permitted only in designated staging areas and as set forth below, unless otherwise approved. All equipment and materials proposed for temporary storage areas within the District allocated staging areas shall be approved in advance. Combustible materials (such as paints, solvents, fuels) shall be stored in a well ventilated and remote building meeting applicable safety standards.

3.6 CONTRACTOR EQUIPMENT

3.6.1 General

The Contractor shall provide all cranes, rigging, lifts, operators, and other necessary means to move equipment and material as required for the execution and Completion of the Work unless otherwise specifically mentioned.

3.6.2 Powerhouse Floors

Staging of equipment from the powerhouse floor areas must be coordinated with the District. The Contractor shall submit a description of each activity that requires equipment staging from the powerhouse floor, including weights and dimensions of equipment, sketch of the proposed location, and detailed schedule of activities.

For all equipment loadings the Contractor shall submit calculations to verify proposed equipment loads do not exceed allowable floor loadings. In addition, the Contractor shall submit drawings showing location of equipment loads on the floor structure, methods for distribution of wheel and outrigger loading, and details of protective structures or equipment needed to prevent damage to the floor structure. Calculations and drawings shall be stamped by a structural engineer licensed in the State of Washington.

3.6.3 Intake Deck

Staging of equipment from the intake deck must be coordinated with the District. The Contractor shall submit a description of each activity that requires equipment staging from the intake deck, including weights and dimensions of equipment, sketch of the proposed location, and detailed schedule of activities.

For all equipment loadings which exceed a Standard Highway HS20 loading the Contractor shall submit calculations to verify proposed equipment loads do not exceed allowable deck loadings. In addition, the Contractor shall submit drawings showing location of equipment loads on the deck structure, methods for distribution of wheel and outrigger loading, and details of protective structures or equipment needed to prevent damage to the deck structure. Calculations and drawings shall be stamped by a structural engineer licensed in the State of Washington.



3.6.4 Testing of Equipment

Before any machinery or mechanized equipment is put to use, Contractor shall be responsible to have it inspected and tested by a qualified person and determined to be in proper operating condition and in compliance with applicable safety requirements.

Equipment shall be of sufficient capacity to safely handle proposed loads or tasks without exceeding the equipment rating established by the manufacturer or special tests.

3.6.5 Contractor’s Cranes

3.6.5.1 General

Contractor's cranes and equipment furnished for Work at the Project site shall conform to all applicable WAC, WISHA, and OSHA requirements for the intended use.

3.6.5.2 Contractor Crane, Lift Truck, and Manlift Operators

Qualified Contractor crane, lift truck, and manlift operators shall be furnished. Operators shall be certified in accordance with Washington State regulations. The operator certification must include a successful passing of a written and practical examination as described in WAC 296-155 Part L.

Each operator shall have had at least one (1) year experience on equipment of equivalent capacity and characteristics. Qualifications for each operator in the form of an affidavit signed by the operator and the Contractor shall be submitted to the District. The affidavit shall include a complete record of all related Work with particular emphasis on experience directly related to operation of a similar piece of equipment handling comparable loads. The operators shall have current (within the previous 12 months) physical or medical examinations with emphasis on hearing, eyesight, and cardiovascular conditions. Dates of the physical or medical exams shall be submitted with the affidavit and updated physical exam information shall be submitted to the District.

3.6.5.3 Contractor Riggers

All rigging and signalmen work activities shall be done by qualified riggers and signalmen per WAC 296-155-53306 and WAC 296-155-53302. An affidavit stating the rigger’s qualifications shall be submitted. The affidavit shall include a complete record of all related experience and be signed by the rigger and the Contractor. 3.6.6 Scaffolding

Contractor shall submit to District information about all scaffolding, ladders, stairways, and other access schemes proposed to be used including type, layout, connections and



any other information requested. Approved anti-slip surface material shall be installed on scaffolding platforms. Scaffolding shall comply in every respect with the requirements of the Washington Administrative Code and any other applicable regulations. In the event Contractor’s scaffolding is to be anchored to the existing powerhouse concrete or steel components, the Contractor shall submit to District all requested information about the anchorage design and requirements. All scaffolding, platforms, and associated anchorages shall be designed by a Structural Engineer licensed in the State of Washington. 3.6.7 Overhead Protection Canopy

In locations that District personnel access or workers may be exposed to falling objects, overhead protection shall be provided. Contractor shall submit to District information about all proposed overhead protection equipment to be used including type, layout, connections and any other information requested. As a minimum overhead protection canopies shall be constructed of steel scaffolding with 2-inch solid planking or equivalent. Overhead protection canopies shall comply in every respect with the requirements of the Washington Administrative Code and any other applicable regulations.

3.7 ACCESS ROADS

3.7.1 Existing Access Roads

Upon completion of Work, Contractor shall restore access roads to pre-existing conditions.

3.8 PARKING AREAS

Contractor shall control vehicular parking to preclude interference with access by emergency vehicles, District’s operations, or construction operations. Privately owned vehicles will be restricted to designated parking areas established within the Project Work areas shown on the Contract Drawings. Only Contractor’s Work vehicles and equipment that are essential to the conduct of the Work will be allowed in the Project Work areas.

3.9 CARE OF DRAINS

Existing powerhouse floor drains shall not be used for disposal of any solid material and or any liquids other than clear water. Drains obstructed by Contractor shall be cleared and cleaned by Contractor.



3.10 CLEANING DURING CONSTRUCTION

In accordance with General Conditions, as may be specified in other Specification sections, and as required herein.

All Work areas at the Project site shall be kept reasonably neat on a daily basis. All debris resulting from the Contractor’s Work, such as unused or excess materials, packing cases, oil and grease spills, and other debris shall be collected, removed, and properly disposed of off the Project site. The District's trash cans, dump boxes, and other containers shall not be used.

Provide Approved containers for collection and disposal of waste materials, debris, and rubbish. Liquid waste shall not be disposed of in powerhouse drains. At least at weekly intervals, dispose of such waste materials, debris, and rubbish offsite.

At least weekly, brush and sweep floor surfaces, entry drive, deck surfaces, and paved roadways and all other streets and walkways affected by the Work and where adjacent to the Work. Wet down exterior surfaces prior to sweeping to prevent blowing of dust and debris.

3.11 DISPOSAL

All items not to be reused shall be disposed of, or salvaged by Contractor. Scrap materials shall be removed from District's property within 90 days of removal from the Work area. Scrap shall not be sold on the project site. Disposal of hazardous wastes shall be in accordance with General Conditions Paragraph GC-71, Hazardous Substances and Environmental Protection.


Exhibit S

Specifications

Bid No. 15-65 Common Product Requirements – 01 61 00 Page 1

SECTION 01 61 00

COMMON PRODUCT REQUIREMENTS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 DEFINITIONS ....................................................................................................... 2 1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS ......................................... 2 1.3 PACKAGING, SHIPPING AND DELIVERY ................................................................... 2 1.4 SHIPPING AND HANDLING ..................................................................................... 5 1.5 STORAGE AND PROTECTION ................................................................................. 6

2.0 PRODUCTS ......................................................................................................... 7 2.1 GENERAL ............................................................................................................ 7

3.0 EXECUTION ......................................................................................................... 7 3.1 INSPECTION ........................................................................................................ 7 3.2 INSTALLATION ..................................................................................................... 7 3.3 FIELD FINISHING .................................................................................................. 8 3.4 ADJUSTMENT AND CLEANING ................................................................................ 8 3.5 LUBRICANTS ....................................................................................................... 8

4.0 LIST OF APPENDICES ....................................................................................... 8 4.1 SHIPPING RELEASE ............................................................................................. 9

Exhibit S

Specifications


SECTION 01 61 00

COMMON PRODUCT REQUIREMENTS

1.0 GENERAL

1.1 DEFINITIONS 1.1.1 Products:

1. New items for incorporation in the Work, whether purchased by Contractor or District for the Project, or taken from previously purchased stock, and may also include existing materials or components required for reuse.

2. Includes the terms material, equipment, machinery, components, subsystem, system, hardware, software, and terms of similar intent and is not intended to change meaning of such other terms used in Contract Documents, as those terms are self-explanatory and have well recognized meanings in construction industry.

3. Items identified by manufacturer’s product name, including make or model designation, indicated in manufacturer’s published product literature, that is current as of the date of the Contract Documents.

1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS The following is a list of standards which may be referenced in this section:

ASTM International (ASTM) D3951 Standard Practice for Commercial Packaging

1.3 PACKAGING, SHIPPING AND DELIVERY 1.3.1 Packaging Equipment shall not be prepared for shipment until it has been inspected and accepted for shipment at origin by the Engineer, or the District’s agents or designees, unless inspection has been waived in writing.

Materials and equipment provided shall be suitably packed for shipment and storage including protection from dirt, moisture, weather, and damage. Due to site storage limitations, some materials may need to be stored outdoors. The District will designate laydown and storage areas available for Contractor’s use for site storage of materials and equipment for this Contract. Contractor shall provide all protective covers, housings, and materials for storage.

Exhibit S

Specifications


1. Packaging shall prevent the entrance of rodents and insects. Silica gel or other desiccant shall be provided to keep the internal parts dry. Provisions shall be provided for easy access for desiccant replacement.

2. A direct reading hydrometer shall be provided to indicate relative humidity for materials where humidity may cause damage.

3. Hydraulic cylinders and like components that are filled with oil during operation and have no other internal corrosion protection shall be shipped filled with oil.

4. Space heaters shall be provided by the Contractor for packaging where needed. Space heaters shall be designed for a 120 Vac, single phase; or 460 Vac, 3-phase, 60 Hz power source. All electrical and electronic cubicles shall have heaters for storage. All temporary power that Contractor requires for storage of equipment shall be the responsibility of Contractor.

Contractor shall be responsible for all materials requiring special storage and handling including controlling temperature, humidity, dust or any other atmospheric conditions.

Standard commercial packaging in accordance with ASTM D3951 will be acceptable except where a different method or more stringent method is required.

Packaging shall have points of lift identified with “Lift Here” marked in appropriate locations. Packages with a total weight greater than 75 pounds shall be marked with the package weight. Packages containing hazardous materials shall have “hazardous” marked on the package and shall have the proper Material Safety Data Sheets (MSDS), and instructions for safe handling and storage. Items which have a limited storage life, such as epoxy resins, shall ship immediately before use.

The spare parts, special tools, test equipment, extra materials, and expendables shall be packed separately from other articles.

Subassemblies shall be provided with adequate protective pads, supports, and blocking and shall be securely restrained to prevent distortion or damage in transit.

1.3.2 Packing List Contractor shall provide a complete bill of materials, packing list, and schedule of shipment and delivery for all shipments. The initial lists shall be provided no later than 30 days prior to the first shipment. The list shall be updated as necessary prior to each shipment. The final list shall include identification of items packed in each crate or container, storage requirements (including power, if any), and individual and total container weight.

The bill of materials shall be accompanied by a current Safety Data Sheet (SDS) for any chemicals included in the shipment.

Exhibit S

Specifications


A packing list shall be:

1. Attached to each shipment listing the contents of each container. 2. Placed in a moisture-proof envelope. 3. Securely fastened to the outside of the container.

Due to security restrictions on Site crates or containers without complete packing lists, sufficient to identify all material shipped, will not be permitted on Site.

1.3.3 Transportation Contractor shall bear all costs of loading, permitting, transporting, duties, fees, taxes, unloading and handling for all required materials from Contractor’s shipping point or points, to the Site. Contractor shall also bear all costs of transporting test instruments and equipment to and from the job site.

Contractor shall prepare all shipping and customs documentation and pay all shipping charges. Contractor shall accept responsibility, for all loss or damage incurred during shipment, unloading, and storage regardless of nature or cause (including damage to the painted surfaces). Contractor shall receive materials and packages on site, unload, and store them.

Shipments shall be made FOB destination to the Rocky Reach Hydroelectric Project with access from State Highway 97A in Chelan County, Washington, approximately five (5) miles north of Wenatchee Washington.

Physical Address: Rocky Reach Hydroelectric Project 5000 Highway 97A North Wenatchee, WA 98801.

District and Engineer shall be notified a minimum of 15 days prior to actual shipping dates of any equipment, the equipment to be shipped, the method of transport, the carriers and routing, the shipping and delivery dates, and the approximate shipping weights.

1.3.4 Shipping Release No shipments shall be made without inspection and/or written release from District. Contractor shall request release for shipment with submittal of all required shipping and inspection documentation including certificate(s) of compliance. When shipment is actually made, transmit shipping notices to the Engineer on each shipment, including a description of the equipment being shipped.

Exhibit S

Specifications


For each shipment, submit “Shipping Release” form, Appendix 4.1 at the end of this section. Accompany each shipment with a packing list of all equipment included in the shipment, including weights.

Materials manufactured to documents that: 1. Have not been submitted for review by Engineer; 2. Have been returned marked “Not Approved,” or; 3. Have been marked “Approved as Revised” without resolution of comments;

shall not be shipped without prior approval, as specified. These requirements also apply to shipments from Contractor's Subcontractors, when item(s) are to be shipped directly to the jobsite.

1.3.5 Final Inspection and Check of Records Contractor shall be responsible for inspecting the item(s) and checking the applicable records, prior to shipment, to verify that all items comply with the Specification requirements.

1.4 SHIPPING AND HANDLING 1.4.1 Deliveries Delivery schedules shall be controlled to minimize long-term storage of products at the Site and overcrowding of construction spaces. In particular, the Contractor shall ensure coordination to ensure minimum holding or storage times for flammable, hazardous, easily damaged, or sensitive materials to deterioration, theft, and other sources of loss.

All freight deliveries directly to the project site shall be made between the hours of 7:30 a.m. and 3:00 p.m. PST/PDT Monday through Friday.

Contractor shall notify District 48 hours in advance of freight deliveries for security inspection and coordination purposes. Equipment shall not be accepted as delivered until inspected by the District.

1.4.2 On-Site Material Handling 1. Clearly mark each item, case, crate, or bundle with the Project name and bid

number: Contract 15-65, Rocky Reach Dam Powerhouse Bridge Cranes Refurbishment.

2. Transport and handle material and equipment in accordance with manufacturer’s instructions.

3. Provide equipment and personnel to handle material and equipment on site by methods to prevent soiling, disfigurement, or damage.

Exhibit S

Specifications


4. Promptly inspect shipments to assure that material and equipment comply with requirements, quantities are correct, and material and equipment are undamaged.

5. Repair or replace equipment or materials damaged in shipment. 6. Plainly mark for identification any articles or materials that might be otherwise

lost. Box or steel band in bundles any such articles or materials. 7. Clearly show the weights of components that exceed 75 pounds and require the

use of forklifts, cranes, or other equipment for safe handling. Provide suitable provisions for handling material for weight and size considerations.

1.5 STORAGE AND PROTECTION

Outdoor storage space is available at the site, and will be made available to the Contractor.

Contractor shall be responsible for the security, safety, condition of materials in storage, and handling and moving materials and parts from storage to assembly areas and the powerhouse.

1. Store and protect material and equipment in accordance with manufacturer’s instructions, with seals and labels intact and legible. Store moisture or temperature sensitive material and equipment in weather tight or climate-controlled enclosures.

2. Provide for off-site storage and protection when site does not permit on-site storage or protection.

3. Cover material and equipment subject to deterioration with impervious sheet covering. Furnish ventilation to avoid condensation or potential degradation of material and equipment.

4. Store electrical, instrumentation, and control products, and equipment with bearings in weather-tight structures maintained above 60 °F. Protect electrical, instrumentation, and control products, and insulate against moisture, water, and dust damage. Connect and operate continuously space heaters furnished in electrical equipment. All temporary power that Contractor requires for storage of equipment shall be the responsibility of Contractor.

5. Provide equipment and personnel to store material and equipment by methods to prevent soiling, disfigurement, or damage.

6. The Contractor shall ensure that surfaces of products exposed to the elements are not adversely affected and that weathering of finishes does not occur.

7. Arrange storage of material and equipment to permit access for maintenance and inspection of stored items.

8. Periodically inspect to assure material and equipment is undamaged and is maintained in acceptable conditions.

Exhibit S

Specifications


9. After receipt of material and equipment, assume responsibility for loss and damage, including but not limited to breakage, corrosion, weather damage, and distortion.

Notify District and Engineer in writing upon acceptance of shipment, in accordance with Section 01 30 00, Administrative Requirements.

2.0 PRODUCTS

2.1 GENERAL Provide manufacturer’s standard materials suitable for service conditions, unless otherwise specified in the individual Specifications.

Where product specifications include a named manufacturer, with or without model number, and also include performance requirements, named manufacturer’s products must meet the performance specifications.

Like items of products furnished and installed in the Work shall be end products of one manufacturer and of the same series or family of models to achieve standardization for appearance, operation, and maintenance, spare parts and replacement, manufacturer’s services, and implement same or similar process instrumentation and control functions in same or similar manner.

3.0 EXECUTION

3.1 INSPECTION Inspect materials and equipment for signs of pitting, rust decay, or other deleterious effects of storage. Do not install material or equipment showing such effects. Remove damaged material or equipment from the Site and expedite delivery of identical new material or equipment. Delays to the Work resulting from material or equipment damage that necessitates procurement of new products will be considered delays within Contractor’s control.

3.2 INSTALLATION Equipment Contract Drawings show general locations of equipment, devices, and materials, unless specifically dimensioned.

Install the Work in accordance with NECA Standard of Installation, unless otherwise specified.

Repaint painted surfaces that are damaged prior to equipment acceptance.

Exhibit S

Specifications


Do not cut or notch any structural member or building surface without specific approval of Engineer.

Handle, install, connect, clean, condition, and adjust products in accordance with manufacturer’s instructions, and as may be specified. Retain a copy of manufacturers’ instructions at Site, available for review at all times.

3.3 FIELD FINISHING In accordance with Section 09 90 04, Painting, and individual Specification sections.

3.4 ADJUSTMENT AND CLEANING Perform required adjustments, tests, operation checks, and other startup activities.

3.5 LUBRICANTS Fill lubricant reservoirs and replace consumption during testing, startup, and operation prior to acceptance of equipment by District.


Appendix 4.1 – Shipping Release

Exhibit S

Specifications


4.1 SHIPPING RELEASE

Contractor:

Supplier:

Supplier’s Location:

Item Released:

Drawing No: Mark No:

All QA/QC Documentation Complete: Yes No Reason:

District Notified: Yes No Reason:

Copy of Packing List Attached Yes No Reason:

Carrier: Way Bill No

Anticipated Ship Date: Anticipated Arrival Date:

Remarks:

The undersigned certify that the above parts and materials meet all applicable parts of the Specifications, Drawings, and Contract.

Supplier: Date:

Contractor: Date:

Released for shipping:

District (or designee): Date:

This shipping release does not constitute acceptance by District and does not release Contractor or the supplier from their obligations under the Contract.

Exhibit S

Specifications



Exhibit S

Specifications

Bid No. 15-65 Contract Closeout – 01 77 00 Page 1

SECTION 01 77 00

CONTRACT CLOSEOUT

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 SUBMITTALS ....................................................................................................... 2 1.2 RECORD DOCUMENTS ......................................................................................... 2


3.1 MAINTENANCE OF RECORD DOCUMENTS ............................................................... 3 3.2 FINAL CLEANING ................................................................................................. 4

Exhibit S

Specifications


SECTION 01 77 00

CONTRACT CLOSEOUT

1.0 GENERAL

1.1 SUBMITTALS 1.1.1 Informational Submittals Submit prior to application for final payment.

1. Record Documents: As required in Contract Documents. 2. Approved Shop Drawings: As required in the Contract Documents. 3. Special bonds, special guarantees, and service agreements. 4. Consent of surety to final payment: As required in General Conditions. 5. Releases or waivers of liens and claims: As required in Contract Documents. 6. Releases from agreements. 7. Certificate and Release (Final Payment): See Contract Documents. 8. Extra Materials: As required by individual Specification sections.

1.2 RECORD DOCUMENTS 1.2.1 Quality Assurance Furnish qualified and experienced person, whose duty and responsibility shall be to maintain Record Documents.

Accuracy of Records:

1. Coordinate changes within Record Documents, making legible and accurate entries on each sheet of drawings and other documents where such entry is required to show change.

2. Purpose of Project Record Documents is to document factual information regarding aspects of the Work, both concealed and visible, to enable future modification of the Work to proceed without lengthy and expensive Site measurement, investigation, and examination.

Make entries within 24 hours after receipt of information that a change in the Work has occurred.

Prior to submitting each request for progress payment, request District’s review and Approval of current status of Record Documents. Failure to properly maintain, update, and submit Record Documents may result in a deferral by District to recommend whole or any part of Contractor’s Application for Payment, either partial or final.

Exhibit S

Specifications



3.0 EXECUTION

3.1 MAINTENANCE OF RECORD DOCUMENTS 3.1.1 General Promptly following commencement of Contract, secure from District at no cost to Contractor, one complete set of Contract Documents. Contract Drawings will be full size.

Label or stamp each Record Document with title, “RECORD DOCUMENTS,” in neat large printed letters.

Record information concurrently with construction progress and within 24 hours after receipt of information that change has occurred. Do not cover or conceal Work until required information is recorded.

3.1.2 Preservation Maintain documents in a clean, dry, legible condition and in good order. Do not use Record Documents for construction purposes.

Make documents and Samples available at all times for observation by District and Engineer.

3.1.3 Making Entries on Contract Drawings Using an erasable colored pencil (not ink or indelible pencil), clearly describe change by graphic line and note as required.

1. Color Coding: a. Green when showing information deleted from Contract Drawings. b. Red when showing information added to Contract Drawings. c. Blue and circled in blue to show notes.

Date entries.

Call attention to entry by “cloud” drawn around area or areas affected.

Legibly mark to record actual changes made during construction, including, but not limited to:

Exhibit S

Specifications


1. Locate existing facilities, equipment, and items critical to the interface between existing physical conditions or construction and new construction.

2. Changes made by Addenda, Speedy Memo, Field Orders, Work Change Directive, Change Order, and Engineer’s written interpretation and clarification using consistent symbols for each and showing appropriate document tracking number.

Dimensions on Schematic Layouts: Show on record drawings, by dimension, the centerline of each run of items such as are described in previous subparagraph above.

1. Clearly identify the item by accurate note. 2. Show, by symbol or note, vertical location of item. 3. Make identification so descriptive that it may be related reliably to

Specifications.

3.2 FINAL CLEANING At completion of the Work or of a part thereof and immediately prior to Contractor’s request for certificate of Substantial Completion; or if no certificate is issued, immediately prior to Contractor’s notice of completion, clean entire Site or parts thereof, as applicable.

1. Leave the Work and adjacent areas affected in a cleaned condition satisfactory to District.

2. Remove grease, dirt, dust, paint splatter, stains, labels, fingerprints, and other foreign materials from exposed surfaces.

3. Repair, patch, and touch up marred surfaces to specified finish and match adjacent surfaces.

4. Clean all windows. 5. Broom clean exterior paved areas. 6. Leave water deck gutters, and drains open and clean.

Use only cleaning materials recommended by manufacturer of surfaces to be cleaned.


Exhibit S

Specifications

Bid No. 15-65 Operation and Maintenance Data – 01 78 23 Page 1

SECTION 01 78 23

OPERATION AND MAINTENANCE DATA

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2

1.1 FORMAT ............................................................................................................. 2 1.2 INSTALLATION INSTRUCTIONS ............................................................................... 4 1.3 OPERATION AND MAINTENANCE MANUALS ............................................................. 4 1.4 SUBMITTAL PROCEDURE ...................................................................................... 8

2.0 PRODUCTS (NOT USED).................................................................................... 9 3.0 EXECUTION (NOT USED) ................................................................................... 9 4.0 LIST OF APPENDICES ....................................................................................... 9

4.1 MAINTENANCE SUMMARY FORM ......................................................................... 10

Exhibit S

Specifications


SECTION 01 78 23

OPERATION AND MAINTENANCE DATA

1.0 GENERAL

The Contractor shall furnish Installation Instructions and Operation and Maintenance (O&M) Manuals for all equipment furnished under this Contract. Installation Instructions shall be submitted and approved prior to start of any work on site. O&M Manuals shall be submitted and approved before commissioning as specified herein.

The Contractor shall be responsible for ensuring complete submittals on individual interrelated equipment components provided by Subcontractors, suppliers and manufacturers as well as integrating O&M data from the District’s existing crane documentation for all existing equipment which will remain and become part of the newly refurbished crane system.

1.1 FORMAT 1.1.1 Construction Installation Instructions and O&M Manuals shall be printed on 20-pound weight minimum, 8½- by 11-inch bright white paper and bound in rigid hard cover binders. Binder width shall be a maximum of three (3) inches. Drawings shall be printed on 20-pound weight minimum, 11X17 bright white paper, folded in accordion style and bound in the O&M binders. Binders shall be such that pages are locked in place and do not inadvertently fall out, Wilson-Jones 365, Avery Dennison Heavy Duty EZD series Or Equal. Punched holes shall be arranged such that they do not remove or obliterate data.

Indexes shall be provided for each Installation Instruction and O&M Manual including dividers and tabs to separate sections of each binder. Vinyl binder sheets for CD media storage, for software and data shall be included in the appropriate Installation Instruction and O&M Manual. For CD/DVD media storage, use Fellowes CD Binder Sheets, #95304 Or Equal.

Text shall be manufacturer's printed data, or neatly typewritten suitable for reproduction, with quality equal to original. Photocopying of material will be acceptable, except for material containing photographs. All standard catalog cut sheets, manufacturer's printed data or descriptive literature, parts sheets, illustrations, etc., shall either be original manufacturer sheets or reproduced copies equal in clarity and durability to the original copies. At least one (1) copy of such Installation Instructions and O&M Manuals

Exhibit S

Specifications


shall contain all original copies of such data – that copy shall be identified as containing originals.

1.1.2 Organization Identify each volume with typed or printed cover and title page as follows:

PUBLIC UTILITY DISTRICT NO. 1 OF CHELAN COUNTY ROCKY REACH DAM POWERHOUSE BRIDGE CRANES REFURBISHMENT

(INSTALLATION INSTRUCTIONS or OPERATIONS AND MAINTENANCE MANUAL)

VOLUME Number x OF y

CONTRACT Number 15-65

[DATE]

[NAME AND ADDRESS OF EQUIPMENT SUPPLIER]

The table of contents shall contain all volumes, chapters, appendixes and a master index. Where more than one volume is required, each subsequent volume shall contain an index for the contents within that respective volume. Each volume shall not be broken between chapters, appendixes, and indexes. Each sheet in the binder shall be numbered and an index provided for ready reference to the data.

All chapters, appendixes and indexes shall be adequately separated and identified by standard line indexes.

1.1.3 Drawings Final Installation Instructions and O&M Manuals shall contain As-Built Contract and Shop Drawings (as required) to ensure correct illustration of completed installation.

Drawings may be reduced to 8½ inches by 11 inches, or 11 inches by 17 inches folded to 8½ inches by 11 inches.

Reduced drawings shall be inserted into Installation Instructions and O&M Manuals using:

1. Ring Binder Insert Strips, Cardinal #21110; 2. 11x17 Fold out Sheet Protectors, Avery® #75256 or; 3. Other District-Approved equal.

Exhibit S

Specifications


Where reduction of drawings is impractical, fold and insert drawings in vinyl, Multi-page capacity, sheet protectors, Avery® #PV119XL-25 (74171). Insert drawing with title and number viewable from front side of page, when inserted into sheet-protector.

1.1.4 Electronic Electronic copies of final Installation Instructions and O&M Manuals, once approved shall be provided. All provided files shall maintain the formats and standards as required in Section 01 30 00, Administrative Requirements. All files shall be named for the section of the Installation Instruction or O&M Manual that is represented within the file or as Approved by the Engineer. All PDF (*.pdf) files shall also be accompanied by the associated ‘native’ files used to create those PDF (*.pdf) files. PDF (*.pdf) ‘native’ files shall also follow the required file formats and standards. Electronic files shall be submitted on CD ROM.

1.2 INSTALLATION INSTRUCTIONS Installation instructions shall include all steps necessary for the proper assembly and installation of the Work. Detailed procedures, figures, and diagrams shall be included for specific activities to assemble the equipment. Procedures and data sheets shall be included for all in-progress measurements and inspections and tests, including alignment, adjusting, calibrating, acceptable tolerances, and pass/fail criteria.

1.3 OPERATION AND MAINTENANCE MANUALS 1.3.1 Scope O&M Manuals shall describe recommended procedures in detail. A detailed theory of operation shall be provided for all equipment. A schedule shall give recommended times for maintenance, lubrication, calibration, and replacement of parts.

O&M Manuals shall include a complete set of drawings with details including dimensions, component values, and industry standard component designations where appropriate.

A parts identification list, with appropriate illustrations identifying each numbered part and its location in the assembled equipment shall be included. All parts shall be identified using industry standard designations or dimensions to the fullest extent possible.

1.3.2 Organization A single O&M Manual made up of similar multiple volumes shall be provided. Major divisions within the manual shall be provided for:

1. Contact Information

Exhibit S

Specifications


2. Warranty Information 3. Commissioning Procedures 4. Operating Instructions 5. Maintenance Instructions 6. Trouble Shooting 7. Equipment Listing followed by data sheets 8. Mechanical Drawings 9. Electrical Drawings

1.3.3 Contents 1.3.3.1 General The following general information shall be provided:

1. Names addresses and telephone numbers of Contractor, Subcontractors and equipment/material suppliers for warranty and maintenance contact.

2. Certificates of equipment warranty with the start and expiration of the warranty period clearly described.

3. Service agreements with equipment manufacturers as applicable. 4. Description of instances that may affect the validity of the warranty. 5. Instrument List including identification and alarm and trip settings.

1.3.3.2 Equipment Sections The major sections of the manual shall have the following contents as appropriate:

1. Equipment specifications that include the following: a. Nameplate Ratings including: voltage, amperage, kW, power factor, RPM,

horsepower, temperature, etc., as appropriate. b. Factory Settings including: temperature, travel speed, limits of travel, etc.

Where there is a range to these values, state as: “Normal Operating Range”.

c. Factory Trip Settings as applicable to the equipment. d. Dimensions and Weight of major components. e. Performance curves. f. Engineering data.

2. Test data from factory tests and acceptance tests. 3. Installation and User manuals or other product data shipped with the product by

the original equipment manufacturer. 4. System/equipment description and operating theory including a description of

significant equipment, components and functions for a complete understanding of the design and operation of the equipment or system. Diagrams and part lists shall be included or referred to as appropriate.

Exhibit S

Specifications


5. Operating Instructions shall be written in a logical sequence including systematic (step-by-step) procedures for operation. a. Startup, break-in, routine, and normal operating instructions. b. Test procedures and results of factory tests where required. c. Regulation, control, stopping, and emergency instructions. d. Description of operation sequence by control manufacturer. e. Shutdown instructions for both short and extended duration. f. Summer and winter operating instructions, as applicable. g. Safety precautions. h. Special operating instructions.

6. Maintenance instructions including: a. Recommended procedures for meeting warranty requirements ensuring

optimal performance and longevity of the provided equipment. b. Recommended maintenance schedule with references to the appropriate

procedures. 7. Guide to troubleshooting with references to the appropriate maintenance

procedures. 8. Part descriptions and diagrams including references to drawings and

manufacturers’ part numbers as applicable. 9. Instructions for repair and adjustment including recommended clearances, bolt

torques, pressure settings, etc. 10. Lubrication instructions for the service intended and shall include charts or

tables indicating items to be lubricated, recommended frequencies, grade and type of lubricant to be used in accordance with AGMA, NLGI, SAE specifications, as applicable. Where the Contractor or the supplier has installed a lubricant or oil prior to shipment to the project site, the "Brand Name" as well as the specification shall be indicated.

11. A listing of the oil, fuel, and other fluid quantities required for filling and operation of fluid-containing systems.

12. Any special handling or storage requirements. 13. A list of any special tools required for maintenance or repairs. 14. Recommended spare parts including identification, nomenclature, part

numbers, required number of parts, recommended list of spare parts to be stocked at the project, actual spare parts supplied under this contract and instructions for ordering spare parts.

15. Parts catalogs shall include the name and addresses of suppliers of parts. All data shall match the actual equipment furnished. Standard catalog cut sheets and diagrams will not be acceptable unless all irrelevant parts are marked out and relevant parts are identified by heavy arrows or equal suitable marking at each side of the applicable data.

16. Drawings: a. Assembly and installation drawings.

Exhibit S

Specifications


b. Drawings showing relations of component parts of equipment and systems. c. Control and interlock system diagrams. d. Logic and flow diagrams. e. Communication diagrams. f. Schematic and wiring diagrams.

17. List of relay and alarm settings. 18. Circuit Directories of Panelboards. 19. Electrical service. 20. Control requirements and interfaces. 21. Communication requirements and interfaces. 22. Software: Full documentation of software. Identify system or equipment and

provide control logic and screen graphics both in printed and electronic format. Include original manufacturer’s instructions.

23. Programming instructions for all software based equipment. A complete listing of all software parameters shall be included.

1.3.4 Maintenance Summary Compile individual Maintenance Summary for each applicable equipment item, respective unit or system, and for components or sub-units.

Format:

1. Use Maintenance Summary Form (Appendix 4.1) or electronic facsimile of such.

2. Each Maintenance Summary may take as many pages as required. 3. Use only 8½-inch by 11-inch size paper. 4. Complete using typewriter or electronic printing.

Include detailed lubrication instructions and diagrams showing points to be greased or oiled; recommend type, grade, and temperature range of lubricants and frequency of lubrication.

Recommended Spare Parts:

1. Data to be consistent with manufacturer’s Bill of Materials/Parts List furnished in O&M manuals.

2. “Unit” is the unit of measure for ordering the part. 3. “Quantity” is the number of units recommended. 4. “Unit Cost” is the current purchase price.

Exhibit S

Specifications


1.4 SUBMITTAL PROCEDURE Contractor shall submit the following in accordance with the Submittal Schedule in Section 01 30 00, Administrative Requirements.

1.4.1 Installation Instruction Outline Submit detailed outline, which includes the Table of Contents of Instruction prior to complete installation.

1.4.2 Complete Installation Instructions 1. Submit two (2) Complete Installation Instructions for review by Engineer. 2. If accepted, submit an additional two (2) copies for a total of three (3) Complete

Installation Instructions and one (1) copy in electronic format. 3. If rejected, one (1) copy will be returned to the Contractor with the Engineer’s

comments for revision and resubmittal.

1.4.3 O&M Manual Outline Submit detailed outline, which includes the Table of Contents of O&M Manual prior to preparation of Draft Manuals.

1. Draft O&M Manuals: a. Submit two (2) bound copies of Draft O&M Manuals. Submit one (1) copy

in electronic format. b. The Engineer shall review the Draft O&M Manuals in accordance with the

Project Correspondence Procedures. 2. Final O&M Manuals:

a. Submit two (2) revised Final O&M Manuals incorporating the comments from the Draft O&M Manuals for review by Engineer.

b. If accepted, submit an additional four (4) copies for a total of five (5) Final O&M Manuals and two (2) copies in electronic format.

c. If rejected, one (1) copy will be returned to the Contractor with the Engineer’s comments for revision and resubmittal.

d. O&M Manuals used for On-site training shall be additional, and provided for each session, unless otherwise Approved by Engineer. Manuals provided for on-site training shall be at no additional cost to the District.

The District's acceptance as “Approved” or “Approved as Revised” shall apply to the general content and shall not relieve the Contractor from the entire responsibility for correctness.

Regardless of approval status, the Contractor shall be responsible for updating the appropriate sections of the Installation Instructions and O&M Manuals as required to

Exhibit S

Specifications


incorporate any changes to the Work resulting from drawing revisions, change orders, as-found conditions, etc. which affect the content of the Installation Instructions and O&M Manuals throughout the life of the Contract, in accordance with Section 01 30 00, Administrative Requirements.




Appendix 4.1 – Maintenance Summary Form

Exhibit S

Specifications


4.1 MAINTENANCE SUMMARY FORM

MAINTENANCE SUMMARY FORM

PROJECT: CONTRACT NO.:

1. EQUIPMENT ITEM

2. MANUFACTURER

3. EQUIPMENT/TAG NUMBER(S)

4. WEIGHT OF INDIVIDUAL COMPONENTS (OVER 100 POUNDS)

5. NAMEPLATE DATA (hp, voltage, speed, etc.)

6. MANUFACTURER’S LOCAL REPRESENTATIVE

a. Name Telephone No.

b. Address

7. MAINTENANCE REQUIREMENTS

Maintenance Operation Comments Frequency Lubricant

(If Applicable) List briefly each maintenance operation required and refer to specific information in manufacturer’s standard maintenance manual, if applicable. (Reference to manufacturer’s catalog or sales literature is not acceptable.)

List required frequency of each maintenance operation.

Refer by symbol to lubricant required.

Exhibit S

Specifications


Maintenance Operation Comments Frequency Lubricant

(If Applicable)

8. LUBRICANT LIST

Reference Symbol Shell

Exxon Mobile

Chevron Texaco BP Amoco Or Equal

List symbols used in No. 7 above.

List equivalent lubricants, as distributed by each manufacturer for the specific use recommended.

9. RECOMMENDED SPARE PARTS FOR DISTRICT’S INVENTORY

Part No. Description Unit Quantity Unit Cost Note: Identify parts provided by this Contract with two asterisks.

Exhibit S

Specifications



Exhibit S

Specifications

Bid No. 15-65 Spare Parts – 01 78 43 Page 1

SECTION 01 78 43

SPARE PARTS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 DESCRIPTION ...................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 2 1.3 PACKAGING ........................................................................................................ 2

2.0 PRODUCTS ......................................................................................................... 3 2.1 MATERIALS ......................................................................................................... 3 2.2 SPECIFIED SPARE PARTS ..................................................................................... 3

3.0 EXECUTION (NOT USED) ................................................................................... 5

Exhibit S

Specifications


SECTION 01 78 43

SPARE PARTS

1.0 GENERAL

1.1 DESCRIPTION Furnish spare parts specified herein, unless otherwise Approved by Engineer.

Spare parts shall be new and of the same design, materials, manufacture, quality, and have the same ratings and be interchangeable with the original materials and parts provided. All parts and materials shall be designed for installation by District personnel.

Furnish “additional” spare parts, as recommended by Contractor in its bid and/or after final design of equipment, if Approved by Engineer.

1.2 SUBMITTALS 1.2.1 Informational Submittals

1. With Contractor’s bid, furnish a list of recommended additional spare parts in addition to those specifically listed herein. This list shall include the manufacturer and part number.

2. Once all the Contractor’s submittal drawings have been Approved, furnish an updated list of recommended additional spare parts.

3. An inventory for spare parts and materials shall be submitted for review. The Spare Parts list shall include the item number, description, manufacturer, part number and quantity. Each spare part item shall be accompanied by a completed “New Inventory Item Request” form (provided by District). Contractor shall complete the form: a. One (1) copy shall be submitted to Engineer at the time of shipment and, b. One (1) copy shall accompany the shipment.

4. Contractor shall submit a final Spare Parts list, when designs are completed. The final Spare Parts list shall include the required Specified Spare Parts and any additional Contractor recommended spare parts which the District has decided to include.

1.3 PACKAGING Packaging, shipping, and delivery of spare parts shall be in accordance with Section 01 61 00 Common Product Requirements.

Exhibit S

Specifications


Packages of spare parts shall be clearly marked to indicate that the contents are spare parts and shall be accompanied by a list of contents, and directions for proper storage.

Spare parts shall be labeled, packed in suitable containers, and crated firmly enough to withstand storage for a minimum of 10 years. Those items in need of rust preventive treatment shall be so treated.

Place all mechanical and electrical parts subject to damage from moisture in hermetically sealed metal containers, in plastic envelopes, or other Approved container within their respective packing cases. Provide suitable desiccant in all sealed containers.

2.0 PRODUCTS

2.1 MATERIALS Contractor shall furnish spare parts which are identical in design and manufacture, and are interchangeable with the corresponding parts of the original equipment.

2.2 SPECIFIED SPARE PARTS The following specified spare parts shall be furnished by the Contractor unless otherwise Approved by the District. Any revisions, additions, or deletions to the specified spare parts shall be made in accordance with General Conditions paragraph Changes in the Work, Field Work Order / Change Orders. Warranty and storage information shall be provided with spare parts. Warranty information shall include contact information for vendor from whom the item was purchased and the purchase order number on which the item was purchased. Storage information shall include any maintenance and power-on requirements and frequency for such requirements.

ITEM DESCRIPTION QUANTITY VFD drive One (1) of each size provided

Electronic equipment power supplies

Two (2) of each type used

Fuses Ten (10) of each type and rating 30 Amps or smaller; Three (3) of each type and rating larger than 30 Amps.

Control transformer One (1) of each type and rating used.

Exhibit S

Specifications


ITEM DESCRIPTION QUANTITY Limit switches Two (2) of each type furnished for

bridge and hoist travel

Auxiliary relays Two (2) of each type used

Coils Two (2) of each type of contactor used

Contacts Two (2) sets for each type of contactor

Indicating light assemblies Two (2) of each type

Indicating light color caps Two (2) of each type and color

Indicating light dropping resistors Two (2) of each type and rating

Lamps Six (6) of each type used in indicating lights. Two (2) for each type used for Floodlight, Crane Cab, Control Panel, and Access lighting

Bearings and seals Two (2) sets of each size and type of motor

Brake shoe / disc kit One (1) for each brake

Brake coil / Actuator One (1) for each type and size

Brake rectifier and control unit One (1) of each type

Radio control transmitter One (1) replacement unit

Radio control transmitter batteries One (1) set

Radio control transmitter battery charger

One (1) unit.

Encoders One (1) of each type used on all motors

Modular terminal blocks 10% of each total terminal block type used (control and 600V), with blank labels. Installed in electrical cabinets as installed spares.

Spare flexible boot for each radio master switch

One (1) spare set FOR RADIO REMOTE

OEM reducer input and output shaft seals

One (1) set for each new reducer supplied.

Exhibit S

Specifications


ITEM DESCRIPTION QUANTITY Split type seals for hoist reducer

input and output shafts Two (2) sets including engineered seal carriers if required to fit the reducer bearing caps

Reducer consumable assembly parts: Gaskets, shims, crush –sleeves, and all other consumable assembly parts.

Two (2) sets for each new reducer supplied.

Main hoist reducer gear set One (1) complete set of main hoist reducer gears (G1 through G6)

Main Hoist motor coupling One (1) complete, bored and keyed to fit the motor and reducer.

Auxiliary Hoist motor coupling One (1) complete, bored and keyed to fit the motor and reducer.

Instrument couplings One (1) complete, for each size / bore used for geared limit switches, motor encoders, etc.

Coupling gaskets, bolts, inserts, and seals

Two (2) sets for each type and size of coupling used (includes hoist and instrument couplings).

Main Hoist motors One (1) replacement unit with encoder

Auxiliary Hoist motors One (1) replacement unit with encoder

Main Hoist brakes One (1) replacement unit with wheel

Auxiliary Hoist brakes One (1) replacement unit with wheel

Trolley motor with brake One (1) replacement unit

Bridge motor with brake One (1) replacement unit

Grease lubrication fittings, tubing, and blocks

25% of each size and type provided.



Exhibit S

Specifications

Bid No. 15-65 Equipment Testing and Commissioning – 01 91 14 Page 1

SECTION 01 91 14

EQUIPMENT TESTING AND COMMISSIONING

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 GENERAL REQUIREMENTS.................................................................................... 2 1.2 REFERENCES, SPECIFICATIONS, CODES AND STANDARDS ...................................... 2 1.3 DEFINITIONS ....................................................................................................... 3 1.4 SUBMITTALS ....................................................................................................... 4 1.5 TESTS ................................................................................................................ 6 1.6 INSPECTION AND TEST PLANS .............................................................................. 6

2.0 PRODUCTS ......................................................................................................... 6 2.1 MEASUREMENT AND TEST EQUIPMENT .................................................................. 6

3.0 EXECUTION ......................................................................................................... 7 3.1 SHOP TESTS ....................................................................................................... 7 3.2 FIELD TESTS AND INSPECTIONS .......................................................................... 10 3.3 FAILURE TO MEET PERFORMANCE REQUIREMENTS .............................................. 20

Exhibit S

Specifications


SECTION 01 91 14

EQUIPMENT TESTING AND COMMISSIONING

1.0 GENERAL

1.1 GENERAL REQUIREMENTS All materials, products and components manufactured, procured or fabricated by Contractor as part of the Work shall be subjected to such tests and inspections as may be necessary to verify compliance with the requirements of the Contract Documents.

All expenses for the tests shall be fully borne by Contractor. Contractor shall prepare and provide all labor, material and equipment necessary for performing specified or required tests. Contractor shall submit the test results to Engineer for Approval.

The Contractor shall prepare test plans and be present to provide technical assistance and interpretation of test plans while conducting acceptance tests of its equipment. Operational acceptance tests shall be the basis for District’s acceptance of the Work, including the operational shop and field tests of all mechanical equipment, electrical equipment, controls, and all accessory items in this Contract.

Inspections shall be performed in accordance with the Approved Contractor Quality Control Plan (CQC). Inspection results shall be part of the quality documentation.

1.2 REFERENCES, SPECIFICATIONS, CODES AND STANDARDS

American National Standards Institute (ANSI) Testing Standards

American National Standards Institute (ANSI)/ American Society for Quality Control (ASQC)

ANSI/ASQC E2 Guide to Inspection Planning

American Society of Mechanical Engineers (ASME)

Institute of Electrical and Electronics Engineers (IEEE) Testing Standards Standard 112 (1996) Test Procedure for Polyphase Induction Motors

and Generators.

Code of Federal Regulations (CFR)

Exhibit S

Specifications


National Electrical Manufacturers Association (NEMA)

MG 1 Motors and Generators ICS 1 General Standards for Industrial Controls and Systems ICS 8 Industrial Control and Systems Crane and Hoist

Controllers

National Institute of Standards and Technology (NIST)

1.3 DEFINITIONS Functional Test: Test or tests in presence of Engineer and District to demonstrate that installed equipment meets manufacturer’s installation, calibration, and adjustment requirements and other requirements as specified.

Performance Test: Test or tests performed after any required functional test in presence of Engineer and District to demonstrate and confirm individual equipment meets performance requirements specified in individual sections.

Shop Acceptance Testing:

All materials, components, and assemblies shall be completely shop tested in accordance with the CQC Plan, Shop Inspection and Test Plan (ITP), in Section 01 45 16.13, Contractor Quality Control, and these Specifications. Contractor shall provide all procedures, equipment, materials, and labor for shop testing identified in the specific equipment sections.

1. A demonstration, conducted by Contractor at its manufacturing facility, performed under the direct supervision of Contractor’s Test engineers, to demonstrate and document the performance of the entire crane system, both manually and automatically (if required), based on criteria developed in conjunction with District and as accepted by Engineer for acceptance of the Work by the District prior to shipment.

2. Shop Acceptance testing shall be witnessed by the District unless otherwise Approved in writing.

3. Shop Acceptance test plan shall be in accordance with the CQC Plan, Shop Inspection and Test Plan (ITP), in Section 01 45 16.13, Contractor Quality Control, and these Specifications.

Exhibit S

Specifications


Field Acceptance Testing:

1. A demonstration, conducted by Contractor, with assistance of District, to demonstrate and document the performance of the entire installed crane system, both manually and automatically (if required), based on criteria developed in conjunction with District and as accepted by Engineer.

2. Such demonstration is for the purposes of (i) verifying to District the entire installed crane system performs as a whole, and (ii) determining that the Contractor has fulfilled the requirements of the Specifications and that the equipment is ready for operation by the District.

3. Field Acceptance test plan shall be in accordance with the CQC Plan, Field Inspection and Test Plan (ITP), in Section 01 45 16.13, Contractor Quality Control, and these Specifications

1.4 SUBMITTALS 1.4.1 General Submit all items in accordance with Section 01 30 00, Administrative Requirements. Submit startup procedures to be included as part of the Shop and Field Inspection and Test Plans, that shall describe the sequence of checks, tests, acceptance criteria, and operation of the equipment. 1.4.2 Inspection and Test Plans Contractor shall submit for review and Approval by the District, in accordance with Section 01 45 16.13, Contractor Quality Control and the requirements of this Section, an Inspection and Test Plan (ITP) for the shop testing program. The plan shall describe inspections to be performed at key stages of assembly and testing of equipment, with applicable illustrations, diagrams, checksheets, and procedures, for fit-up, dimensional correctness, alignment, and sequential checkout, startup, and operation of equipment at the shop.

Contractor shall submit for review and Approval by the District, in accordance with Section 01 45 16.13, Contractor Quality Control and the requirements of this Section, an ITP for the field inspection program. The plan shall describe inspections to be performed at key stages of assembly and testing of equipment, with applicable illustrations, diagrams, checksheets, and procedures, for fit-up, dimensional correctness, alignment, and sequential checkout, startup, and operation of equipment at the project site.

Exhibit S

Specifications


1.4.3 Informational Submittals Submit acceptance test report(s) for shop testing, including test data sheets with Contractor’s Test engineer’s signature or initials, confirming Contractor’s witness and agreement that test results meet the stated acceptance criteria.

Submit acceptance test report(s) for field testing, including test data sheets with Contractor’s Installation Supervisor’s signature or initials, confirming Contractor’s witness and agreement that test results meet the stated acceptance criteria.

1.4.4 Test Weight Plan Submit a test weight plan for District Approval. The plan shall include the following:

1. Type of test weights to be used (water bags, concrete, steel, etc.) Note: Water bags shall be used for test weights when testing the 250 ton main hoist sytems;

2. Test Weight handling procedures (include details on staging, assembly, and disassembly of the test weights);

3. Detailed drawings showing the test weight configuration with the crane, powerhouse, generator, and other pertinent project features.

4. Drawings shall be to scale and show details of lifting beams, shackles, slings, and related equipment. District lifting beams and devices shall not be used with the test weights.

5. Load measuring devices such as water flow meters and load indicators shall have calibration certificates issued within the last two years to be provided with the test plan.

6. If water bags are used, provide details on means for filling and draining the water bags as well as provisions for secondary containment to prevent discharge of any water leakage that could occur within the powerhouse.

7. Water bags shall be non-contaminated in order to drain the bags into existing surface drainage catch basins outside of the powerhouse. Drains within the powerhouse shall not be used for draining of water bags.

8. Contractor shall submit bag cleanliness certification at least 10 days prior to start of testing. Information included as part of the bag cleanliness certification shall be the storage locations and all locations bags have been used since last certification, invasive species removal verification, and cleaning techniques after usage. Failure to provide an acceptable bag cleanliness certification shall require the Contractor to provide complete containment, clean-up and disposal of all water used during the load testing procedure, including any spilled water. Water bags and associated hoses and valves shall be checked for leaks prior to use on-site. Equipment that leaks during testing shall be replaced to keep spilled water to a minimum.

Exhibit S

Specifications


1.5 TESTS

Contractor shall evaluate test results and advise Engineer immediately of any discrepancy between test results and test limits or the failure of any item to meet the test criteria.

Contractor shall protect all material and equipment during and after testing and checking to provide that subsequent testing of other equipment or systems does not disturb, damage, or otherwise interfere with functional capability of material and equipment.

In the event that test results do not fulfill the requirements specified in these Specifications or that any defects attributable to Contractor are found in test results, Contractor shall repair, adjust or correct and retest at its own expense to the satisfaction of Engineer. Repairs shall be subject to the Approval of Engineer. Even in such an event, Contractor shall be responsible for maintaining the Project schedule and milestone completion dates.

1.6 INSPECTION AND TEST PLANS The ITPs shall list all required inspections and tests, references to test methods, applicable standards and procedures, acceptance criteria, and results and shall be supplemented with any test determined by the District as necessary to determine the Contract requirements have been fulfilled.

The ITPs shall be revised as necessary if the planned tests change. Any changes to the ITPs shall be resubmitted to the District for Approval.

Separate ITPs shall be submitted for shop and field test programs. The ITPs shall include as a minimum:

1. Material test certificates 2. Visual inspections 3. Test Procedures 4. Test Personnel Qualifications

2.0 PRODUCTS

2.1 MEASUREMENT AND TEST EQUIPMENT

Measurement and test equipment (meters, gauges, torque wrenches, sensors, etc.) supplied or used by Contractor for taking or recording of data shall:

Exhibit S

Specifications


1. Have accuracy equal to or greater than stated acceptance criteria tolerances for test or work being performed.

2. Have current calibration with traceability to National Institute of Standards and Technology (NIST). Calibration records shall be maintained as required by ANSI/ASQC E2 and submitted if requested by Engineer.

3. Have traceability to national standards in the country of use, subject to Approval by Engineer, where such equipment is supplied and used in facilities outside the United States.

3.0 EXECUTION

3.1 SHOP TESTS 3.1.1 General All materials, components, and assemblies shall be completely shop tested in accordance with the CQC Plan, Shop Inspection and Test Plan (ITP), in Section 01 45 16.13, Contractor Quality Control, and these Specifications. Contractor shall provide all procedures, equipment, materials, and labor for shop testing identified in the specific equipment sections.

Shop tests shall be performed by personnel experienced in the type of test being performed under the direct supervision of Contractor’s Test engineers.

The results of all inspections and tests shall be fully documented in accordance with Section 01 45 16.13, Contractor Quality Control.

All shop assemblies and tests specified for the various items of equipment shall be witnessed by the Engineer and/or a representative of the District. Completed shop inspection forms shall be signed by Engineer and Contractor. Copies of all shop inspection records shall be furnished to the District. No equipment shall be shipped from Contractor’s shops until it has been inspected and released for shipment.

Required repairs or replacements to correct defects and deficiencies, as determined by Contractor and Engineer, shall be made at no additional cost to District. Trial testing and operating shall be repeated after defects and deficiencies have been corrected, at no additional cost to the District.

3.1.2 Motor Factory Testing Each induction motor shall be given the standard factory routine and performance tests as specified in NEMA MG 1. Performance curves indicating the results of these motor tests shall be furnished as follows:

Exhibit S

Specifications


1. Performance Test – Torque or percent of rated horsepower output as abscissa versus efficiency, power factor, amperes, watts, and revolutions per minute (rpm) or percent slip as ordinates.

2. Speed-Torque Test – Method of test shall be as required by clause 7.3 IEEE Standard 112. Record of test shall be documented as a speed-torque, versus speed in rpm or percent of synchronous speed, as ordinates.

Contractor shall submit motor test reports in accordance with paragraph 1.4 Submittals of this section. 3.1.3 Holding Brakes Factory Testing Each holding brake shall be given the following factory performance tests, as applicable, in accordance with NEMA ICS 1 and NEMA ICS 8 as follows:

1. Range of Operation – Demonstrate that shunt coils shall release at 80 percent or less than rated voltage and that brake shall operate satisfactorily at 110 percent of rated voltage.

2. Temperature Rise – Demonstrate by resistance method that the operating coils shall not exceed allowable temperature rise.

3. Dielectric – Demonstrate that the operating coil shall withstand a power frequency test.

4. Braking Torque – Certify rated and factory-adjusted torque values. Contractor shall submit brake test reports and brake torque rating certificates in accordance with paragraph 1.4 Submittals of this section. 3.1.4 Control System and Equipment Factory Testing Factory production testing of the control systems shall be performed in accordance with NEMA ICS 1. Factory tests shall demonstrate that the control system is complete, fully functional, and meets the requirements of these specifications. Control systems shall be complete and fully assembled for testing, including control and protective panels with the integrated radio control system, operator’s consoles, motors, and brakes to the maximum extent practicable for the test. Where control items required for testing are not available, the Contractor shall provide a simulation of the components to verify operation. The Contractor shall submit the control system factory test plan as part of the shop ITP. Test results for the control system factory tests shall be submitted within seven (7) days from the date the tests are completed.

Exhibit S

Specifications


3.1.5 Auxiliary Hoist Shop Assembly and Tests The auxiliary hoist equipment, controls, and appurtenant items shall be completely assembled, tested, and inspected in the shop, unless otherwise Approved, to ensure satisfactory field installation and function. Adjoining components shall be fitted, doweled, and bolted together to ensure proper fit during field erection and assembly. Assembled components shall be shop-welded in their final positions as much as shipping limitations and field installation conditions will permit.

Shop assembled components shall be inspected for accurate fit, correctness of dimensions, accuracy of alignment, ease of movement, and proper painting. Errors, misalignments, and quality deficiencies discovered shall be corrected at no additional cost to the District.

Hoist and drive machinery shall be checked for correct direction of rotation and quiet and uniform engagement of gearing. Hoist and drives shall be verified for satisfactory operation and proper speeds; the hoist need not be reeved. After the shop tests are complete the equipment shall be disassembled to the minimum extent necessary to allow shipment.

Before disassembling, and after installation of dowels and fitted bolts between bolted subassemblies, all parts shall be clearly match-marked. Match-mark diagrams shall be prepared for field erection and submitted for review.

3.1.6 Load Tests Load block hooks, lifting beams, and other specified lifting devices shall be load tested in accordance with ASME B30.10 and B30.20. When load testing to both ASME B30.10 and B30.20, any references to the word “should” shall be interpreted as “shall”.

Hook forgings shall be examined using ultrasonic testing before final machining and proof load testing in accordance with ASTM A388. The finished hooks shall be magnetic particle examined after the proof load test in accordance with ASTM E 709.

Submit test certificate documenting test results.

3.1.7 Rope Proof Test. Each size and type of hoisting rope furnished with the crane shall be pull-tested to demonstrate its actual breaking strength.

Submit test certificate(s) documenting pull test results.

Exhibit S

Specifications


3.1.8 Shop Test Report Contractor shall prepare a complete test report showing in detail the results of shop tests, including dimensional checks. The test report shall include a detailed tabulation showing design values, values of measurements, and all adjustments recorded during the tests.

3.2 FIELD TESTS AND INSPECTIONS 3.2.1 General All components and assemblies installed at Site shall be completely tested in accordance with the CQC Plan, Field Inspection and Test Plan (ITP), in Section 01 45 16.13, Contractor Quality Control, and these Specifications. Contractor shall provide all procedures, oversight, and documentation for field testing of equipment supplied under this contract.

Furnish qualified manufacturers’ representatives, when required by individual Specification sections.

Obtain and submit from equipment manufacturer’s representative Manufacturer’s Certificate of Proper Installation Form, in accordance with Section 01 45 16.13, Contractor Quality Control, when required by individual Specification sections.

Contractor shall provide all personnel necessary to conduct the testing of the installed equipment. The personnel shall include but are not limited to manufacturers’ representatives, riggers, and other personnel required during the course of testing.

Contractor shall provide all equipment necessary to conduct the testing of the installed equipment. The equipment shall include, but not be limited to test weights, rigging, safety gear, electrical meters, measuring devices’ and other equipment required during the course of testing.

Checkout, operate, adjust, and test all equipment in accordance with the requirements specified herein and the manufacturer’s written instructions and procedures prepared by Contractor and Approved by Engineer. Check physical connections, clearances, wiring, controls, limit switches, and other devices as required.

Field tests shall be performed by personnel experienced in the type of test being performed and under the direction of the Contractor’s test engineer. In addition, all field tests shall be conducted in the presence of Engineer for the purpose of demonstrating the equipment’s compliance with these Specifications. Contractor shall have operated all equipment and shall have made all necessary corrections and adjustments before testing in the presence of Engineer. A representative of the Contractor responsible for the Work shall be present to direct the testing.

Exhibit S

Specifications



Ready-to-test determination will be by Engineer based at least on the following:

1. Acceptable Operation and Maintenance Data. 2. Notification by Contractor of equipment readiness for testing. 3. Receipt of Manufacturer’s Certificate of Proper Installation, if so specified. 4. Adequate completion of work adjacent to, or interfacing with, equipment to be

tested, including items to be furnished by District. 5. Availability and acceptability of manufacturer’s representative, when specified,

to assist in testing of respective equipment. 6. Satisfactory fulfillment of other specified manufacturer’s responsibilities. 7. Equipment and electrical tagging complete. 8. Delivery of all spare parts and special tools.

3.2.2 Construction Tests After all rehabilitation work is completed and each crane system has been completely reassembled, adjusted, lubricated, and otherwise been made ready for operation; the Contractor shall perform Construction Tests for each crane system to verify that the crane is ready for turnover to commissioning. The Contractor shall perform preliminary post rehabilitation initial checks and adjustments, no load static tests, and no load tests as a quality control function. The Contractor shall correct any deficiencies and repeat portions of the inspections and tests as required verifying all cranes systems and equipment are ready for turnover to commissioning. Test reports summarizing results from Construction Tests shall be included with the Construction Turnover to Commissioning Form.

3.2.3 Construction Turnover to Commissioning Contractor is responsible for initiating the Construction Turnover to Commissioning activities for each crane. Contractor shall fill out a Construction Turnover to Commissioning Form (part of the Field ITP) when a crane is completed, Construction Tests are complete and the complete crane system is judged ready for Preoperational Testing. Contractor’s Superintendent of Construction and Site Quality Representative shall verify that the Work associated with the crane is complete before signing the Construction Turnover to Commissioning Form. Contractor’s Superintendent of Construction shall ensure the latest “As-Built” Drawings are available to Contractor’s Test engineer and District at the time of system turn over. The completed turnover form, including the system punchlist, shall be forwarded to Contractor’s Test engineer and District’s Test engineer.

Exhibit S

Specifications


The District’s Test engineer shall have a minimum of 48 hours to review and Approve the Turnover to Commissioning Form.

3.2.4 Inspection and Turnover Contractor’s Test engineer and District’s Test engineer shall perform an inspection of the crane, adding to the crane punchlist items that are either not completed or need corrective action to comply with design and indicate to Contractor’s Superintendent of Construction any items that must be completed prior to acceptance of the complete crane system for testing. A crane shall not be accepted with deficiencies that will preclude proper testing of the crane system or equipment, or invalidate such testing once the deficiency is corrected.

The following attributes shall be verified as completed as appropriate for each system:

1. Installation complete 2. Quality Records Complete 3. Construction Testing Complete and Satisfactory 4. Equipment Ready for Continued Testing

When Contractor’s Test engineer and District’s Test engineer are satisfied that the the crane is ready for Preoperational Testing, they shall sign the turnover form.

Contractor’s Test engineer shall maintain the punchlist until final acceptance of each crane. Additional items will be added to the punchlist during the commissioning program by Contractor’s and District Test engineers, as it becomes appropriate. Contractor’s Superintendent of Construction shall ensure that uncompleted and unsatisfactory items are resolved and removed from the punchlist on a timely basis to support the Commissioning program.

If at any time during commissioning deficiencies are discovered that preclude commissioning of the crane system, the crane will be turned back to the Contractor for correction of the deficiencies. This process will be documented in the Turnover Procedure. A turn back to construction shall not result in an extension of schedule. Any schedule or cost impacts associated with the turnover process, turn back to construction, or correcting deficiencies shall be borne by Contractor.

3.2.5 Initial Checks and Adjustments Operating and startup current measurements shall be recorded for electrical equipment (motors and coils) using appropriate instrumentation. Speed measurements shall be recorded. Recorded values shall be compared with design values; differences shall be

Exhibit S

Specifications


explained in the remarks column of data collection sheets and submitted for Approval or appropriate adjustments performed. In addition, high temperatures, noise, or abnormal operation of any equipment or machinery shall be noted, investigated, and corrected. Hoist, trolley, or bridge (traversing) speeds shall be recorded during each test cycle.

1. Check field wiring after installation and connection, to verify conformance with the drawings, Approved Shop Drawings, and schematic wiring diagrams to ensure proper phasing and polarity of all power conductors and to confirm that cable shields are grounded.

2. Complete the applicable field portions of the electrical testing required by Specifications Section 26 08 00, Electrical Testing.

3. Check electrical controls by trial operation of control equipment after wiring is completed to ensure that each interlock and control function operates according to the connection diagrams, as well as in accordance with the manufacturer’s schematics and operating instructions.

4. Check all incidental equipment including load cells, cable carriers (festoons), locking and indicating devices, and lights to ensure proper operation.

5. Verify all brakes have been adjusted and burnished and that brake torques has been verified.

6. Verify that the each crane has been cleaned up. 7. Test and adjust operation of operator’s cab and remote radio controls, travel

switch settings, indicating lights, position and load indication, holding and control brakes, and all other control logic functions.

8. Test and adjust operation of ancillary mechanical and electrical equipment, such as heaters, fans, and indicating devices.

9. All gearing, bearings, couplings, and rotating parts shall be checked for proper alignment.

10. Alignment and operating clearances (approaches). Verify crane alignment, clearance between the crane and the runway / facility, and the hook approaches.

11. Data shall include a written record of all digital controller settings, test point voltages, supply voltages, motor voltages, motor currents, and test conditions such as ambient temperature, motor load, date performed, and person performing the adjustments.

12. A copy of the final data shall be stored in the control panel door.

3.2.6 Equipment Monitoring Improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies shall be monitored during testing. Defects observed during the testing period shall be reported immediately to Engineer and the testing operations may be suspended by the Engineer until defects are corrected. The following inspections, as a minimum, shall be made and reported on during testing:

Exhibit S

Specifications


1. Inspect for evidence of slippage in wire rope sockets and fittings. 2. Check for overheating in brake operation; check for proper stopping. All safety

devices including emergency stop switches shall be tested and inspected to verify proper operation of brakes and control devices.

3. Check main hoist motor coupling alignment using a laser alignment instrument. Alignment to be per laser alignment manufacturer’s standard.

4. Check for abnormal noise or vibration and overheating in machinery drive components (sheaves, equalizer bars, and drum spooling, etc.).

5. Check wire rope sheaves and drum spooling for proper reeving and operation, freedom of movement, and abnormal noise or vibration.

6. Check electrical drive components for proper operation, freedom of chatter, noise, and overheating.

7. Inspect for abnormal wear, damage, or inadequate lubrication. 8. Inspection covers shall be removed from gear reducers for inspection of gearing

after all load tests are complete. 9. Inspection covers shall be removed from drum and pinion gears for inspection

after all load tests are complete. 10. Inspect and check operation and cleanliness of lubricating system.

3.2.7 No-Load Static Tests 1. All gearing, bearings, couplings, and rotating parts shall be checked for proper

oil level or lubrication, and hydraulic brakes, if any, shall be checked for brake fluid.

2. The controller for each motion shall be checked to ensure that hook and travel motions agree with marked controller directions.

3. All hooks shall be numbered and all throat openings shall be measured and recorded. These values shall be compared to the dimensions recorded by Contractor. A throat dimension base measurement shall be established by installing two (2) tram points and measuring the distance between these tram points.

3.2.8 No-Load Tests Perform the following tests in the unloaded condition.

3.2.8.1 Hoist The main and auxiliary hoists for each crane shall be fully tested. Each load hook shall be raised and lowered through the full range of normal travel at rated speed and other speeds of the crane. The load hook shall be stopped below the geared limit switch upper setting. Proper setpoint and operation of upper and lower limit switches shall be verified at a slow speed. The test shall be repeated a minimum of three (3) times to demonstrate proper operation, followed by operation at a high speed. Brake action

Exhibit S

Specifications


shall be tested in each direction. Dynamic and holding brake action shall be verified. Correct brake timing sequence shall be verified and insure that the holding brakes set and release without load droop.

3.2.8.2 Trolley Travel Each trolley shall be operated the full distance of the existing girder mounted trolley runway rails exercising all drive speed controls in each direction. Proper tracking of the trolley along its runway rails and adequate clearances between the trolley and bridge girder structure shall be verified. Brake operation shall be verified in each direction. Proper operation (interrupt power, automatic reset) of the trolley limit switches at both limits of trolley motion shall be tested in slow speed. The trolley bumpers shall contact the trolley stops located on the bridge girders in slow speed. The trolley shall be run in each direction of travel for at least four (4) complete cycles of trolley travel to disclose any noisy operation and misalignments at bearings, gearing, or motors.

3.2.8.3 Bridge Travel Each bridge crane shall be operated the full distance of its runway, exercising all drive speed controls in each direction. Brake operation shall be verified in each direction. Proper operation (interrupt power, automatic reset) of the bridge limit switches at both limits of bridge motion shall be tested in slow speed. The crane bridge bumpers shall contact the runway rail stops in slow speed.

3.2.8.4 Hoist Loss of Power Raise hooks to a safe working level above the deck to perform no-load test. While slowly lowering each hook, the main power source shall be disconnected verifying that the hook stops lowering and that both holding brakes set.

3.2.8.5 Travel Loss of Power With the hook raised to clear obstructions and one traversing motion (trolley or bridge) in slow speed, the main power source shall be disconnected verifying that the traversing motion stops and that the parking brake sets. Repeat test for each traversing motion of the crane. Repeat loss of power test at full speed to verify that brakes operate properly within acceptable stopping distance.

3.2.9 Load Tests Perform the following tests on each bridge crane using a test load of one-hundred percent (100%) rated load.

Contractor shall provide all required test weights for load testing of the crane. In addition, test weights provided for main hoist load testing shall be water bag weights.

Exhibit S

Specifications


Details of test weights shall be submitted. Loads from test weights shall not exceed allowable powerhouse floor loading capacities.

Water bag test weights shall be non-contaminated in order to drain the bags into existing surface drainage catch basins outside of the powerhouse. Water bags shall not be discharged into drains within the powerhouse.

Test weights shall be accurate to within plus 5%, minus 0% of the required test load.

3.2.9.1 Main Hoist 250 Ton Capacity 1. Hoist Static Load Test: Holding brakes and hoisting components shall be

tested by raising the test load approximately one (1) foot and manually releasing one of the holding brakes. The load shall be held for ten (10) minutes. The first holding brake shall be reapplied and the second holding brake released. The load shall be held for ten (10) minutes. Any lowering of the load during either of the ‘10-Minute Hold’ tests, indicates a malfunction of the brakes.

2. Hoist Dynamic Load Test: The test load shall be raised and lowered over the maximum hoisting distance practical but not less than 15 feet of travel. The hook shall be stopped, both holding brakes allowed to set with the load suspended. The hook shall be restarted twice in both raise and lower directions, demonstrating both holding brakes release on start of motion, and both holding brakes set in reverse sequence. Load memory shall be demonstrated to verify no load droop for rapid restart of the hoist after both holding brakes have been set. Baseline voltage and current readings shall be taken for the hoist motor and brakes and reported on the Field Test Report. The hook shall be accelerating through the full speed range. Speeds shall be within +/- 10% of the specified speeds and within 1% of the calculated speed.

3. Hoist Loss of Power Test: After raising the test load to approximately eight (8) feet, begin slowly lowering the test load and trip the main power source to verify that the test load does not lower and that both brakes set.

4. Travel Dynamic Load Test: With test load on the hook, one (1) traversing motion (trolley or bridge) shall be operated for the full length of its runway in both directions. Proper function of all drive speed control points and brake action without mechanical binding shall be verified. Repeat test for each traversing motion of the crane. Baseline voltage and current readings shall be taken for the travel motors and brakes and reported on the Field Test Report.

5. Travel Loss of Power Test: With the hook raised to clear obstructions and one traversing motion (trolley or bridge) in slow speed, the main power source shall be disconnected verifying that the traversing motion stops and that the parking

Exhibit S

Specifications


brake sets. Repeat test for each traversing motion of the crane. Repeat loss of power test at full speed to verify that brakes operate properly within acceptable stopping distance.

3.2.9.2 Auxiliary Hoist 25 Ton Capacity 1. Hoist Static Load Test: Holding brakes and hoisting components shall be

tested by raising the test load approximately one (1) foot and manually releasing one of the holding brakes. The load shall be held for ten (10) minutes. The first holding brake shall be reapplied and the second holding brake released. The load shall be held for ten (10) minutes. Any lowering of the load during either of the ‘10-Minute Hold’ tests, indicates a malfunction of the brakes.

2. Hoist Dynamic Load Test: The test load shall be raised and lowered over the maximum hoisting distance practical but not less than 15 feet of travel. The hook shall be stopped, both holding brakes allowed to set with the load suspended. The hook shall be restarted twice in both raise and lower directions, demonstrating both holding brakes release on start of motion, and both holding brakes set in reverse sequence. Load memory shall be demonstrated to verify no load droop for rapid restart of the hoist after both holding brakes have been set. Baseline voltage and current readings shall be taken for the hoist motor and brakes and reported on the Field Test Report. The hook shall be accelerating through the full speed range. Speeds shall be within +/- 10% of the specified speeds and within 1% of the calculated speed.

3. Hoist Loss of Power Test: After raising the test load to approximately eight (8) feet, begin slowly lowering the test load and trip the main power source to verify that the test load does not lower and that both brakes set.

3.2.10 Overload Tests Unless otherwise indicated, the following tests shall be performed using a test load of one-hundred twenty-five percent (125%) rated load.

Contractor shall provide all required test weights for load testing of the crane. In addition, test weights provided for main hoist load testing shall be water bag weights. Details of test weights shall be submitted Loads from test weights shall not exceed allowable powerhouse floor loading capacities.

Water bag test weights shall be non-contaminated in order to drain the bags into existing surface drainage catch basins outside of the powerhouse. Water bags shall not be discharged into drains within the powerhouse.

Test weights shall be accurate to within plus 5%, minus 0% of the required test load.

Exhibit S

Specifications


3.2.10.1 Main Hoist 250 Tons Capacity 1. Position the trolley at location determined to cause the largest girder deflections

under applied load. 2. The hoist shall be checked to determine whether it can torque prove, release

holding brakes, raise, and set holding brakes in sequence and hold the overload without drift of the load. The same shall be confirmed in the lowering direction. Hoist shall be checked to determine that the load does not lower on any hoisting position.

3. The throat openings of all hooks shall be re-measured and recorded after the overload test and compared to the initial measurements to check for deformation.

4. The crane structure shall be checked for excessive deflection while loaded with one-hundred twenty-five percent (125%) of rated capacity. Contractor shall submit plan for measuring deflection for Approval by Engineer.

5. No trolley or bridge travel shall be required during the overload tests. 6. Testing performed shall satisfy Washington State Codes (WAC) in order to

certify the crane for operation.

3.2.10.2 Auxiliary Hoist 25 Ton Capacity 1. Position the trolley at location determined to cause the largest girder deflections

under applied load. 2. The hoist shall be checked to determine whether it can torque prove, release

holding brakes, raise, set holding brakes in sequence and hold the overload without drift of the load. The same shall be confirmed in the lowering direction. Hoist shall be checked to determine that the load does not lower on any hoisting position.

3. The throat openings of all hooks shall be re-measured and recorded after the overload test and compared to the initial measurements to check for deformation.

4. No trolley or bridge travel shall be required during the overload tests. 5. Testing performed shall satisfy Washington State Codes (WAC) in order to

certify the crane for operation.

3.2.11 Supplemental Functional Tests Perform the following functional tests in the field in addition to those tests specified above.

1. Tandem Crane Operation: a. Operate both bridge cranes in tandem with the District’s 470 ton lifting

beam assembly attached to the main hoist hooks and the bridge cranes physically linked together using the bridge connection links.

Exhibit S

Specifications


b. Operate the bridge cranes through all tandem functions to demonstrate satisfactory operation.

c. The bridge cranes while configured for tandem operation shall be operated the full distance of its runway, exercising all drive speed controls in each direction for each crane motion (bridge, trolley, and hoisting).

2. Express Speed Verification: Operate the hoist with the lifting beam only attached and verify and record the hoist express speeds in the unloaded condition. The lifting beam shall be raised and lowered over the full travel with the hook accelerating through the full speed range. Speeds shall be within +/- 10% of the specified speeds and within 1% of the calculated speed.

3.2.12 Field Test Reports Within 24 hours of completion of each field test, outlined in the field test procedures, the Contractor shall submit one (1) copy of the test results to Engineer, unless specified otherwise. The report shall include a comparison of the performance as determined by test and the guaranteed performance data. The report shall include the following: purpose of the test, test procedure, participants in the test and their roles, test dates and times, list of measuring instruments with make, model and accuracy, sketch(es) indicating location of test instruments, calibration data for each instrument, calculation of measurement uncertainty, sample calculation of how test results were obtained from the measured data, photographs, and anything else required to provide a complete documentation of the test. Each final report shall include a copy of all gathered data.

The test report shall include a detailed tabulation showing values of measurements and deviations (plus/minus) with respect to design values, and all adjustments recorded during the tests. During each test run the following data and observations, as a minimum, shall be recorded.

1. Speeds. 2. Settings. 3. Test weights. 4. Pertinent observations regarding such events as unusual sounds, malfunctions

or difficulties encountered, and adjustments required. 5. Motor current and voltage. 6. Deflections of the crane girders and hook throat openings at maximum loading.

To the fullest extent possible, all data gathered electronically shall be in a form easily imported to Microsoft Excel. District shall be furnished an electronic copy of all original and manipulated test data.

Exhibit S

Specifications


3.3 FAILURE TO MEET PERFORMANCE REQUIREMENTS If the crane system does not meet the Performance requirements specified in this section and those in Section 41 22 10.13, Bridge Crane Mechanical Rehabilitation; Contractor may make modifications and request a retest. Any modifications shall have the prior Approval of Engineer. All expenses of the retest shall be the responsibility of the Contractor.



Bid No. 15-65 Selective Removal and Modifications – 02 41 19 Page 1

SECTION 02 41 19

SELECTIVE REMOVAL AND MODIFICATIONS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 3 1.3 PERSONNEL ........................................................................................................ 3


3.1 PRE – WORK TESTING ......................................................................................... 3 3.2 DEMOLITION ........................................................................................................ 3 3.3 SALVAGE ............................................................................................................ 5

3.4 DISPOSAL ........................................................................................................... 5 3.5 SPILL RESPONSE ................................................................................................ 5



SECTION 02 41 19

SELECTIVE REMOVAL AND MODIFICATIONS

1.0 GENERAL

Executing Work requiring disturbing or removal of hazardous substances shall be in compliance with the requirements of General Conditions paragraph GC-69, Hazardous Substances and Environmental Protection, the requirements of Section 01 35 24, Safety, the requirements of Section 02 82 13.01, Class II Asbestos Abatement, the requirements of Section 02 83 33.13, Lead Based Paint Removal and Disposal, and the requirements specified herein.

Refurbishment of the Rocky Reach Powerhouse Bridge Cranes necessitates working in an environment where hazardous substances are present. This project will require disassembling and removing components that may contain:

1. Residue from cleaning products or lubricants 2. Coatings and conduit that may contain lead and other regulated metals 3. Measurable amounts of greases, oils, and other liquids in piping systems,

reservoirs, and cavities 4. Asbestos insulation 5. Lead sheathed electrical cables 6. Asbestos dust from brake linings

Contractor shall follow all local, state, and federal laws when removing, handling, or disturbing any hazardous substances, including, but not limited to asbestos, polychlorinated biphenyls, and lead as part of the Work.

1.1 REFERENCES


Washington Administrative Code (WAC) Title 296-24 General Safety and Health Standards Title 296-62 General Occupational Health Standards Title 296-155 Safety Standards for Construction Work Title 296-800-140 Accident Prevention Program Title 296-809 Confined Space Title 296-820 Core Rules Title 296-841 Respiratory Hazards



1.2 SUBMITTALS

Contractor shall submit an equipment removal and demolition work plan before beginning any equipment demolition work. The plan shall be submitted 30 days prior to the start of any on-site work and shall include the following:

1. Describe methods, equipment, and sequence to be used for removal of all crane equipment and components that are to be removed;

2. Include description of all cranes, manlifts, tools, cutting equipment, protective enclosures and other items required for equipment removal.

3. Hazardous Substance detection, sampling and testing procedures for equipment to be removed;

4. Methods to prevent spills or discharge of any wastes or materials during equipment removal and methods which will be used to assure that contaminants do not enter the environment or the powerhouse;

5. Methods for disposal of all removed equipment and associated waste materials.

1.3 PERSONNEL

Contractor shall utilized personnel fully trained and certified in detecting, handling and disposal of hazardous wastes. Each person sampling hazardous materials shall be properly trained to do so.

Contractor’s personnel exposed to hazardous materials and wastes shall be trained in proper handling, storage, and protection from and of hazardous materials.


3.0 EXECUTION

3.1 PRE – WORK TESTING

Contractor shall perform presumptive testing for presence of lead and other regulated metals. Testing for metals and other hazardous substances shall be in accordance with General Conditions paragraph GC-69, Hazardous Substances and Environmental Protection.

3.2 DEMOLITION

3.2.1 General

The equipment and materials to be removed shall be removed in a manner that does not damage those portions of the structure that are to be reused. After removal all nicks, burrs, cracks, notches, etc., shall be removed by grinding to provide a smooth finished surface. In the event of damage to that portion of the structure that is to be reused, the



Contractor shall submit a repair plan for District Approval. No repairs shall be made without Approval. The cost of repairs shall be considered to be incidental to the Work.

The crane is painted with paint likely to contain significant quantities of lead. Any demolition activities that may disturb the paint shall comply with the requirements of Section 02 83 33.13 Lead Based Paint Removal and Disposal. In addition, crane equipment including brakes, electrical panels, conduit, and wiring may contain asbestos. Demolition activities that may disturb asbestos containing materials shall comply with the requirements of Section 02 82 13.01 Class II Asbestos Abatement.

3.2.2 Existing Crane and Crane Equipment Weights

The Contractor shall make his own determination of crane and crane equipment weights. For details of the existing crane see the Reference Drawings. The Contractor shall verify all measurements and weights in the field as necessary for proper planning and execution of his Work. 3.2.3 Selective Removal

The Contractor shall remove and dispose of crane equipment on both cranes as shown on the Drawings and as summarized herein:

1. Selected portions of bridge walkway including handrails shall be removed. Floor plate shall be cut at each end from portions of walkway to remain. Cut ends of walkway that remain in place shall be dressed and ground smooth. Support plates shall be unbolted from clip plates attached to bridge girders. Clip plates attached to bridge girders shall remain.

2. Bridge drive system complete with all controls and wiring. Includes removal of brake, motor, brake, bleeder, pedal, hydro-pneumatic system, tubing, reducer, cross-shaft, couplings, pillow blocks and supports, and pinion gears.

3. All existing electrical control panels with associated controls. All wiring shall be removed from the crane. The existing conduit shall remain in-place to be reused with new panels, except for any EMT and / or flex conduit, which shall be replaced in its entirety.

4. The complete radio control system shall be removed, including its associated conduit.

5. All limit switches except for the trolley travel limit switches. 6. The complete trolley cross-conductor system. Brackets and clips connecting to

the structure may be reused. Any that are not reused shall be removed and ground flush.

7. Panelboard, disconnect switch, contactor, transformer and other controls on the back wall of the operators cab. Existing master switches and their console shall remain and be re-used.

8. All crane lighting systems and controls. 9. Auxiliary hoist drum, pillow blocks, load block, rope, reducer, motor, brake, and

drive pinion gear. 10. Main hoist motor and brake.



11. Main hoist reducer input shaft assembly complete, 1st intermediate shaft assembly complete, and the intermediate reduction gear (G4) from the 2nd intermediate shaft assembly. NOTE: Reducer gear G4, shall be salvaged and delivered to the District for storage.

12. Main hoist wire rope. 13. Trolley drive motor, brake, and controls. 14. Bridge drive truck wheel bearings and seals. 15. Bridge idler truck wheel bearings and seals. 16. Trolley drive wheel bearings and seals. 17. Trolley idler wheel bearings and seals. 18. Main hoist bearings and seals (but not bushings nor the main hoist drum shaft,

output shaft, and hook swivel bearings). 19. Main hoist drum idler-end pillow block housing, if required by Contractor design. 20. Trolley ladder and handrail as required. 21. Existing upstream crossover platform.

3.3 SALVAGE

The Contractor shall deliver salvaged materials to the District’s designated on-site storage areas. All salvaged materials shall be thoroughly cleaned of all grease, oils, lubricants or any other surface contaminants by the Contractor prior to delivery to the District. Salvaged machined parts shall be protected with a long-life rust preventative coating and neatly palletized for storage by the District. Salvaged materials shall be loaded, transported, and unloaded at the onsite storage area by the Contractor.

3.4 DISPOSAL

The Contractor shall manage all waste generated from the equipment demolition work. Equipment and materials shall be recycled to maximum extent practicable and all disposals shall comply with local, state and federal laws in addition to the requirements in General Conditions paragraph GC-71, Hazardous Substances and Environmental Protection.

Payment for selective removal and disposal of the existing crane equipment will based on the unit lump sum bid item pricing for selective crane equipment removal included in the Bid Form.

3.5 SPILL RESPONSE

In accordance with the requirements of General Conditions paragraph Hazardous Substances and Environmental Protection.



Bid No. 15-65 Class II Asbestos Abatement – 02 82 13.01 Page 1

SECTION 02 82 13.01

CLASS II ASBESTOS ABATEMENT

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 GENERAL REQUIREMENTS.................................................................................... 2 1.2 DESCRIPTION OF WORK ....................................................................................... 2 1.3 REFERENCES ...................................................................................................... 3

1.4 DEFINITIONS ....................................................................................................... 3 1.5 SUBMITTALS ....................................................................................................... 4

1.6 MEDICAL REQUIREMENTS .................................................................................... 5 1.7 TRAINING ............................................................................................................ 5 1.8 PERMITS AND NOTIFICATIONS ............................................................................... 5

1.9 PERSONAL PROTECTIVE EQUIPMENT .................................................................... 5 1.10 WARNING SIGNS AND TAPE .................................................................................. 6

1.11 WARNING LABELS ............................................................................................... 6 1.12 PERSONNEL ........................................................................................................ 6

2.0 PRODUCTS (NOT USED).................................................................................... 6

3.0 EXECUTION ......................................................................................................... 6 3.1 PRE—WORK TESTING ......................................................................................... 6

3.2 PROTECTION OF ADJACENT WORK AREAS ............................................................. 7

3.3 INITIAL AIR MONITORING AND RESPIRATORY PROTECTION ...................................... 7

3.4 REMOVAL METHODS ............................................................................................ 7 3.5 DISPOSAL ........................................................................................................... 7

3.6 SITE INSPECTION ................................................................................................. 7 4.0 ATTACHMENTS .................................................................................................. 8

4.1 BULK ASBESTOS FIBER ANALYSIS SAMPLE 1 ......................................................... 8 4.2 BULK ASBESTOS FIBER ANALYSIS SAMPLE 2 ......................................................... 8



SECTION 02 82 13.01

CLASS II ASBESTOS ABATEMENT

1.0 GENERAL

1.1 GENERAL REQUIREMENTS

This Section describes procedures and equipment required for sampling and initial air monitoring and also procedures and equipment required to protect workers and occupants of the work area from contact with airborne asbestos fibers and asbestos-containing materials (ACM) dust and debris generated as the result of ACM removal. Asbestos removal and disposal on mechanical and electrical equipment shall be incidental to the work and no separate payment will be made.

In addition to the detailed requirements included in the provisions of this contract, work performed shall comply with all applicable federal, state, and local laws, along with ordinances and regulations. Submit matters of interpretation of standards to the appropriate administrative agency for resolution before starting work. Where the requirements of this specification, applicable laws, criteria, ordinances, regulations, and referenced documents vary, the most stringent requirements shall apply.

1.2 DESCRIPTION OF WORK

The District has performed testing on the Rocky Reach powerhouse bridge cranes for the presence of ACM and has determined that ACM are present on the cranes. Findings of the District asbestos survey are attached, see Section 4.0, Attachments.

The removal of asbestos on the bridge cranes is considered a Class II operation. The Contractor shall assume that all brakes contain asbestos. The existing operator's cab and equipment panels may also contain asbestos panels (transite panels). Additionally, wiring throughout the cranes may contain asbestos in the fabric insulation. ACM shall be removed and disposed of and the asbestos work area shall be completely cleaned and free of asbestos contamination before equipment is replaced. The Contractor shall be responsible for the following asbestos abatement work items:

1. Contractor shall perform presumptive testing for presence of asbestos on all equipment that could have ACM to confirm the findings of the District survey as well as identify any ACM items that may not have been previously identified.

2. Pre-activity air testing to determine background levels of airborne asbestos and initial air monitoring to determine the level of friable asbestos created upon removal of ACM.

3. Removal and disposal of all asbestos containing material.



1.3 REFERENCES


Washington Administrative Code (WAC) WAC 296-24 General Safety and Health Standards WAC 296-62 General Occupational Health Standards WAC 296-62-77 Asbestos, Tremolite, Anthophylite, and Actinolite WAC 296-65 Safety Standards for Asbestos Removal and

Encapsulation WAC 296-155 Safety Standards for Construction Work WAC 296-800-140 Accident Prevention Program WAC 296-809 Confined Space WAC 296-820 Core Rules WAC 296-841 Respiratory Hazards

1.4 DEFINITIONS

1.4.1 Class II Asbestos Work

A term as defined in WAC 296-62-7703, Class II asbestos work means Class II asbestos activities involving the removal of ACM which is not thermal system insulation or surfacing material. This includes, but is not limited to, the removal of asbestos-containing wallboard, floor tile and sheeting, roofing and siding shingles, and construction mastics.

1.4.2 Regulated Area

A term as defined in WAC 296-62-7703, a regulated area is an area contained and controlled either by an enclosed containment (full containment area, single or double bulkhead containment area, mini-containment area), modified containment, glove bag or outdoor techniques, where asbestos containing materials (ACM) operations are performed and isolated by physical boundaries to prevent the spread of ACM and control access to authorized persons.

1.4.3 Permissible Exposure Limit (PEL)

The PEL, as defined in WAC 296-62-7705 is the level of concentration of airborne asbestos fibers that shall not be exceeded for unprotected employee exposure.



1.5 SUBMITTALS

The following shall be submitted In accordance with Section 01 30 00 Administrative Requirements:

1. Site Safety & Health Plan – In accordance with Section 01 35 24, Safety; the Contractor shall submit a site specific Work Plan and Safety & Health Plan before beginning on-site activities. These plans shall detail the response actions to be taken for asbestos work (ACM items to be abated and method of abatement for each abatement work task) and the control procedures (containment techniques to include safety precautions and work procedures) to be used in the abatement of the ACM. The plan shall be prepared by, signed and dated by the Contractor's Industrial Hygienist (IH) or an accredited Asbestos Project Designer. Such plan shall include, but not be limited to the precise personal protective equipment to be used, the location of asbestos regulated work areas, abatement method, sequencing of asbestos related work, disposal procedures and plan, planned air monitoring strategies, and a detailed description of the method to be employed in order to control the spread of ACM wastes and airborne fiber concentrations. The asbestos hazard abatement plan shall be submitted at least 30 days prior to start of work. This plan must be accepted by the District prior to the start of any asbestos abatement work.

2. Qualifications -- A written qualifications and organization report providing evidence of qualifications of the asbestos abatement contractor, his onsite supervisor, and workers to perform asbestos abatement activities as required herein shall be submitted. The report shall specify the Contractor's staff organization to include subcontractors, independent IH firm and testing laboratory chain of command to be used for this project. The Contractor's qualification report shall contain information required below: a. Evidence of Contractor certification. b. Evidence that Contractor's full-time onsite supervisor for the asbestos Work

is designated as, and is qualified to be a "competent person" as defined in WAC 296-62-7703. The Contractor shall also submit evidence that this person has a minimum of two (2) years of on-the-job asbestos abatement supervisory experience.

c. The name, address and telephone number of each independent testing laboratory selected to perform the sample analyses and report the testing results shall be submitted. The testing laboratory shall be completely independent from the Contractor.



3. Air Sampling Results – Air sample fiber counting from initial air monitoring shall be completed and results provided within 24 hours after completion of a sampling period. The District shall be notified immediately of any airborne levels of asbestos fibers in excess of established requirements. Written sampling results shall be provided within five (5) working days of the date of collection. The written results shall be signed by testing laboratory principal and the Contractor's Air Sampling Technician.

1.6 MEDICAL REQUIREMENTS

Medical requirements shall conform to WAC 296-62-7725. The Contractor shall institute a medical surveillance program for all employees who for a combined total of 30 or more days per year are engaged in Class I, II, and III work, or are exposed at or above the permissible exposure limit for combined 30 days or more per year; or who are required by the standard to wear negative pressure respirators.

1.7 TRAINING

Only certified asbestos workers working under the direction of a certified Asbestos Supervisor may work on an asbestos project as required by WAC 296-65-010 and WAC 296-62-07722. If the competent person determines that the content of the approved asbestos worker training course is not adequate for all elements of the Class II work required for this project, additional training shall be provided. The additional training shall address the work practices and engineering controls specifically related to the class II asbestos work required for this project, and shall include "hands-on" training in the work practices applicable to class II materials. The cost of additional training, if required, shall be considered incidental to the Work.

1.8 PERMITS AND NOTIFICATIONS

Necessary permits shall be obtained in conjunction with the project asbestos abatement, transportation and disposal actions and timely notification furnished of such actions required by Federal, state, regional, and local authorities and as otherwise specified herein. The Contractor shall notify the state's environmental protection agency responsible for asbestos air emissions and the District in writing at least ten (10) days prior to the commencement of Work.

1.9 PERSONAL PROTECTIVE EQUIPMENT

1.9.1 Respirators

Respiratory protection shall comply with the requirements of WAC 296-62-07715. A qualitative or quantitative fit test shall be conducted by the Contractor's IH for each Contractor worker required to wear a respirator.

1.9.2 Protective Clothing

Protective clothing shall comply with the requirements of WAC 296-62-07717.



1.10 WARNING SIGNS AND TAPE

Contractor shall ensure that all personnel understand the warning signs. Warning signs and tape printed in English shall be provided at the regulated boundaries and entrances to asbestos regulated work areas. Signs shall be located at such a distance that personnel may read the sign and take the necessary protective steps required before entering the area. Warning signs shall be in vertical format conforming to WAC 296-62-7721.

1.11 WARNING LABELS

Warning labels shall be affixed to all asbestos disposal containers used to contain asbestos materials, scrap, waste debris, and other products contaminated with asbestos. Containers with preprinted warning labels conforming to the requirements specified herein are acceptable. Warning labels shall conform WAC 296-62-7721 and shall be of sufficient size to be clearly legible displaying the following legend.

1.12 PERSONNEL

Contractor shall utilize personnel fully trained and certified in detecting, handling and disposal of hazardous wastes. Each person sampling hazardous materials shall be properly trained to do so.



3.0 EXECUTION

3.1 PRE—WORK TESTING

Contractor shall perform presumptive testing for presence of asbestos and other regulated materials on:

1. Any surface before performing any cutting, grinding, welding, or work that would release dust, fumes, or fibers into the atmosphere.

2. Existing conduit before pulling in new cables that would be contaminated by asbestos fiber residue on the interior of the conduit.

Testing for hazardous substances shall be accomplished by collecting samples from the subject item and sending the sample(s) to an authorized, independent testing facility. Proper chain of custody documentation shall be prepared and submitted.



3.2 PROTECTION OF ADJACENT WORK AREAS

Asbestos abatement work shall be performed without damage or contamination of adjacent work or areas. Where such work or area is damaged or contaminated as verified by the District using visual inspection and/or sample analysis, it shall be restored to its original condition or decontaminated by the Contractor at no expense to the District as deemed appropriate by the District. This includes inadvertent spill of dirt, dust or debris, in which it is reasonable to conclude that asbestos may exist. When these spills occur, work shall stop in all affected areas immediately and the spill shall be cleaned. When satisfactory visual inspection and/or sampling analysis results are obtained and have been evaluated by the Contractor's IH and the District, work may proceed.

3.3 INITIAL AIR MONITORING AND RESPIRATORY PROTECTION

Personal exposure monitoring shall be made from breathing zone air samples that are representative of the 8 hour Time Weighted Average (TWA) and 30 minute short term exposures of each worker. Monitoring and testing shall be in accordance with WAC 296-62-7709. If acceptable airborne levels are exceeded, a containment area and personal protective equipment shall be required.

The Contractor's Air Sampling Technician shall select and approve the air monitoring equipment to be provided and used by the Contractor for evaluation of airborne asbestos fiber concentrations.

3.4 REMOVAL METHODS

The Contractor shall remove the brakes intact and shall use a wet method and/or a HEPA vacuum to remove ACM dust residual. All removal methods shall be in accordance with WAC 296-62-7712. Mechanical removal methods will not be allowed.

3.5 DISPOSAL

ACM, waste, scrap, debris, bags, containers, equipment, and clothing contaminated with asbestos shall be collected and disposed of in sealed containers. Disposal shall be in accordance with General Conditions paragraph GC-69, Hazardous Substances and Environmental Protection.

3.6 SITE INSPECTION

While performing asbestos removal work, the Contractor shall be subject to onsite inspection by the District’s onsite representative, quality assurance personnel, and or safety and industrial hygiene personnel. If the work is found to be in violation of this specification, the District Project Manager will issue a stop work order to be in effect immediately and until the violation is resolved. Standby time required to resolve the violation shall be at the Contractor's expense.



4.0 ATTACHMENTS

4.1 BULK ASBESTOS FIBER ANALYSIS SAMPLE 1

4.2 BULK ASBESTOS FIBER ANALYSIS SAMPLE 2


stevew

Text Box

SECTION 02 82 13.01 ATTACHMENT 4.1 BULK FIBER ANALYSIS SAMPLE 1

stevew

Text Box

SECTION 02 82 13.01 ATTACHMENT 4.2 BULK FIBER ANALYSIS SAMPLE 2


Bid No. 15-65 Lead Based Paint Removal and Disposal – 02 83 33.13 Page 1

SECTION 02 83 33.13

LEAD BASED PAINT REMOVAL AND DISPOSAL

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 GENERAL REQUIREMENTS.................................................................................... 2 1.2 DESCRIPTION OF WORK ....................................................................................... 2 1.3 REFERENCES ...................................................................................................... 3

1.4 DEFINITIONS ....................................................................................................... 3 1.5 SUBMITTALS ....................................................................................................... 4

1.6 MEDICAL REQUIREMENTS .................................................................................... 5 1.7 TRAINING ............................................................................................................ 5 1.8 BLOOD LEAD TESTING ......................................................................................... 5

1.9 PERSONAL PROTECTIVE EQUIPMENT .................................................................... 5 1.10 WARNING SIGNS AND TAPE .................................................................................. 5

1.11 PERSONNEL ........................................................................................................ 6 2.0 PRODUCTS (NOT USED).................................................................................... 6 3.0 EXECUTION ......................................................................................................... 6

3.1 PRE – WORK TESTING ......................................................................................... 6 3.2 PROTECTION OF ADJACENT WORK AREAS ............................................................. 6

3.3 LEAD BASED PAINT REMOVAL .............................................................................. 6

3.4 DISPOSAL ........................................................................................................... 7

3.5 SITE INSPECTION ................................................................................................. 7 4.0 ATTACHMENTS .................................................................................................. 7

4.1 SPECTRA LABORATORIES – CRANE COATING ANALYSIS ......................................... 7



SECTION 02 83 33.13

LEAD BASED PAINT REMOVAL AND DISPOSAL

1.0 GENERAL


This Section describes procedures and equipment required for sampling, removal, handling and storage of lead based paint (LBP) materials; and also procedures and equipment required to protect workers and occupants of the work area from contact with LBP materials, dust and debris generated as the result of LBP removal. LBP removal and disposal on mechanical and electrical equipment shall be incidental to the work and no separate payment will be made.

In addition to the detailed requirements included in the provisions of this contract, work performed shall comply with all applicable federal, state, and local laws, along with ordinances and regulations. Contractor shall submit matters of interpretation of standards to the appropriate administrative agency for resolution before starting work. Where the requirements of this specification, applicable laws, criteria, ordinances, regulations, and referenced documents vary, the most stringent requirements shall apply.

1.2 DESCRIPTION OF WORK

The District has performed testing on the Rocky Reach powerhouse bridge cranes for the presence of LBP and has determined that LBP is present on the crane. Findings of the District survey are attached, see Section 4.0, Attachments.

The powerhouse bridge cranes were originally painted with a lead based paint system. All structural components have the LBP. Mechanical/electrical items such as electric motors and gear reducers that were shop painted by the equipment manufacturers may or may not have LBP.

To the maximum extent possible no cutting, grinding, sanding, heat application, or any other operation that would create a hazardous waste shall be performed on any surfaces coated with LBP. To the maximum extent possible parts shall be mechanically disassembled by unbolting, unscrewing, uncoupling connections, etc. in a manner to prevent creation of a hazardous waste.

If any LBP must be removed at the project site in a manner that creates a hazardous waste, then all operations for removal, handling, and storage of LBP shall be in compliance with Federal, state, and local laws, as outlined below, and in accordance with General Conditions paragraph Hazardous Substances and environmental



Protection. If paint must be removed then the paint shall be removed at least four (4) inches away from the point of heat application when welding, grinding, cutting such as torch or air arc, and similar operations.

1.3 REFERENCES


Washington Administrative Code (WAC) WAC 296-24 General Safety and Health Standards WAC 296-62 General Occupational Health Standards WAC 296-155 Safety Standards for Construction Work WAC 296-800-140 Accident Prevention Program WAC 296-809 Confined Space WAC 296-820 Core Rules WAC 296-841 Respiratory Hazards

1.4 DEFINITIONS

1.4.1 Lead

A term as defined in WAC 296-155-17605, Lead means metallic lead, all inorganic lead compounds, and organic lead soaps.

1.4.2 Action Level

A term as defined in WAC 296-155-17605, Action level means employee exposure, without regard to the use of respirators, to an airborne concentration of lead of 30 micrograms per cubic meter of air calculated as an 8-hour time weighted average (TWA).

1.4.3 Permissible Exposure Limit (PEL)

PEL, as defined in WAC 296-155-17607 is the level of concentration of airborne lead that shall not be exceeded for unprotected employee exposure.

1.4.4 Competent Person

The competent person, as defined in WAC 296-155-17605 is the one who is capable of identifying existing and predictable lead hazards in the surroundings or working conditions and who has authorization to take prompt corrective measures to eliminate them.



1.5 SUBMITTALS

The following shall be submitted In accordance with Section 01 30 00 Administrative Requirements:

1. Site Safety & Health Plan – In accordance with Section 01 35 24, Safety; the Contractor shall submit a site specific Work Plan and Safety & Health Plan before beginning on-site activities. These plans shall detail the response actions to be taken for lead based paint removal work (LBP items to be abated and method of abatement for each abatement work task) and the control procedures (containment techniques to include safety precautions and work procedures) to be used in the abatement of the LBP. The plan shall be prepared by, signed, and dated by the Contractor's competent person responsible for the lead based paint removal work. As a minimum the plan shall include: a. Hazardous Substance detection, sampling, and testing procedures b. A description of each activity in which lead is emitted and the specific

nature of operations which could result in exposure to lead above the action level (equipment used, materials involved, controls in place, crew sizes, and employee job responsibilities);

c. Removal procedures including the specific means that will be employed to ensure employee exposure is below the PEL (include, as a minimum, programs for air sampling, medical surveillance, respiratory protection, personal hygiene, OSHA personal monitoring, and employee training);

d. A report of the technology considered in meeting the PEL; e. Air monitoring data which documents the source of lead emissions; f. Onsite handling and storage procedures

2. Proof of certification: The name, address and telephone number of the independent testing laboratory selected to perform the blood level testing. The testing laboratory shall be completely independent from the Contractor.

3. Test results for worker blood level testing. Blood lead testing shall be performed within two (2) days before start of LBP removal and within two (2) days after completion of LBP removal.

4. Qualifications -- A written qualifications and organization report providing evidence of worker qualifications to perform LBP removal and abatement work. The Contractor's qualification report shall contain information required below: a. Evidence that each employee is properly trained to perform LBP removal

and abatement work (training shall be as required by WAC 296-155-17625).

b. Evidence that Contractor's full-time onsite supervisor for the LBP removal work is designated as, and is qualified to be a "competent person" as defined in WAC 296-155-17605. The Contractor shall also submit evidence that this person has a minimum of two (2) years of on-the-job LBP abatement supervisory experience.



1.6 MEDICAL REQUIREMENTS

Medical requirements shall conform to WAC 296-155-17621. The Contractor shall institute a medical surveillance program for all employees who are or may be exposed at or above the action level for more than 30 days in any 12 consecutive months.

1.7 TRAINING

Workers performing LBP abatement shall be properly trained as required by WAC 296-155-17625. If the competent person determines that the content of the approved LBP worker training course is not adequate for all elements of the LBP removal and abatement work required for this project, additional training shall be provided. The additional training shall address the work practices and engineering controls specifically related to the LBP removal and abatement work required for this project, and shall include "hands-on" training in the work practices applicable to this project.

1.8 BLOOD LEAD TESTING

All workers involved with LBP removal operations shall have blood lead testing performed prior to commencement of work and after completion of all work. The blood level testing laboratory shall be certified in the State of Washington. Submit proof of certification to the District.

1.9 PERSONAL PROTECTIVE EQUIPMENT

1.9.1 Respirators

Respiratory protection shall comply with the requirements of WAC 296-155-17613. A qualitative or quantitative fit test shall be conducted by the Contractor's industrial hygienist (IH) for each Contractor worker required to wear a respirator.

1.9.2 Protective Clothing

Protective clothing shall comply with the requirements of WAC 296-155-17615. Workers shall use appropriate protective clothing including non absorbent gloves, fog-proof goggles, full-body coveralls with head covers, and half-mask air purifying respirators equipped with HEPA filters. Coverall sleeves shall be secured at the wrist and pant legs at the ankle with tape.

1.10 WARNING SIGNS AND TAPE

Contractor shall ensure that all personnel understand the warning signs. Warning signs and tape shall be printed in English shall be provided at the regulated boundaries and entrances to each work area were an employee’s exposure to lead is above the PEL. Signs shall be located at such a distance that personnel may read the sign and take the necessary protective steps required before entering the area. Warning signs shall be in vertical format conforming to WAC 296-155-17627.



1.11 PERSONNEL

Contractor shall utilized personnel fully trained and certified in detecting, handling and disposal of hazardous wastes. Each person sampling hazardous materials shall be properly trained to do so.



3.0 EXECUTION

3.1 PRE – WORK TESTING

Contractor shall perform presumptive testing for presence of lead and other regulated metals on:

1. Any surface before performing any cutting, grinding, welding, or similar metalwork that would release lead dust or fumes into the atmosphere.

2. Existing conduit before pulling in new cables that would be contaminated by lead residue on the interior of the conduit.

Testing for metals and other hazardous substances shall be accomplished by collecting samples from the subject item and sending the sample(s) to an authorized, independent testing facility. Proper chain of custody documentation shall be prepared and submitted. Lead check swabs or kits shall not be used.

3.2 PROTECTION OF ADJACENT WORK AREAS

LBP abatement work shall be performed without damage or contamination of adjacent work or areas. Where such work or area is damaged or contaminated as verified by the District using visual inspection and/or sample analysis, it shall be restored to its original condition or decontaminated by the Contractor at no expense to the District as deemed appropriate by the District. This includes inadvertent spill of dirt, dust, fumes, or debris, in which it is reasonable to conclude that lead may exist. When these spills occur, work shall stop in all affected areas immediately and the spill shall be cleaned. When satisfactory visual inspection and/or sampling analysis results are obtained and have been evaluated by the Contractor's IH and the District, work may proceed.

3.3 LEAD BASED PAINT REMOVAL

LBP shall be removed by a wet method such as solvents or chemical paint removers and clean rags, whenever practical.



If a dry removal method is used the system shall be connected to a HEPA filtered vacuum system. The systems shall be suitably sized for the project, and filters shall be capable of removing particles as small as 0.3 micrometers at a minimum efficiency of 99.97 percent.

Removal methods by abrasive blasting or the use of chemical stripper shall also include the use of a lead binding agent such as Blast-Tox, Strip-Tox or equivalent.

3.4 DISPOSAL

Disposal shall be in accordance with General Conditions paragraph GC-69, Hazardous Substances and Environmental Protection.

3.5 SITE INSPECTION

While performing LBP removal work, the Contractor shall be subject to onsite inspection by the District’s onsite representative, quality assurance personnel, and or safety and industrial hygiene personnel. If the work is found to be in violation of this specification, the District Project Manager will issue a stop work order to be in effect immediately and until the violation is resolved. Standby time required to resolve the violation shall be at the Contractor's expense.

4.0 ATTACHMENTS

4.1 SPECTRA LABORATORIES – CRANE COATING ANALYSIS


stevew

Text Box

SECTION 02 83 33.13 ATTACHMENT 4.1 SPECTRA LABORATORIES - CRANE COATING ANALYSIS

Exhibit S

Specifications

Bid No. 15-65 Welding – 05 05 23 Page 1

SECTION 05 05 23

WELDING

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 DEFINITIONS ....................................................................................................... 3 1.3 SUBMITTALS ....................................................................................................... 3 1.4 QUALIFICATIONS .................................................................................................. 4 1.5 SEQUENCING AND SCHEDULING ............................................................................ 5

2.0 PRODUCTS ......................................................................................................... 5 2.1 DELIVERY STORAGE AND HANDLING ..................................................................... 5 2.2 SOURCE QUALITY CONTROL................................................................................. 6

3.0 EXECUTION ......................................................................................................... 6 3.1 GENERAL ............................................................................................................ 6 3.2 WELDING PROCEDURES ....................................................................................... 7 3.3 QUALIFICATION OF WELDERS ............................................................................... 8 3.4 WELDING EQUIPMENT .......................................................................................... 8 3.5 WELDING SHOWN ON DRAWINGS .......................................................................... 8 3.6 CONTROL OF DEFORMATIONS ............................................................................... 9 3.7 PREPARATION FOR WELDING................................................................................ 9 3.8 TEMPORARY WELDS ............................................................................................ 9 3.9 TACK WELDS .................................................................................................... 10 3.10 SURFACE FINISH OF WELDS ............................................................................... 10 3.11 EXAMINATION OF WELDS ................................................................................... 10 3.12 FIELD QUALITY CONTROL ................................................................................... 14 3.13 WELD DEFECT REPAIR ...................................................................................... 14

4.0 LIST OF APPENDICES ..................................................................................... 14 4.1 WELDING AND NONDESTRUCTIVE TESTING TABLE ................................................ 15

Exhibit S

Specifications


SECTION 05 05 23

WELDING

1.0 GENERAL


American Society of Mechanical Engineers (ASME) BPVC-V BPVC Section V-Nondestructive Examination BPVC-VIII BPVC Section VIII-Rules for Construction of Pressure

Vessels BPVC-IX BPVC Section IX-Welding, Brazing, and Fusing

Qualifications B31.1 Power Piping

American Society of Nondestructive Testing (ASNT) ASNT SNT-TC-1A Personnel Qualification and Certification in

Nondestructive Testing ASTM International (ASTM)

A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products American Welding Society (AWS)

A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination

A3.0M/A3.0 Standard Welding Terms and Definitions; Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting and Thermal spraying

D1.1/D1.1M Structural Welding Code – Steel D1.2/D1.2M Structural Welding Code Aluminum D1.3/D1.3M Structural Welding Code Sheet Steel D1.6/D1.6M Structural Welding Code Stainless Steel D14.1/D14.1M:97 Specification for Welding of Mill Cranes and other

Material Handling Equipment QC1 Standard for AWS Certification of Welding Inspectors

Exhibit S

Specifications


1.2 DEFINITIONS CJP: Complete Joint Penetration.

CWI: Certified Welding Inspector.

MT: Magnetic Particle Testing.

NDE: Nondestructive Examination.

NDT: Nondestructive Testing.

PJP: Partial Joint Penetration.

PQR: Procedure Qualification Record.

PT: Liquid Penetrant Testing.

RT: Radiographic Testing.

UT: Ultrasonic Testing.

VT: Visual Testing.

WPQ: Welder/Welding Operator Performance Qualification.

WPS: Welding Procedure Specification.

Principle Structural Weldments: as defined in AWS D14.1/D14.1M:97.

Primary Welds: as defined in AWS D14.1/D14.1M:97

Secondary Welds: as defined in AWS D14.1/D14.1M:97.

1.3 SUBMITTALS Submit the following in accordance with Section 01 30 00 Administrative Requirements. Provide a minimum of 30 calendar days prior to the work unless noted otherwise.

1.3.1 Action Submittals 1. Shop and field WPSs and PQRs. 2. NDT procedure specifications prepared in accordance with ASME BPVC

SEC V. 3. Welding Data (Shop and Field):

a. Show on Shop Drawings or weld map(s) complete information regarding base metal specification designation, location, type, size, and extent of

Exhibit S

Specifications


welds with reference called out for WPS and NDE numbers in tails of combined welding and NDE symbols as indicated in AWS A2.4.

b. Clearly distinguish between shop and field welds. c. Indicate, by welding symbols or sketches, details of welded joints and

preparation of base metal. Provide complete joint welding details showing bevels, groove angles, and root openings for welds.

d. Welding and NDE symbols shall be in accordance with AWS A2.4. e. Welding terms and definitions shall be in accordance with

AWS A3.0M/A3.0. f. Submit welding data together with Shop Drawings as a complete package.

4. Weld repair procedure: a. Welding repair procedure for major repairs after initial stress relief.

5. Stress-Relief Time-Temperature Charts: a. Stress-relief time-temperature charts, a maximum of 30 calendar days after

stress relieving parts.

1.3.2 Informational Submittals 1. WPQs. 2. CWI credentials. 3. Testing agency personnel credentials. 4. CWI reports. 5. Welding Documentation: Submit on appropriate forms in referenced welding

codes.

1.4 QUALIFICATIONS 1.4.1 WPSs In accordance with AWS D14.1/D14.1M:97 (Annex A Forms), AWS D1.1/D1.1M (Annex N Forms), or ASME BPVC SEC IX (Forms QW-482 and QW-483) as applicable.

1.4.2 WPQs In accordance with AWS D14.1/D14.1M:97 (Annex A Forms), AWS D1.1/D1.1M (Annex N Forms), or ASME BPVC SEC IX (Form QW-484) as applicable.

1.4.3 CWI Certified in accordance with AWS QC1, and having prior experience with the welding codes as specified. Alternate welding inspector qualifications require approval by the Engineer.

1.4.4 Testing Agency Personnel performing tests shall be NDT Level II or Level III certified in accordance with ASNT SNT-TC-1A, and shall meet minimum experience requirements specified.

Exhibit S

Specifications


1.5 SEQUENCING AND SCHEDULING Unless otherwise specified, all Submittals required in this section shall be submitted and approved prior to commencement of welding operations.

2.0 PRODUCTS

2.1 DELIVERY STORAGE AND HANDLING 2.1.1 General All filler metals, electrodes, fluxes, and other welding materials shall conform to the requirements of AWS D14.1/D14.1M:97, or referenced welding code, and be delivered to the site in manufacturers' original packages and stored in a dry space until used. Packages shall be properly labeled and designed to give maximum protection from moisture and to insure safe handling.

SMAW electrodes shall be handled, stored, and conditioned as outlined in AWS D1.1/D1.1M.

2.1.2 Material Control Materials shall be stored in a controlled access, clean, dry area that is weather-tight and is maintained at a temperature recommended by the manufacturer. The materials shall not be in contact with the floor and shall be stored on wooden pallets or cribbing. Storage and handling practices of welding consumables shall be in accordance with the manufacturer’s recommendations, or the applicable portions of AWS D1.1/D1.1M, whichever is the most stringent.

Low-hydrogen steel electrodes shall be stored in original sealed shipping container. If the seal is damaged during shipment or storage, and the damage is not immediately detected, the covered electrodes in that container shall be discarded. If a container is damaged in storage and the damage is witnessed, the electrodes from that container shall be immediately placed in a storage oven. The storage oven temperature shall be as recommended by the manufacturer or the welding material specification.

When a container of covered electrodes is opened and only a portion of the content is issued, the remaining portion shall, prior to use, be placed in an oven and dried in accordance with AWS D1.1.

2.1.3 Damaged Materials Damaged materials shall be discarded. All covered electrodes which are oil or water-soaked, dirty, or on which the flux has separated from the wire shall be discarded.

Exhibit S

Specifications


2.2 SOURCE QUALITY CONTROL Contractor’s CWI shall be present whenever shop welding is performed. CWI shall perform inspection, as necessary, prior to fit-up and assembly, during fit-up and assembly, during welding, and after welding. CWI shall perform inspections as required in AWS D14.1/D14.1M:97 or referenced welding code and as follows:

1. Verifying conformance of specified job material and proper storage 2. Monitoring conformance with approved WPS 3. Monitoring conformance of WPQ 4. Inspecting weld joint fit-up and performing in-process inspection 5. Providing 100 percent (100%) visual inspection of welds 6. Supervising nondestructive testing personnel and evaluating test results 7. Maintaining records and preparing report confirming results of inspection and

testing comply with the Work

3.0 EXECUTION

3.1 GENERAL All welding, welded joints and structures fabricated by welding shall be in accordance with the applicable welding code requirements and additional requirements, as specified below. Contractor shall ensure that suppliers comply with these requirements as they apply to the equipment being manufactured. Deviations from applicable codes, Approved procedures, and Approved detail drawings will not be permitted without prior written District Approval. Materials or components with welds made offsite will not be accepted if the welding does not conform to the requirements of this Specification. Procedure shall be developed by Contractor for welding all metals included in the Work. Welding operations shall not commence until welding procedures, welders, and welding operators have been qualified in accordance with the applicable welding code and Approved by the District.

Selection of welding processes and development of weld procedures is part of the design process established by Contractor which shall take into account the stress levels and use of the specific component. It is the responsibility of Contractor to ensure that welded joints are designed and sized in accordance with applicable codes and standards and the most advanced engineering standards and practices for each class of equipment.

Principle structural weldments, all primary welds, and all secondary welds used in the manufacture of the crane and crane components shall be designed, produced, qualified, inspected, accepted, and repaired in accordance with these specifications and AWS D14.1/D14.1M:97. Welding procedure specifications for all principle structural weldments, all primary welds, and all secondary welds used in the manufacture of the

Exhibit S

Specifications


crane and crane components shall be qualified for notch toughness by limiting heat input; charpy testing of weld metal and heat-affected zone shall be done as a part of the welding procedure qualification. Full-size specimens shall be charpy tested in accordance with ASTM A370 at a test temperature of -40°F. The minimum average energy of the test coupons shall not be less than 25 foot-pounds with no one specimen being less than 15 foot-pounds.

Welding and Fabrication by Welding for ancillary components and assemblies shall conform AWS D1.1/D1.1M or to governing welding codes referenced in attached Welding and Nondestructive Testing Table (Appendix 4.1).

Pipe and pipe related welds shall be designed, produced, qualified, inspected, accepted, and repaired in accordance with these Specifications and ASME B31.1. Welding procedure specifications for all pressure piping shall be qualified for notch toughness by limiting heat input; charpy testing of weld metal and heat-affected zone shall be done as a part of the welding procedure qualification. Full-size specimens shall be charpy tested in accordance with ASTM A370 at a test temperature of 30°F. The minimum average energy of the test coupons shall not be less than 25 foot-pounds.

All welded components and assemblies, which are to be machined, shall be stress relieved prior to final machining. The stress relief shall be performed in accordance with the requirements of the applicable welding specification.

As a minimum, the ‘Safe Practices’ as stated in Annex R of AWS D1.1 shall be followed. Welding screens/curtains shall be used at site to protect the casual passerby from welding operations. All field welding WPS’s shall conform to AWS D14.1/D14.1M:97 requirements.

Peening shall not be used unless specifically approved by Engineer. Welding shall only be done on materials above 50°F and on dry surfaces. Short circuiting arc GMAW is prohibited.

3.2 WELDING PROCEDURES Welding Procedure Specifications (WPS’s) for all welds shall be qualified in accordance with AWS D14.1/D14.1M or referenced welding code as applicable. Contractor shall prepare written WPS’s and PQR’s that specify all the essential variables in a format similar to the sample forms noted in AWS D14.1/D14.1M:97 (Annex A Forms), AWS D1.1 (Annex N Forms) or ASME BPVC SEC IX (Forms QW-482 and QW-483) as applicable. All WPS’s shall be approved by Engineer prior to use for fabrication.

Contractor shall ensure that approved WPS’s are in the presence of welding personnel prior to production welding and that the contents of the WPS are being followed.

Exhibit S

Specifications


3.3 QUALIFICATION OF WELDERS Contractor shall be responsible for the quality of the work performed by its welding organization. Welding Performance Qualification (WPQ’s) records for all welding personnel shall be qualified in accordance with AWS D14.1/D14.1M:97 or referenced welding code as applicable. Contractor shall prepare written WPQ’s that specify all the essential variables in a format similar to the sample forms noted in AWS D14.1/D14.1M:97, D1.1/D1.1M, and ASME BPVC Section IX as applicable.

Field welding and welding operator’s qualification test record shall be furnished to Engineer prior to the commencement of the Work. Factory welding and welding operator’s certificates shall be furnished to Engineer prior to the commencement of the Work, if requested. Welder qualification test records shall be maintained and kept current by Contractor for the duration of the Work.

When there is a specific reason to question the welder’s ability to make welds in accordance with these requirements, Engineer may request that the welder in question be retested. Contractor shall retrain or replace a welder if the welder cannot maintain the quality level as specified in these requirements to the satisfaction of Engineer.

3.4 WELDING EQUIPMENT All welding equipment, such as welding machines, torches, transformers, cables, electrodes, etc., for welding at the factory and at site shall be of reputable make and maintained in such condition as to enable qualified welders, welding operators, and tack welders to follow qualified welding procedures. Consumable material (electrodes etc.) shall be provided by Contractor. Only low hydrogen electrodes shall be used for SMAW. Filler metals shall be chosen by Contractor to suit the base metal and process used in accordance with above referenced standards.

For site operations, welding machines and leads shall be grounded at all times in a manner to prevent damage to surrounding equipment from welding currents.

3.5 WELDING SHOWN ON DRAWINGS Drawings submitted to Engineer for approval shall indicate the presence of welds. The following information shall be shown on, or supplied with, the drawings for each welded joint:

1. Type and size of weld, using AWS symbols, 2. Weld procedure employed, 3. Examination procedures and acceptance criteria applied.

Contractor shall also submit a welding map for each fabrication or assembly being welded, which identifies the associated welding process, WPS/PQR, and materials.

Exhibit S

Specifications


3.6 CONTROL OF DEFORMATIONS Contractor shall prepare detailed welding instructions for the major joints to minimize distortions in the pieces that will not be post weld heat treated for stress relief. Provisions shall be made to permit the checking and control of deformations during the welding process. The maximum permitted deformation values shall be determined as a function of the component to be welded and the tolerances and the gaps of the assembled parts.

3.7 PREPARATION FOR WELDING Members and sections to be joined by welding shall be cut accurately to size, with their edges sheared, flame-cut or machined to suit the required type of welding and to allow full penetration. The cut surfaces shall expose sound metal free from lamination or carburized material, or other injurious defects. The surfaces of members or sections to be welded shall be free from rust, grease, and other foreign matters for a distance of at least three (3) inches back from each edge of the weld.

Plates to be joined by welding shall be rolled by pressure to the required curvature, which shall be continuous from the edge. Flattening in the curvature along the edges with correction by blows is prohibited.

All butt joints shall be accurately aligned and retained in position during the welding operations so that the finished joint the projection of one plate beyond its adjoining plate shall be no more than 1/16 inch (1.5 mm). The throat gap for butt joints shall not exceed 1/8 inch (3 mm).

3.8 TEMPORARY WELDS Temporary welds shall be made under the controlled conditions prescribed herein for permanent work. All temporary welds shall be made by using welders qualified for permanent work as specified elsewhere in these Specifications. Preheat furnished for the temporary welds shall be the same as for permanent welds. In making temporary welds, arcs shall not be struck in other than weld locations. Each temporary weld and arc strike shall be removed, ground flush with adjacent surfaces, and the surfaces restored to their original condition.

All temporary bracing and attachments shall be removed, exercising care that the base metal to which they are attached is not adversely affected. Projecting welds remaining after this operation shall be chipped and ground flush. Tears in the base metal shall be welded and ground flush. Upon removing these attachments, the base metal shall be ground flush and inspected for cracks.

Exhibit S

Specifications


3.9 TACK WELDS Tack welds that are to be incorporated into the permanent work shall be subject to the same quality and qualification requirements as the permanent welds. Preheating shall be performed as specified for permanent welds. Such tack welds shall be cleaned and fused thoroughly with the permanent welds. Multi-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

3.10 SURFACE FINISH OF WELDS Welds shall in general be treated so that they display good appearance and a surface suitable for painting. Welds shall show uniform sections, smoothness of weld metal, feather-edges without overlap, and freedom from porosity. Structural welds shall be ground and blended to avoid stress risers. All welds that require radiographic or other nondestructive examination shall be dressed by chipping and grinding as required for good interpretation of radiographic film or interpretation by other weld examination methods. Details of weld dressing and finishing and NDT testing shall be shown on the drawings submitted for approval.

3.11 EXAMINATION OF WELDS 3.11.1 General Contractor shall submit procedures for review that shall define the areas, extent, and type of nondestructive examination employed. The nondestructive standards of welds shall be clearly indicated on the Drawings. Contractor shall submit all NDE records to District as requested. The detailed program for nondestructive examination of welds shall be submitted for review.

Inspectors shall be qualified to Level 2 or Level 3 of the American Society of Nondestructive Testing (ASNT). All welding shall be inspected to ensure that the welds conform to the requirements of these Specifications, the appropriate sections of AWS D14.1/D14.1M:97, ASME BPVC, or referenced welding code as applicable; and the approved welding procedure.

Inspections and tests shall be performed as necessary prior to welding, during welding, and after welding to ensure material and workmanship meet the requirements specified. In addition to visual inspection, all welds on weld-fabricated parts shall be given complete nondestructive examination. Supplemental radiographic examination shall include examination of critical high-stressed areas where interpretations of other methods are unclear, or where the integrity of the weld is doubtful.

3.11.2 Weld Inspection Criteria Selection of welds to be tested, unless 100% NDT is specified herein, shall be as agreed upon between Engineer and Contractor.

Exhibit S

Specifications


Unless otherwise specified, perform NDT of welds at a frequency as shown below or in the attached table (Appendix 4.1 – Welding and Nondestructive Testing Table) in accordance with the referenced welding codes as follows. Perform UT on CJP groove welds that cannot be readily radiographed. In case there is a conflict the higher frequency level of NDT shall apply. Visual inspection by Contractor’s CWI is required for all welding.

3.11.2.1 Primary Welds for Crane For all primary welds used in the manufacture of the crane and crane components, the Contractor shall perform nondestructive examinations in accordance with AWS D14.1/D14.1M:97; as a minimum the following examinations and frequency shall be performed at the Contractor’s expense.

1. CJP Butt Joint Welds: 100% volumetric exam (either UT or RT) and 100% MT or PT.

2. CJP Groove Welds: 100% volumetric exam (either UT or RT) and 100% MT or PT.

3. Multi Pass Welds: 100% MT of root pass. 4. Fillet Welds: 20% PT or MT 5. PJP Groove Welds: 50% PT or MT. 6. All Welds: 100% VT.

At a minimum the procedure for making, evaluating and reporting the radiographic testing (RT), ultrasonic testing (UT), magnetic particle inspection (MT), and liquid penetrant inspection (PT) of the welds shall conform to the requirements of AWS D14.1/D14.1M:97. For additional criteria see paragraph 3.11.4 Nondestructive Weld Testing Requirements of this section.

3.11.2.2 Secondary Welds for Crane For all secondary welds used in the manufacture of the crane and crane components, the Contractor shall perform nondestructive examinations in accordance with AWS D14.1/D14.1M:97; as a minimum the following examinations and frequency shall be performed at the Contractor’s expense.

1. CJP Butt Joint Welds: 100% volumetric exam (either UT or RT) and 100% MT or PT.

2. CJP Groove Welds: 100% volumetric exam (either UT or RT) and 100% MT or PT.

3. Multi Pass Welds: 100% MT of root pass. 4. Fillet Welds: 10% random PT or MT 5. PJP Groove Welds: 20% random PT or MT. 6. All Welds: 100% VT.

Exhibit S

Specifications


At a minimum the procedure for making, evaluating and reporting the radiographic testing (RT), ultrasonic testing (UT), magnetic particle inspection (MT), and liquid penetrant inspection (PT) of the welds shall conform to the requirements of AWS D14.1/D14.1M:97. For additional criteria see paragraph 3.11.4 Nondestructive Weld Testing Requirements.

3.11.3 District Quality Assurance All welds shall be subject to inspection by the District. District may require that coupons be cut from any location in any joint when doubt as to soundness cannot be resolved by nondestructive inspection.

District reserves the right to require Contractor to conduct additional nondestructive examination of any weld via PT, MT, UT and/or RT; in addition, the District reserves the right to hire a 3rd party inspection agency to perform PT, MT, UT and/or RT inspections on any weld at the District’s sole discretion. If defects are located as a result of any of these inspections; Contractor shall pay for all costs associated with the repairs and the inspection.

3.11.4 Nondestructive Weld Testing Requirements 3.11.4.1 General Weldments shall be subject to inspection to determine conformance with the requirements of ASME and AWS Codes, and provisions stated elsewhere in these Specifications. All welds and nondestructive testing shall be inspected by Contractor’s inspectors. NDT personnel qualifications shall be submitted. Methods and procedures of inspection, the evaluation of indications/defects and acceptance standards for indications/defects shall conform to these Specifications. Inspection reports shall compare the “as-found” condition with the applicable standard.

3.11.4.2 Visual Examination (VT) Prior to the use of any material, it shall be thoroughly visually examined to determine its suitability for use. All completed welds shall be cleaned and examined carefully for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement, contour and finish and other surface defects.

Acceptance Criteria: 1. Principle structural weldments, all primary welds, and all secondary welds used

in the manufacture of the crane and crane components: as per requirements of AWS D14.1/D14.1M:97.

2. All Other Structural Steel: AWS D1.1/D1.1M, Paragraph 6.9, Visual Inspection.

Exhibit S

Specifications


Defects shall be corrected or repaired as provided in the respective section of AWS D14.1/D14.1M or AWS D1.1 as applicable.

The individual performing the VT tests shall be an AWS certified welding inspector (CWI) with a minimum of two (2) years experience within the last three (3) years.

3.11.4.3 Liquid Penetrant Inspection (PT) The penetrant tests and inspection shall conform to the requirements of Appendix 8, Section VIII of the ASME BPVC, except that penetration time is 15 minutes minimum below 50°F. All indications exceeding the acceptance standards permitted by Appendix 8 of the ASME BPVC shall be repaired in accordance with AWS D14.1/D14.1M or AWS D1.1/D1.1M as applicable and reinspected per Appendix 8, at Contractor’s expense.

The individual performing the PT tests shall, as a minimum, be ASNT-TC-1A Level 2 qualified, with a minimum of one (1) year of current experience at this level.

3.11.4.4 Magnetic Particle Inspection (MT) The magnetic particle tests and inspection shall conform to the requirements of Appendix 6, Section VIII of the ASME BPVC. All indications exceeding the acceptance standards permitted by Appendix 6 of the ASME BPVC shall be repaired in accordance with AWS D14.1/D14.1M or AWS D1.1/D1.1M as applicable and reinspected per Appendix 6, at Contractor’s expense.

The individual performing the MT tests shall, as a minimum, be ASNT-TC-1A Level 2 qualified, with a minimum of one (1) year of current experience at this level.

3.11.4.5 Ultrasonic Inspection (UT) The services of an independent party shall be employed to ultrasonically test (UT) as specified herein. The individual performing the work shall, as a minimum, be ASNT-TC-1A Level 3 qualified, or Level 2 qualified with three (3) years of current experience at this level. Appropriate test blocks simulating the material to be tested shall be prepared for equipment calibration. Appropriate test heads shall be prepared and used with the ultrasonic equipment.

The ultrasonic tests and inspection shall conform to the requirements of Appendix 12, Section VIII of the ASME BVPC. All indications exceeding the acceptance standards permitted by Appendix 12 of the ASME BPVC shall be repaired in accordance with AWS D14.1/D14.1M or AWS D1.1/D1.1M as applicable and reinspected per Appendix 12, at Contractor’s expense.

Exhibit S

Specifications


A certified written report by the independent party shall be prepared and submitted to District. The report shall set forth the UT procedures used, equipment used, a mapping of the areas tested and interpretation of results, specifically addressing lack of bond or fusion, cracks, voids, and slag, the size and description of surface discontinuities and their accumulated total surface area relative to the inspected surface area, and the size and description of subsurface discontinuities.

3.11.4.6 Radiographic Examination The services of an independent party shall be employed to radiographically test as specified herein. The individual performing the work shall be, as a minimum, ASNT-TC-1A Level 3 qualified, or Level 2 qualified with three (3) years of current experience at this level.

All radiographic tests and inspection shall conform to the requirements of AWS D14.1/D14.1M.

All indications exceeding the acceptance standards permitted by AWS D14.1/D14.1M shall be repaired per AWS D14.1/D14.1M and re-inspected at Contractor’s expense.

3.12 FIELD QUALITY CONTROL The Contractor’s CWI shall be present whenever field welding is performed. The CWI shall perform inspection, as necessary, prior to assembly, during assembly, during welding, and after welding. CWI shall perform inspections as required in AWS D14.1/D14.1M or referenced welding code and as follows:

1. Verifying conformance of specified job material and proper storage 2. Monitoring conformance with approved WPS 3. Monitoring conformance of WPQ 4. Inspecting weld joint fit-up and performing in-process inspection 5. Providing 100% visual inspection of all welds 6. Supervising nondestructive testing personnel and evaluating test results 7. Maintaining records and preparing report confirming results of inspection and

testing comply with the Work

3.13 WELD DEFECT REPAIR Repair and retest rejectable weld defects until sound weld metal has been deposited in accordance with appropriate welding codes.


Appendix 4.1 – Welding and Nondestructive Testing Table

Exhibit S

Specifications


4.1 WELDING AND NONDESTRUCTIVE TESTING TABLE

Welding and Nondestructive Testing

Specification Section

Governing Welding Codes or Standards

Submit WPS

Submit WPQ

Onsite CWI

Req’d

Submit Written NDT Procedure Specifications NDT Requirements

05 05 23 Welding; and 41 22 10.13 Bridge Crane Mechanical Rehabilitation

(Welding requirements for Crane Primary and Secondary Structure)

AWS D14.1/D14.1M, 1997 Edition (NOT current edition) Specification for Welding of Mill Cranes and other Material Handling Equipment.

Yes Yes Yes Yes 100% VT

100% UT/RT for all full-penetration welds

Varying MT/PT for other welds, see Paragraph 3.11

05 05 23 Welding (requirements for welded steel pipe and fittings)

ASME BPVC, Section IX; and AWS D1.1/D1.1M, Structural Welding Code - Steel

Yes Yes Yes Yes 100% VT; see paragraph 3.1, General

05 50 00 Metal Fabrications

AWS D1.1/D1.1M, Structural Welding Code–Steel or AWS D1.2/D1.2M, Structural Welding Code Aluminum or AWS D1.6/D1.6M, Structural Welding Code Stainless Steel

Yes Yes Yes Yes 100% VT; also see Section 05 50 00.

Also see paragraph 3.11 Examination of Welds for NDT requirements for Primary and Secondary welds.

05 56 00 Castings

ASME BPVC, Section V and Section VIII

Yes Yes Yes Yes 100% VT; also see Section 05 56 00.

05 58 00 Forgings

ASME BPV Code, Section V and Section VIII

Yes Yes Yes Yes 100% VT; also see Section 05 58 00


Exhibit S

Specifications

Bid No. 15-65 Fasteners – 05 05 24 Page 1

SECTION 05 05 24

FASTENERS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 GENERAL REQUIREMENTS.................................................................................... 2 1.2 REFERENCES ...................................................................................................... 2 1.3 SUBMITTALS ....................................................................................................... 4

2.0 PRODUCTS ......................................................................................................... 4 2.1 MACHINE BOLTS, STUDS, SCREWS, AND WASHERS ............................................... 4 2.2 HIGH STRENGTH STRUCTURAL BOLTS .................................................................. 5

3.0 EXECUTION ......................................................................................................... 6 3.1 BOLTED CONNECTIONS ........................................................................................ 6 3.2 SET SCREWS ...................................................................................................... 6

Exhibit S

Specifications


SECTION 05 05 24

FASTENERS

1.0 GENERAL

1.1 GENERAL REQUIREMENTS Bolts, studs, nuts and screws shall conform to ASME standard thread forms and dimensions and be of high quality material.

All bolts, studs, nuts and screws (including their washers) shall be well protected against corrosion according to the site of their installation or made of corrosion resistant material. Fastener materials shall be as close together as possible in the galvanic series to minimize electrical potential differences. Fitted bolts shall be a driving fit in reamed holes they occupy, shall have the screwed portion of a diameter such that it will not be damaged in driving and shall be marked in a conspicuous position to ensure correct assembly at Site.

Washers, locking devices and anti-vibration arrangements shall be provided and shall be subject to the approval of Engineer. Taper washers shall be fitted where necessary.

Nuts, bolts and screws that might become loose during operation shall be locked in fastened position by means Approved by Engineer.

All torque values shall be stated on the Shop Drawings or torque value listing.

Bolts, nuts and studs, except for fitting-up bolts and shaft coupling bolts, shall be as specified below.

Zinc plated fasteners are prohibited.


American Society of Mechanical Engineers (ASME) B1.1 Unified Inch Screw Threads (UN and UNR Thread Form) B1.15 Unified Inch Screw Threads (UNJ Thread Form) B1.13M Metric Screw Threads (M Profile) B1.21M Metric Screw Threads (MJ Profile) B18.2.1 Square and Hex Bolts and Screws (Inch Series) B18.2.3.1M Metric Hex Cap Screws B18.2.3.2M Metric Formed Hex Screws

Exhibit S

Specifications


American Society of Mechanical Engineers (ASME) B18.2.3.3M Metric Heavy Hex Screws B18.2.3.4M Metric Hex Flange Screws B18.2.3.5M Metric Hex Bolts B18.2.3.6M Metric Heavy Hex Bolts B18.2.3.7M Metric Heavy Hex Structural Bolts B18.2.3.8M Metric Hex Lag Screws B18.2.3.9M Metric Heavy Hex Flange Screws B18.2.2 Square and Hex Nuts B18.2.4.1M Metric Hex Nuts, Style 1 B18.2.4.2M Metric Hex Nuts, Style 2 B18.2.4.3M Metric Slotted Hex Nuts B18.2.4.4M Metric Hex Flange Nuts B18.2.4.5M Metric Hex Jam Nuts B18.2.4.6M Metric Heavy Hex Nuts B18.3 Socket Cap, Shoulder, and Set Screws, Hex and Spline Keys

(Inch Series) B18.6.2 Slotted Head Cap Screws, Square Head Set Screws, and

Slotted Headless Set Screws B18.3.1M Socket Head Cap Screws B18.6.3 Machine Screws and Machine Screw Nuts B18.6.7M Metric Machine Screws B18.21.1 Lock Washers (Inch Series) B18.22M Metric Plain Washers B18.22.1 Plain Washers

ASTM International (ASTM) A307 Specification for Carbon Steel Bolts and Studs, 60,000 PSI

Tensile A325 Specification for Structural Bolts, Steel, Heat Treated

120/105 ksi Minimum Tensile Strength A490 Specification for Structural Bolts, Steel, Heat Treated, 150 ksi

Minimum Tensile Strength A563 Specification for Carbon and Alloy Steel Nuts F436 Specification for Hardened Steel Washers

Society of Automotive Engineers (SAE) J429 Mechanical and Material Requirements for Externally

Threaded Fasteners J1199 Mechanical and Material Requirements for Metric Externally

Threaded Steel Fasteners

Exhibit S

Specifications


1.3 SUBMITTALS

1.3.1 Informational Submittals 1. High-Strength Bolts (Plain Noncoated and Hot-Dip Galvanized):

a. Certificates of Compliance that products meet chemical and mechanical requirements of standards specified.

b. Manufacturer’s inspection test report results for production lot(s) furnished, to include: 1) Tensile strength. 2) Yield strength. 3) Reduction of area. 4) Elongation and hardness.

c. Certified Mill Test Reports for Bolts and Nuts: 1) Name and address of manufacturer. 2) Bolts correctly marked. 3) Marked bolts and nuts used in required mill tests and manufacturer’s

inspection tests.

2.0 PRODUCTS

2.1 MACHINE BOLTS, STUDS, SCREWS, AND WASHERS 2.1.1 General Machine bolts, studs, screws and washers furnished as an integral part of a catalog item shall conform to the manufacturer's standard practice. Except where otherwise specified, machine bolts, studs, screws and washers shall conform to the applicable requirements specified herein.

2.1.2 Threads All bolts, studs, machine screws, nuts and tapped holes shall be threaded in accordance to either ASME B1.1, B1.15 for U.S. Customary forms, or ASME B1.13M, B1.21M for metric forms.

Fine pitched threads shall be made to Class 3 tolerances for U.S. Customary forms and to Class 4h & 5H for metric bolts and nuts respectively.

Fasteners subjected to fatigue loads shall have rolled UNJ or MJ thread forms.

2.1.3 Bolts Bolts shall be finished hex bolts conforming to either ASME 18.2.1 for U.S. Customary or ASME B18.2.3.xM for metric.

Exhibit S

Specifications


Carbon steel bolts shall be SAE J429 Grade 2 or higher and/or SAE J1199 Grade 5.8 or higher, or Engineer Approved equal.

2.1.4 Nuts Nuts shall be finished hex nuts conforming to either ASME B18.2.2 or ASME B18.2.4.xM.

Nuts and tapped holes shall be selected / designed to support more load than the bolt, and to minimize galling.

2.1.5 Cap and Set Screws Cap and set screws shall conform to the applicable requirements of ASME B18.3 and/or ASME B18.6.2 for U.S. Customary screws, and to ASME B18.3.1M for metric screws.

The hardness of socket head cap screws utilized in load carrying members shall not exceed Rockwell C40.

2.1.6 Machine Screws and Nuts Machine screws and nuts shall conform to the requirements of ASME B18.6.3 for U.S. Customary screws, and to ASME B18.6.7M for metric screws.

2.1.7 Washers Plain washers shall be hardened and conform to the requirements of ASME B18.22.1 for U.S. Customary and to ASME B18.22M for metric.

Lock washers shall conform to the requirements of ASME B18.21.1 for helical spring type.

2.2 HIGH STRENGTH STRUCTURAL BOLTS High-Strength Bolts:

1. ASTM A325 bolt type, plain non-coated and galvanized. Bolt length and thread length shall be as required for the connection type, with hardened washers as required.

2. ASTM A490 bolt type 3, plain non-coated. Bolt length and thread length shall be as required for the connection type, with hardened washers as required.

Nuts: ASTM A563, type to match bolt type and finish.

Hardened Steel Flat and Beveled Washers: ASTM F436, type to match bolt finish.

Exhibit S

Specifications


3.0 EXECUTION

3.1 BOLTED CONNECTIONS 3.1.1 General Bolts, nuts, and washers shall be of the type specified or as indicated on the Drawings. All nuts shall be equipped with washers except as indicated otherwise. Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Where the use of high strength bolts is specified, the materials, workmanship, and installation shall conform to the applicable provisions of the specification for Structural Joints Using ASTM A325 or ASTM A490 Bolts issued by the Research Council on Riveted and Bolted structural Joints of the Engineering Foundation. Ribbed bolts will not be acceptable.

3.1.2 Bolt Holes 1. Regular Bolts: Holes for regular bolts shall be drilled or subdrilled and reamed.

Holes shall be accurately located, smooth, perpendicular to the member, cylindrical and not more than 1/16-inch larger than the diameter of the bolt, unless shown or noted otherwise.

2. Fitted Bolts: Holes for fitted bolts shall be match-reamed or drilled. Holes shall be smooth, perpendicular to the member and cylindrical. Burrs resulting from reaming shall be removed. The threads shall be entirely outside of the holes. The body diameter of the bolt shall have tolerances as recommended by ASME B4.1 for the class to fit specified. Fitted bolts shall be fitted in reamed holes by selective assembly to provide an LC 7 or closer tolerance fit.

3. High Strength Bolts: Holes for high strength bolts shall be accurately spaced, cylindrical and perpendicular to the member. The diameter of the hole shall be not more than 1/16-inch larger than the bolt diameter. If the thickness of the material is not greater than the diameter of the bolt, the holes may be punched. If the thickness of the material is greater than the diameter of the bolt, the holes will be either drilled full size or shall be sub-punched or sub-drilled at least 1/8-inch smaller than the diameter of the bolt and then reamed to full size. Poor matching of holes will be cause for rejection. Drifting done during assembly shall not distort the metal or enlarge the holes.

3.2 SET SCREWS Set screws shall be of the socket type, with sockets of the hexagonal or multisplined shape. Set screws shall not be used for transmitting torsion. Set screws shall be installed using Loctite.


Exhibit S

Specifications

Bid No. 15-65 Metal Fabrications – 05 50 00 Page 1

SECTION 05 50 00

METAL FABRICATIONS

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 DEFINITIONS ....................................................................................................... 4 1.3 SUBMITTALS ....................................................................................................... 5 1.4 QUALITY ASSURANCE .......................................................................................... 5 1.5 DELIVERY, STORAGE, AND HANDLING ................................................................... 5

2.0 PRODUCTS ......................................................................................................... 6 2.1 GENERAL ............................................................................................................ 6 2.2 ACCESSORIES ..................................................................................................... 6 2.3 FABRICATION ...................................................................................................... 7 2.4 SOURCE QUALITY CONTROL................................................................................. 9

3.0 EXECUTION ......................................................................................................... 9 3.1 INSTALLATION OF METAL FABRICATIONS ................................................................ 9 3.2 ACCESS COVERS .............................................................................................. 10 3.3 ELECTROLYTIC PROTECTION .............................................................................. 10 3.4 REPAIR OF GALVANIZED STEEL .......................................................................... 11

Exhibit S

Specifications


SECTION 05 50 00

METAL FABRICATIONS

1.0 GENERAL


The Aluminum Association (AA) ADM The Aluminum Design Manual

American Galvanizers Association (AGA) Inspection of Products Hot-Dip Galvanized After Fabrication

American Institute of Steel Construction (AISC) S329 Allowable Stress Design Specification for Structural Joints

using ASTM A325 or A490 Bolts American Iron and Steel Institute (AISI)

Stainless Steel Types American Ladder Institute (ALI)

ANSI-A14.3 Ladders - Fixed - Safety Requirements American National Standards Institute (ANSI)

American Society of Mechanical Engineers (ASME)

B1.1 Unified inch Screw Threads (UN and UNR Thread Form) American Welding Society (AWS)

D1.1/D1.1M Structural Welding Code - Steel D1.2/D1.2M Structural Welding Code Aluminum D1.6/D1.6M Structural Welding Code Stainless Steel

ASTM International (ASTM) A36/A36M Standard Specification for Carbon Structural Steel A53/A53M Standard Specification for Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless A108 Standard Specification for Steel Bar, Carbon and Alloy,

Cold-Finished A123/A123M Standard Specification for Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products

Exhibit S

Specifications


ASTM International (ASTM) A143/A143M Standard Practice for Safeguarding Against Embrittlement of

Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement

A148/A148M Standard Specification for Steel Castings High Strength, for Structural Purposes

A153/A153M Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

A193/A193M Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

A194/A194M Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both

A240/A240M Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

A276/A276M Standard Specification for Stainless Steel Bars and Shapes A283/A283M Specification for Low and Intermediate Tensile Strength

Carbon Steel Plates A307 Standard Specification for Carbon Steel Bolts, Studs, and

Threaded Rod 60000 PSI Tensile Strength A325 Standard Specification for Structural Bolts, Steel, Heat

Treated, 120/105 ksi Minimum Tensile Strength A380/A380M Standard Practice for Cleaning, Descaling, and Passivation of

Stainless Steel Parts, Equipment, and Systems A384/A384M Standard Practice for Safeguarding Against Warpage and

Distortion During Hot-Dip Galvanizing of Steel Assemblies A385/A385M Standard Practice for Providing High-Quality Zinc Coatings

(Hot-Dip) A500/A500M Standard Specification for Cold-Formed Welded and

Seamless Carbon Steel Structural Tubing in Rounds and Shapes

A501/A501M Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing

A563 Standard Specification for Carbon and Alloy Steel Nuts A653/A653M Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

A780/780M Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

A967/A967M Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts

A992/A992M Standard Specification for Structural Steel Shapes

Exhibit S

Specifications


ASTM International (ASTM) B209 Standard Specification for Aluminum and Aluminum-Alloy

Sheet and Plate B308/B308M Standard Specification for Aluminum-Alloy 6061-T6 Standard

Structural Profiles B429/B429M Standard Specification for Aluminum-Alloy Extruded Structural

Pipe and Tube D1056 Standard Specification for Flexible Cellular Materials—

Sponge or Expanded Rubber F436 Standard Specification for Hardened Steel Washers F468 Standard Specification for Nonferrous Bolts, Hex Cap Screws,

Socket Head Cap Screws, and Studs for General Use F593 Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs F594 Specification for Stainless Steel Nuts F844 Specification for Washers, Steel, Plain (Flat), Unhardened for

General Use F1554 Standard Specification for Anchor Bolts, Steel, 36, 55, and

105-ksi Yield Strength

Occupational Safety and Health Administration (OSHA) 29 CFR 1910.27 Fixed Ladders 29 CFR 1926.105 Safety Nets 29 CFR 1926.502 Fall Protection Systems Criteria and Practices

Specialty Steel Industry of North America (SSINA) Design Guidelines for the Selection and Use of Stainless Steel - Designer Handbook Specifications for Stainless Steel - Designer Handbook Stainless Steel Fabrication - Designer Handbook Stainless Steel Fasteners - Designer Handbook

1.2 DEFINITIONS Corrosive Area: Containment area or area exposed to delivery, storage, transfer, or use of chemicals.

Exterior Area: Location not protected from the weather by a building or other enclosed structure.

Interior Dry Area: Location inside building or structure where floor is not subject to liquid spills or washdown, nor where wall or roof slab is common to a water-holding or earth-retaining structure.

Exhibit S

Specifications


1.3 SUBMITTALS Submit the following in accordance with Section 01 30 00, Administrative Requirements.

1.3.1 Action Submittals Shop Drawings:

Metal fabrications, including welding and fastener information. 1.3.2 Informational Submittals

Ladders: Letter of certification that ladder meets OSHA 29 CFR 1910.27 requirements.

Hot-Dip Galvanizing: Certificate of compliance signed by galvanizer, with description of material processed and ASTM standard used for coating.

Passivation method for stainless steel members.

1.4 QUALITY ASSURANCE 1.4.1 Qualifications A Galvanized Coating Applicator: Company specializing in hot-dip galvanizing after fabrication and following procedures of Quality Assurance Manual of the American Galvanizers Association.

1.5 DELIVERY, STORAGE, AND HANDLING Insofar as practical, factory assemble items specified herein. Assemblies that due to necessity have to be shipped unassembled, shall be packaged and tagged in manner that will protect materials from damage and will facilitate identification and field assembly.

Package stainless steel items in a manner to provide protection from carbon impregnation.

Protect painted coatings and hot-dip galvanized finishes from damage due to metal banding and rough handling. Use padded slings and straps.

Store fabricated items in dry area, not in direct contact with ground.

Exhibit S

Specifications


2.0 PRODUCTS

2.1 GENERAL Unless otherwise indicated, meet the following requirements:

Item ASTM Reference Steel Wide Flange Shapes A992/992M

Other Steel Shapes and Plates A36/A36M

Steel Pipe A501/A501M or A53/A53M, Type E or S, Grade B

Hollow Structural Sections A500/A500M, Grade B

Stainless Steel:

Bars and Angles A276, AISI Type 316 (316L for welded connections)

Shapes A276, AISI Type 304 (304L for welded connections)

Steel Plate, Sheet, and Strip A240/A240M, AISI Type 316 (316L for welded connections)

Aluminum Plates and Structural Shapes B209 and B308/B308M, Alloy 6061-T6

Aluminum Bolts and Nuts F468, Alloy 2024-T4

Bolts, Washers, and Nuts: As specified in 05 05 24 Fasteners.

Hinges: Heavy-duty brass or stainless steel with stainless steel pins.

Fabricated Steel: ASTM A36/A36M.

2.2 ACCESSORIES 2.2.1 Anti-seizing Lubricant for Stainless Steel Threaded Connections:

1. Suitable for potable water supply. 2. Resists washout. 3. Manufacturers and Products:

a. Bostik, Middleton, MA; Never-Seez. b. SAF-T-EZE Div., STL Corp., Lombard, IL; Anti-Seize.

Exhibit S

Specifications


2.2.2 Neoprene Gasket: 1. ASTM D1056, 2C1, soft, closed-cell neoprene gasket material, suitable for

exposure to sewage and sewage gases, unless otherwise shown on Drawings. 2. Thickness: Minimum 1/4 inch. 3. Furnish without skin coat. 4. Manufacturer: Rubatex Corporation, Bedford, VA.

2.3 FABRICATION 2.3.1 General Finish exposed surfaces smooth, sharp, and to well-defined lines.

Furnish necessary rabbets, lugs, and brackets so work can be assembled in neat, substantial manner.

Conceal fastenings where practical; drill metalwork and countersink holes as required for attaching hardware or other materials.

Grind cut edges smooth and straight. Round sharp edges to small uniform radius. Grind burrs, jagged edges, and surface defects smooth.

Fit and assemble in largest practical sections for delivery to site.

2.3.2 Materials Use steel shapes, unless otherwise noted.

Steel to be hot-dip galvanized: Limit silicon content to less than 0.04 percent or to between 0.15 and 0.25 percent.

Fabricate aluminum in accordance with AA Specifications for Aluminum Structures – Allowable Stress Design.

2.3.3 Welding Weld connections and grind exposed welds smooth. When required to be watertight, make welds continuous.

Welded fabrications shall be free from twisting or distortion caused by improper welding techniques.

Steel: Meet fabrication requirements of AWS D1.1/D1.1M, Section 5.

Aluminum: Meet requirements of AWS D1.2/D1.2M.

Stainless Steel: Meet requirements of AWS D1.6/D1.6M.

Exhibit S

Specifications


Complete welding before applying finish.

2.3.4 Painting Shop prime with rust-inhibitive primer as specified in Section 09 90 04, Painting, unless otherwise indicated.

Do not apply protective coating to galvanized steel anchor bolts or galvanized steel welded anchor studs, unless indicated otherwise.

2.3.5 Galvanizing Fabricate steel to be galvanized in accordance with ASTM A143/A143M, ASTM A384/A384M, and ASTM A385/385M. Avoid fabrication techniques that could cause distortion or embrittlement of the steel.

Provide venting and drain holes for tubular members and fabricated assemblies in accordance with ASTM A385/A385M.

Remove welding slag, spatter, burrs, grease, oil, paint, lacquer, and other deleterious material prior to delivery for galvanizing.

Remove by blast cleaning or other methods surface contaminants and coatings not removable by normal chemical cleaning process in the galvanizing operation.

Hot-dip galvanize steel members, fabrications, and assemblies after fabrication in accordance with ASTM A123/A123M.

Hot-dip galvanize bolts, nuts, washers, and hardware components in accordance with ASTM A153/A153M. Oversize holes and nut threads to allow for zinc alloy growth. Shop-assemble bolts and nuts.

Galvanized steel sheets in accordance with ASTM A653/A653M.

Galvanize components of bolted assemblies separately before assembly. Galvanizing of tapped holes is not required.

2.3.6 Watertight Seal Where required or shown, furnish neoprene gasket of a type that is satisfactory for use in contact with water. Cover full bearing surfaces.

2.3.7 Fitting Where movement of fabrications is required or shown, cut, fit, and align items for smooth operation. Make corners square and opposite sides parallel.

Exhibit S

Specifications


2.3.8 Accessories Furnish as required for a complete installation. Fasten by welding or with stainless steel bolts or screws.

2.4 SOURCE QUALITY CONTROL 2.4.1 Visually inspect all fabrication welds and correct any deficiencies.

1. Steel: AWS D1.1/D1.1M, Section 6 and Table 6.1, Visual Inspection Acceptance Criteria.

2. Aluminum: AWS D1.2/D1.2M. 3. Stainless Steel: AWS D1.6/D1.6M.

2.4.2 Hot-Dip Galvanizing

1. An independent testing agency shall be retained by Contractor and approved by Engineer to inspect and test hot-dip galvanized fabricated items in accordance with ASTM A123/A123M and ASTM A153/A153M.

2. Visually inspect and test for thickness and adhesion of zinc coating for minimum of three test samples from each lot in accordance with ASTM A123/A123M and ASTM A153/A153M.

3. Reject and retest nonconforming articles in accordance with ASTM A123/A123M and ASTM A153/A153M.

3.0 EXECUTION

3.1 INSTALLATION OF METAL FABRICATIONS 3.1.1 General Install metal fabrications plumb or level, accurately fitted, free from distortion or defects.

Install rigid, substantial, and neat in appearance.

Install manufactured products in accordance with manufacturer’s recommendations.

Obtain Engineer approval prior to field cutting steel members or making adjustments not scheduled.

Anti-seizing Lubricant: Use on all stainless steel threads.

3.1.2 Aluminum Do not remove mill markings from concealed surfaces.

Remove inked or painted identification marks on exposed surfaces not otherwise coated after installed material has been inspected and approved.

Exhibit S

Specifications


Fabrication, mechanical connections, and welded construction shall be in accordance with the AA Aluminum Design Manual.

3.2 ACCESS COVERS Install access covers, floor hatches, and hinged covers in accordance with manufacturer’s instructions.

Accurately position such that covers are flush with floor surface.

3.3 ELECTROLYTIC PROTECTION 3.3.1 Aluminum and Galvanized Steel Coat surfaces of galvanized steel and aluminum fabricated items to be in direct contact with dissimilar metals, as specified in Section 09 90 04 Painting, unless indicated otherwise.

Do not apply protective coating to galvanized steel anchor bolts or galvanized steel welded anchor studs, unless indicated otherwise.

Allow coating to dry before installation of the material.

Protect coated surfaces during installation.

Should coating become marred, prepare and touch up in accordance with paint manufacturer’s written instructions.

3.3.2 Stainless Steel During handling and installation, take necessary precautions to prevent carbon impregnation of stainless steel members.

After installation, visually inspect stainless steel surfaces for evidence of iron rust, oil, paint, and other forms of contamination.

Remove contamination using cleaning and passivation methods in accordance with requirements of ASTM A380/A380M and ASTM A967/A967M.

Brushes used to remove foreign substances shall utilize only stainless steel or nonmetallic bristles.

After treatment, visually inspect surfaces for compliance.

Exhibit S

Specifications


3.4 REPAIR OF GALVANIZED STEEL Repair of Damaged Hot-Dip Galvanized Coating:

1. Conform to ASTM A780/A780M. 2. For minor repairs at abraded areas, use sprayed zinc conforming to

ASTM A780/A780M. 3. For flame cut or welded areas, use zinc-based solder, or zinc sticks, conforming

to ASTM A780/A780M. 4. Use magnetic gauge to determine that thickness is equal to or greater than the

base galvanized coating.


Exhibit S

Specifications

Bid No. 15-65 Castings – 05 56 00 Page 1

SECTION 05 56 00

CASTINGS

TABLE OF CONTENTS


2.0 PRODUCTS ......................................................................................................... 3 2.1 CASTINGS GENERAL ............................................................................................ 3 2.2 SOURCE QUALITY CONTROL................................................................................. 3

3.0 EXECUTION ......................................................................................................... 4 3.1 REPAIR OF CASTINGS .......................................................................................... 4 3.2 FIELD QUALITY CONTROL ..................................................................................... 5

Exhibit S

Specifications


SECTION 05 56 00

CASTINGS

1.0 GENERAL

1.1 GENERAL REQUIREMENTS This Section includes general requirements for castings. Unless modified by mutual agreement between Contractor and Engineer, testing and nondestructive examination of castings shall be as specified herein and Section 41 05 13.13 Basic Mechanical Requirements for Bridge Cranes.


American Society of Mechanical Engineers (ASME) BPVC-VIII-1 BPVC Section VIII-Rules for Construction of Pressure

Vessels Division 1 BPVC-V BPVC Section V-Nondestructive Examination

ASTM International (ASTM) A370 Standard Test Methods and Definitions for Mechanical

Testing of Steel Products

1.3 SUBMITTALS

1.3.1 Informational Submittals 1. Certificates of Compliance that products meet chemical and mechanical

requirements of standards specified. 2. Certificates of Compliance that castings meet the design requirements for the

equipment. 3. Qualifications of the individuals performing inspection, nondestructive

examination, and repairing. 4. Manufacturer’s inspection test and examination reports.

Exhibit S

Specifications


2.0 PRODUCTS

2.1 CASTINGS GENERAL Castings shall be true to pattern, of workmanlike finish, free from blowholes, porosity, hard spots, shrinkage defects, cracks, or other injurious defects, and shall be satisfactorily cleaned for inspection. The structure of castings shall be homogeneous and free from excessive nonmetallic inclusions. All joints shall be machined; all bolt head and nut locations shall be spot faced; and castings shall be machined on any part which acts as a bearing surface. The surfaces of castings which are not machined shall be free from excessive foundry irregularities, such as projections, ridges, hollows, honeycombing, pock marks, or chip marks, so that they will not require smoothing operations prior to painting. All bronze castings for bushings and bearings shall be centrifugally cast. Castings shall be produced in accordance with procedures and instructions developed for the castings. Contractor shall have available documentation demonstrating that the casting process has been undertaken with an implemented and enforced quality control program sufficient to demonstrate that the following requirements have been achieved for the specific design of the casting.

1. Dimensional accuracy of the patterns and cores; 2. Dimensional accuracy and features of the mold; 3. Metallurgy and temperature control of the melt; 4. Pouring or casting process including metallurgical aspects of preheat, rate of

pouring, cooling and shakeout; 5. Dimensional accuracy of castings; 6. Visual examinations; 7. Nondestructive examinations; 8. Repairs; and 9. Stress relieving.

Large fillets compatible with the design shall be incorporated wherever a change in section occurs. The casting molds and casting practice shall be designed to minimize the occurrence of high stresses and defects caused by the mold.

2.2 SOURCE QUALITY CONTROL 2.2.1 Material Testing Test coupons shall be provided for major castings. The test coupons shall be subject to the normal physical tests. Normalized castings shall also be inspected by microstructure examination to confirm full heat treatment (normalization) of the material.

Exhibit S

Specifications


2.2.2 Dimensions Dimensions of castings shall not be reduced due to shop or foundry practices by an amount sufficient to impair the strength of castings by more than 10%, as calculated from Shop Drawing dimensions. Dimensions shall not be oversized to the extent that a casting interferes with processing operations or proper fit with other parts. Warped or otherwise distorted castings shall not be used without submitting complete details for Engineer’s review.

3.0 EXECUTION

3.1 REPAIR OF CASTINGS Defects in castings shall be reported to Engineer with recommendations for repair or rejection. A complete descriptive report of defects, supplemented with sketches, photographs, and metallurgical test reports, as the case may warrant, shall be submitted for Engineer review. Castings shall be repaired only when the defects are small and/or when the strength, use, or machinability of the casting is not adversely affected. Repairs in excess of that permitted by the applicable ASTM standard shall not be made on the castings after final stress relieving of the casting without acceptance by Engineer. Injurious defects in iron castings shall not be repaired without prior agreement of Engineer. For purposes of these Specifications, the interpretation of an "injurious defect" shall be as defined in paragraph 3.2.1, Definitions of this section. Steel castings may be repaired by welding, provided that the strength, use, or machinability of the casting is not adversely affected. Prior to weld repairs, injurious defects shall be completely removed to sound metal. Bridging of unsuitable material will not be accepted. Samples of unusual defects shall be removed, and afterwards retained and tested in order to determine the cause of the defect. An excessive segregation of impurities or alloys in a casting shall be cause for its rejection by District. If Contractor submits proof in writing for Engineer’s review that such defects may be accepted as is, or successfully repaired, then due consideration may be given. Repair of major defects shall be made on the castings in the foundry prior to final stress relieving of the castings. Repair welds shall be done in accordance with the requirements specified in Section 05 05 23 Welding. Under no circumstances shall welds in excess of those permitted by the applicable ASTM standard be applied after stress relieving unless agreed to in writing by Engineer.

Exhibit S

Specifications


3.2 FIELD QUALITY CONTROL 3.2.1 Definitions The following definitions shall be used in classifying defects: 3.2.1.1 Injurious Defects A defect shall be considered injurious if its presence impairs the strength of the casting, causes unacceptable stress concentration, or affects machinability. All linear discontinuities shall be considered injurious. All injurious defects shall be completely removed and repairs carried out to make the casting satisfactory for its intended purpose. Unusual defects such as excessive segregation shall be brought to the attention of District. Samples shall be tested to determine the cause. 3.2.1.2 Major Defects Major defects shall be defined as those whose cavities, after preparation for welding, have depths requiring weld repair greater than 20% of the metal thickness, or one (1) inch, whichever is the lesser, or have depths requiring weld repair greater than one-half (½) inch over a continuous area of six (6) inches by six (6) inches or more. 3.2.1.3 Minor Defects Minor defects shall be defined as those whose cavities, after removal of the defect, require repair welding less than the limits specified for major defects. However, an accumulation of minor defects, which in the opinion of Engineer casts doubts as to the general casting quality shall be considered as a major defect. Minor defects that will not impair the strength or serviceability of the castings may be repaired by welding in accordance with an established commercial casting repair procedure without prior review. 3.2.1.4 Other Defects In general, other visible defects such as blowholes and sand spots shall be considered injurious only if they are closely grouped or if they fall within fillets or areas designated for special inspection. 3.2.1.5 Centerline Shrinkage However, centerline shrinkage in bolting flanges or other stressed areas shall be considered injurious, and shall be reported to District for review. These shall be repaired where there is a risk of interference with machining operations. 3.2.2 Examination of Castings

Exhibit S

Specifications


3.2.3 General After removing from the mold, and heat treatment and clean up is done, an initial examination of all major castings shall be carried out by 100% visual inspection, 100% ultrasonic inspection and 100% magnetic particle inspection; except for non-magnetic stainless steels where 100% ultrasonic and 100% liquid penetrant examination shall be done. Ultrasonic inspection shall be performed by Contractor on all bolting flanges and whenever a subsurface defect is suspected. Defects in castings shall be reported to Engineer with recommendations for repair or rejection. Repairs are subject to approval of Engineer. 3.2.4 Major Castings For all major castings, after repair of casting defects, heat treatment and final machining has been completed, a final examination of the finished surface of the casting shall be carried out by 100% visual and 100% liquid penetrant methods. Major castings incorporated in the equipment or their components which are castings shall be given complete nondestructive examination by ultrasonic, dye penetrant, and magnetic particle methods supplemented by radiographic examination. Supplemental radiographic examination shall include examination of critical high-stressed areas where interpretation of other methods is unclear or where the integrity of the casting is doubtful. Nondestructive examination of other castings shall be in accordance with accepted good practice to assure sound castings and shall be indicated on the Drawings. 3.2.5 Steel Castings The nondestructive examination of steel castings shall be in accordance with the following methods and acceptance standards:

EXAMINATION METHOD

STANDARD FOR METHOD

STANDARD FOR ACCEPTANCE

Radiographic ASME Sec. V, Art. 2 ASME Sec. VIII, Div. 1 Appendix 7

Ultrasonic ASME Sec. V, Art. 5 ASME Sec. VIII, Div, 1, Appendix 7

Magnetic Particle ASME Sec. VIII, Div. 1, Appendix 6

ASME Sec. VIII, Div, 1, Appendix 7

Liquid Penetrant ASME Sec. VIII, Div. 1, Appendix 8

ASME Sec. VIII, Div. 1, Appendix 7

Exhibit S

Specifications


3.2.6 Classification of Defects A complete descriptive report of all injurious and major defects, supplemented with sketched, photographs, and metallurgical test reports, as the case may warrant, and the proposed repair procedure shall be submitted for review prior to any repair of major defects. If removal of defects reduces the stress-resisting cross-section of the casting by more than 30% or if the calculated stress in the remaining metal exceeds the allowable stress by more than 30%, the casting may be rejected. All castings having a major defect repaired after heat treatment, or any defects which will impair the strength of the stress-resisting cross-section or the dimensional stability of the finished part repaired after heat treatment, shall be reheat treated.


Exhibit S

Specifications

Bid No. 15-65 Forgings – 05 58 10 Page 1

SECTION 05 58 10

FORGINGS

TABLE OF CONTENTS


2.0 PRODUCTS ......................................................................................................... 3 2.1 FORGINGS GENERAL ........................................................................................... 3 2.2 SOURCE QUALITY CONTROL................................................................................. 3

3.0 EXECUTION ..............................................ERROR! BOOKMARK NOT DEFINED. 3.1 EXAMINATION OF FORGINGS ................................................................................. 4 3.2 REPAIR OF FORGINGS .......................................................................................... 5

Exhibit S

Specifications


SECTION 05 58 10

FORGINGS

1.0 GENERAL

1.1 GENERAL REQUIREMENTS This Section includes general requirements for forgings. Unless modified by mutual agreement between Contractor and Engineer, testing and nondestructive examination of forgings shall be as specified herein and Section 41 05 13.13 Basic Mechanical Requirements for Bridge Cranes.


American Society of Mechanical Engineers (ASME) BPVC-VIII-1 BPVC Section VIII-Rules for Construction of Pressure

Vessels Division 1 BPVC-V BPVC Section V-Nondestructive Examination

American Society of Mechanical Engineers (ASNT) ASNT SNT-TC-1A Personnel Qualification and Certification in Nondestructive

Testing ASTM International (ASTM)

A275/A275M Standard Practice for Magnetic Particle Examination of Steel Forgings

A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products

A388/A388M Standard Practice for Ultrasonic Examination of Steel Forgings

1.3 SUBMITTALS

1.3.1 Informational Submittals 1. Certificates of Compliance that products meet chemical and mechanical

requirements of standards specified. 2. Certificates of Compliance that forgings meet the design requirements for the

equipment. 3. Qualifications of the individuals performing inspection, nondestructive

examination, and repairing.

http://www.astm.org/Standards/A388.htm

http://www.astm.org/Standards/A388.htm

Exhibit S

Specifications


4. Manufacturer’s inspection test and examination reports. 5. Descriptive report of defects and repair procedures.

2.0 PRODUCTS

2.1 FORGINGS GENERAL The ingots from which the forgings are made shall be cast in metal molds. The forgings shall be homogeneous and free from all defects affecting their strength and durability, including seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive nonmetallic inclusions and segregations. Surfaces of forgings which do not undergo machining shall be dressed for good appearance and for painting. An excessive concentration of impurities or separation of alloying elements at critical points in a forging shall be cause for its rejection.

Large fillets compatible with the design shall be incorporated wherever a change in section occurs. Tool marks or tearing of the metal by the finishing tool will not be permitted on the surface of the fillets. Grinding or polishing shall be required to remove such marks if they occur. All finished surfaces of forgings shall be smooth and free from tool marks. The forgings shall be clearly stamped with the heat number in such locations as to be readily observed when the forging is assembled in a complete unit.

Forgings shall be produced in accordance with procedures and instructions developed for the forgings. Contractor shall have available documentation demonstrating that the forging process has been undertaken with an implemented and enforced quality control program sufficient to demonstrate that the following requirements have been achieved for the specific design of the forging:

1. Dimensional accuracy of the dies; 2. Dimensional accuracy of forgings; 3. Visual examinations; 4. Nondestructive examinations; 5. Repairs; and 6. Stress relieving.

2.2 SOURCE QUALITY CONTROL 2.2.1 General Contractor shall provide copies of inspection test and examination reports prepared by qualified individuals; a record of evaluation of the data and a certificate that the forgings meet the design requirements for the equipment. Contractor shall make available for examination, a certificate attesting to the qualifications of the individuals performing inspection, nondestructive examination, and repairing.

Exhibit S

Specifications


2.2.2 Material Testing Test coupons shall be provided for forgings. The test coupons shall be subject to the normal physical tests and to Charpy V-notch impact tests as specified in ASTM A370. Each specimen sample for V-notch impact tests shall be tested at -40ºF and the average energy value shall be not less than 25 ft-lb with no one (1) specimen being less than 15 ft-lb. Normalized forgings shall also be inspected by microstructure examination to confirm full heat treatment (normalization) of the material.

2.2.3 Dimensions Dimensions of forgings shall not be reduced due to shop practices by an amount sufficient to impair the strength of forgings by more than 10%, as calculated from Shop Drawing dimensions. Dimensions shall not be oversized to the extent that a forging interferes with processing operations or proper fit with other parts. Warped or otherwise distorted forgings shall not be used without submitting complete details for Engineer’s review.

3.0 EXECUTION

3.1 EXAMINATION OF FORGINGS 3.1.1 General All forgings shall be given complete ultrasonic examination with liberal overlap and other approved nondestructive tests, to determine that they are sound. Nondestructive examination of other forgings shall be in accordance with accepted good practice to assure their soundness and shall be indicated on the Drawings. The structure of forgings shall be homogeneous and free from excessive nonmetallic inclusions. Examination of steel forgings shall be in accordance with the methods of ASTM A388/A388M and of ASTM A275/A275M.

3.1.2 Inspection Criteria After removing from the die, and heat treatment and clean up is done, an initial examination of all forgings shall be carried out by 100% visual inspection, 100% ultrasonic inspection and 100% magnetic particle inspection; except for non-magnetic stainless steels where 100% ultrasonic and 100% liquid penetrant examination shall be done. Ultrasonic inspection shall be performed by Contractor on all bolting flanges and whenever a subsurface defect is suspected.

For all forgings, after repair of defects, heat treatment and final machining has been completed, a final examination of the finished surface of the forging shall be carried out by 100% visual and 100% liquid penetrant methods.

Exhibit S

Specifications


Personnel performing tests shall be NDT Level II or Level III certified in accordance with ASNT SNT-TC-1A, and shall meet minimum experience requirements as follows:

1. Visual Examination (VT): The individual performing the VT tests shall be an AWS Certified Welding Inspector (CWI) with a minimum of two (2) years experience within the last three (3) years.

2. Liquid Penetrant Inspection (PT): The individual performing the PT tests shall, as a minimum, be ASNT-TC-1A Level 2 qualified, with a minimum of one (1) year of current experience at this level.

3. Magnetic Particle Inspection (MT): The individual performing the MT tests shall, as a minimum, be ASNT-TC-1A Level 2 qualified, with a minimum of one (1) year of current experience at this level.

4. Ultrasonic Inspection (UT): individual performing the work shall, as a minimum, be ASNT-TC-1A Level 3 qualified, or Level 2 qualified with three (3) years of current experience at this level.

5. Radiographic Examination: The individual performing the work shall be, as a minimum, ASNT-TC-1A Level 3 qualified, or Level 2 qualified with three (3) years of current experience at this level.

3.1.3 Nondestructive Testing Requirements The nondestructive examination of steel forgings, as a minimum, shall be in accordance with the following methods and acceptance standards:

EXAMINATION METHOD

STANDARD FOR METHOD

STANDARD FOR ACCEPTANCE

Radiographic ASME Sec. V, Art. 2 ASME Sec. VIII, Div. 1 Appendix 7

Ultrasonic ASTM A388/A388M ASME Sec. V, Art. 23, SA-388

Magnetic Particle ASTM A275/A275M ASME Sec. VIII, Div. 1, Appendix 6

Liquid Penetrant ASME Sec. V, Art. 6 ASME Sec. VIII, Div. 1, Appendix 8

3.2 REPAIR OF FORGINGS Defects in forgings shall be reported to Engineer with recommendations for repair or rejection. A complete descriptive report of defects, supplemented with sketches, photographs, and metallurgical test reports, as the case may warrant, shall be submitted for Engineer review. Repairs are subject to Approval of Engineer.



Bid No. 15-65 Painting – 09 90 04 Page 1

SECTION 09 90 04

PAINTING

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 DEFINITIONS ....................................................................................................... 3 1.3 SUBMITTALS ....................................................................................................... 3 1.4 QUALITY ASSURANCE .......................................................................................... 5 1.5 DELIVERY, STORAGE, AND HANDLING ................................................................... 6 1.6 PROJECT CONDITIONS ......................................................................................... 6 1.7 EXTRA MATERIALS .............................................................................................. 7

2.0 PRODUCTS ......................................................................................................... 7 2.1 MANUFACTURERS................................................................................................ 7 2.2 ABRASIVE MATERIALS .......................................................................................... 7 2.3 PAINT MATERIALS ............................................................................................... 8 2.4 COLORS ............................................................................................................. 8 2.5 SHOP FINISHES ................................................................................................... 9

3.0 EXECUTION ....................................................................................................... 10 3.1 GENERAL .......................................................................................................... 10 3.2 ASSESSING COMPRESSED AIR CLEANLINESS ....................................................... 11 3.3 SURFACE PREPARATION INSPECTION: ................................................................. 11 3.4 PROTECTION OF MATERIALS NOT TO BE PAINTED................................................ 12 3.5 TOUCH-UP ........................................................................................................ 12 3.6 FIELD SANDBLASTING ........................................................................................ 13 3.7 APPLICATION SAFETY ........................................................................................ 13 3.8 PREPARATION OF SURFACES .............................................................................. 13 3.9 PAINT MIXING ................................................................................................... 14 3.10 PAINT APPLICATION ........................................................................................... 14 3.11 GALVANIZED, ALUMINUM, ALUMINUM ALLOY, OR COPPER SURFACES .................... 16 3.12 PROTECTIVE COATINGS SYSTEMS AND APPLICATION SCHEDULE ........................... 17 3.13 QUALITY CONTROL ............................................................................................ 20 3.14 MANUFACTURER’S SERVICES ............................................................................. 21 3.15 CLEANUP .......................................................................................................... 22 3.16 PURCHASED COMPONENTS PAINTING ................................................................. 22 3.17 SURFACES NOT REQUIRING PAINTING ................................................................. 22

4.0 LIST OF APPENDICES ..................................................................................... 23 4.1 PAINT SYSTEM DATA SHEET .............................................................................. 24 4.2 PAINT PRODUCT DATA SHEET ............................................................................ 25



SECTION 09 90 04

PAINTING

1.0 GENERAL


American Institute of Steel Construction (AISC) / The Society for Protective Coatings (SSPC)

AISC 420-10/ SSPC-QP 3

Certification Standard for Shop Application of Complex Protective Coating Systems

ASTM International (ASTM) A380/A380M Standard Practice for Cleaning, Descaling, and Passivation of

Stainless Steel Parts, Equipment, and Systems D3359 Standard Test Methods for Measuring Adhesion by Tape Test D4285 Standard Test Method for Indicating Oil or Water in Compressed

Air D4417 Standard Test Methods for Field Measurement of Surface Profile

of Blast Cleaned Steel D4541 Standard Test Method for Pull-Off Strength of Coatings Using

Portable Adhesion Testers International Organization of Standards Laboratories (ISO)

ANSI/ISO/IEC 17025

General requirements for the competence of calibration laboratories

NACE International (NACE) SP0188 Discontinuity (Holiday) Testing of New Protective Coatings on

Conductive Substrates National Conference of Standards Laboratories (NCSL)

ANSI/NCSL Z540.3

Requirements for the Calibration of Measuring and Test Equipment

The Society for Protective Coatings (SSPC)

PA 1 Shop, Field and Maintenance Painting of Steel PA 2 Measurement of Dry Coating Thickness with Magnetic Gages PA 3 Guide to Safety in Paint Applications SP 1 Solvent Cleaning SP 2 Hand Tool Cleaning SP 3 Power Tool Cleaning



The Society for Protective Coatings (SSPC) SP 5 Joint Surface Preparation Standard White Metal Blast Cleaning SP 6 Joint Surface Preparation Standard Commercial Blast Cleaning SP 7 Joint Surface Preparation Standard Brush-Off Blast Cleaning SP 10 Joint Surface Preparation Standard Near-White Blast Cleaning SP 11 Power Tool Cleaning to Bare Metal SP WJ-1 Waterjet Cleaning of Metals -- Clean to Bare Substrate SP WJ-2 Waterjet Cleaning of Metals -- Very Thorough Cleaning SP WJ-3 Waterjet Cleaning of Metals -- Thorough Cleaning SP WJ-4 Waterjet Cleaning of Metals -- Light Cleaning

1.2 DEFINITIONS Terms used in this section:

1. Coverage: Total minimum dry film thickness in mils or square feet per gallon. 2. DFT: Dry Film Thickness, mils 3. HCl: Hydrochloric Acid. 4. MDFT: Minimum Dry Film Thickness, mils. 5. MDFTPC: Minimum Dry Film Thickness per Coat, mils. 6. Mil: Thousandth of an inch. 7. PDS: Product Data Sheet. 8. PSDS: Paint System Data Sheet. 9. PVC: Polyvinyl Chloride. 10. SDS: Safety Data Sheet 11. SFPG: Square Feet per Gallon. 12. SFPGPC: Square Feet per Gallon per Coat. 13. SP: Surface Preparation.

1.3 SUBMITTALS Submit in accordance with Section 01 30 00, Administrative Requirements.

1.3.1 Procedures 1. Work Plan, including planning and schedule of systematic activities for carrying

out specified Work in the shop and in the field. 2. Containment Plan for Site Painting Work: Plan shall include site specific plan for

containment all waste materials and potential overspray. 3. QA/QC Plan: In accordance with Section 01 45 16.13, Contractor Quality

Control. 4. Inspection and Test Plan: In accordance with Section 01 45 16.13, Contractor

Quality Control.



1.3.2 Product Data Sheets 1. For each product, furnish a Product Data Sheet (PDS), the manufacturer’s

technical data sheets, and paint colors available (where applicable). The PDS form is appended to the end of this section (Appendix 4.2).

2. For each paint system, furnish a Paint System Data Sheet (PSDS). The PSDS form is appended to the end of this section (Appendix 4.1).

3. Furnish copies of paint system submittals to coating applicator. 4. Furnish detailed chemical and gradation analysis for each proposed abrasive

material. 5. Indiscriminate submittal of manufacturer’s literature is not acceptable.

1.3.3 Safety Data Sheet For each coating products and coating related products used at site, furnish, maintain and make readily available all SDSs.

1.3.4 Samples Reference Panel:

1. Prior to start of surface preparation, furnish a 4-inch by 4-inch steel panel prepared to specified requirements for each grade of sandblast specified herein.

a. Provide panel representative of steel used, and prevent from deterioration of surface quality.

b. Upon approval by Engineer, preserve panel as reference source for inspection.

1.3.5 Color Swatches Provide color swatches of colors available for painting of the Bridge Crane Equipment. The District will select a color from the standard colors available from the painting system manufacturer.

1.3.6 Informational Submittals 1. Reports: Inspection reports and data collection sheets for surface preparation

and profile checks, coating thickness measurements for each coat, ambient conditions, and other pertinent records. Test/inspection reports shall:

a. State the date the test/inspection was performed and the issue date of the report.

b. Provide identification of the specimen tested, location of test on specimen, source of supply, manufacturer, model or series number, or both, and any other pertinent information.



c. Have a detailed description of the specimen or specimens tested including the type of test, the type of coating, the method of paint application, the procedure used to cure it, and the dry film thickness, etc.

d. A statement that the test or tests were conducted in accordance with the methods and procedures as specified herein, and the test results. If deviations from these methods and procedures were made, they shall be described in the report.

e. Be issued within 48 hours of completing the Work. 2. Manufacturer’s written verification that submitted products are suitable for the

intended use. 3. Factory Applied Coatings: Manufacturer’s certification stating factory applied

coating system meets or exceeds requirements specified herein. 4. If manufacturer of finish coating differs from that of shop primer, provide both

manufacturers written confirmation that materials are compatible. 5. Coating Manufacturer’s Certificate of Compliance.

1.3.7 Qualifications Proof of qualifications of Contractor and all Subcontractors to perform painting related Work, in accordance with requirements of paragraph 1.4 Quality Assurance below.

1.4 QUALITY ASSURANCE 1.4.1 Applicator’s Experience The Contractor and all Subcontractors that perform surface preparation or coating application shall be certified by the Society for Protective Coatings to the requirements of AISC 420-10/SSPC-QP 3 or AISC SPE program (recognized as an equivalent to SSPC-QP 3), or equivalent experience proven through documented work and references provided to and approved by Engineer. Applicator's experience shall be a minimum of 5 years practical experience in application of the specified products. Documentation shall include a list of the last three (3) comparable jobs including name and location, specifying authority and project manager, start and completion dates, and value of the painting portion of the Work.

The Contractor and all Subcontractors must remain so certified for the duration of the project. If the Contractor or a Subcontractor’s certification expires, the company will not be allowed to perform any Work until the certification is reissued. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not apply. Notify Engineer of any change in Contractor or Subcontractor certification status.

All Contractors and Subcontractors involved in the disturbance of hazardous coatings (i.e. lead or other hazardous metals), incidental to demolition or repair work shall meet the requirements of Section 02 83 33.13 Lead Based Paint Removal and Disposal.



Subcontractor shall be subject to Engineer’s approval.

1.4.2 Regulatory Requirements Meet federal, state, and local requirements limiting emission of volatile organic compounds.

Perform surface preparation and painting in accordance with recommendations of the following:

1. Paint manufacturer’s instructions. 2. AISC 420-10/SSPC PA 3, Certification Standard for Shop Application of

Complex Protective Coating Systems. 3. Federal, state, and local agencies having jurisdiction.

1.5 DELIVERY, STORAGE, AND HANDLING Deliver materials to Site in unopened containers that plainly show designated name, date of manufacture, color, and manufacturer.

Store paints in a protected area that is heated or cooled to maintain temperature range recommended by paint manufacturer. Paint storage and storage cabinets shall comply with all local, Washington State and Federal OSHA-requirements.

1.6 PROJECT CONDITIONS 1.6.1 Measurement of Ambient Conditions Measuring ambient conditions entails obtaining an air temperature, surface temperature, percent relative humidity, and dew point temperature. The coating manufacturer shall be consulted to establish air temperature and relative humidity ranges (max & min) outside of which the coating materials should not be applied and cured. The ambient conditions must be obtained, documented, and compared with the coating manufacturer’s established ranges.

Air temperature, relative humidity, and dew point shall be determined by instrumentation, including psychrometers instruments that give direct read-out recordings of humidity and dew point. Measurements with these instruments shall be taken before work begins each day and periodically throughout the day. The minimum frequency shall be every 4 hours, but the readings can be more often if weather conditions appear to be changing.

Determination of surface temperatures shall be via surface temperature thermometers consisting of a bimetallic sensing element that is shielded from drafts, or direct reading thermocouple-type thermometers.



All readings shall be taken at the actual location of the work. However, for general readings the coldest and warmest point on the structure shall be used to ensure that coatings are not applied outside of their temperature limitations

1.6.2 Environmental Requirements: 1. Do not apply paint in temperatures outside of manufacturer’s recommended

maximum or minimum allowable, or in dust, smoke-laden atmosphere, damp or humid weather.

2. Do not perform abrasive blast cleaning whenever relative humidity exceeds 85 percent, or whenever surface temperature is less than 5 degrees F above dewpoint of ambient air. Strictly adhere to coating manufacturer’s recommendations.

1.7 EXTRA MATERIALS Contractor shall provide 5 gallons of each type and color of paint used as part of this Work as touch-up paint for District use. Touch-up paints shall be delivered in the original, unopened containers at the completion functional testing of the crane system.

2.0 PRODUCTS

2.1 MANUFACTURERS Paint manufacturer shall be nationally recognized manufacturer of paints and protective coatings and regularly engaged in production of such materials that have essentially identical service conditions as this Project.

Minimum of 5 years verifiable experience in manufacture of specified products.

International Paint Products can be obtained from:

PCCI 1501 South 92nd PL Suite A Seattle, WA 98108 Contact: Brett Bechtel Phone: 206-762-6119, Office or 206-510-8664, Cell.

2.2 ABRASIVE MATERIALS Select abrasive type and size to produce surface profile that meets coating manufacturer’s recommendations for specific primer and coating system to be applied.



2.3 PAINT MATERIALS 2.3.1 General Material Quality: Manufacturer’s highest quality products and suitable for the intended service.

Materials, Including Primer and Finish Coats: Produced by same paint manufacturer.

Thinners, Cleaners, Driers, and Other Additives: As recommended by paint manufacturer of particular coating.

2.3.2 Products

Product Definition Alkyd Enamel Optimum quality, gloss or semigloss finish as

specified, medium long oil Silicon Alkyd 30% copolymerized silicon alkyd, 2 to 4 mils per

coat (DFT), as recommended by the coating manufacturer.

Epoxy Primer Converted epoxy primer containing rust-inhibitive pigments

High Build Surface Tolerant Epoxy

Two-component high build, high solids, surface tolerant, epoxy primer; semigloss finish. Approved Product: International Protective Coatings Interseal 670HS, or approved equal.

Polyurethane Enamel Two-component, aliphatic or acrylic based polyurethane; high gloss finish Approved Product: International Protective Coatings Interthane 990 HS or approved equal.

Rust-Inhibitive Primer Single-package steel primers with anticorrosive pigment loading

High Solids Amine-Cured Epoxy

Two component high build, high solids epoxy coating, matte finish.

Amino-Amine Cured Epoxy

Two-component high build, high solids epoxy coating, self priming.

2.4 COLORS Paint color shall match the existing crane color, blue high-gloss. The Contractor shall take samples of the existing crane paint to formulate and match the top coat color.

Color coding will be supplied by District prior to equipment fabrication.



Contractor shall submit color samples (approximately 4 by 6 inches) for District Approval.

The Approved top coat color will be used for touch-up painting of all crane surfaces where coatings have been disturbed by execution of the Work and other locations of paint repairs as Directed by the District.

Additional colors for Contractor purchased items (such as electrical panels and equipment enclosures) may be submitted for Approval by the Contractor.

Contractor shall submit a description and drawing showing the trip hazard and pinch hazard locations that will be painted with WISHA/OSHA safety color, along with the proposed paint color and product for these areas.

Formulate with colorants free of lead, lead compounds.

Proprietary identification of colors is for identification only. Any authorized manufacturer may supply matches.

2.5 SHOP FINISHES 2.5.1 Shop Blast Cleaning Reference paragraph 2.5.3 Shop Coating Requirements, of this section.

2.5.2 Surface Preparation Provide Engineer minimum of 7 days advance notice to start of shop surface preparation Work and coating application Work.

2.5.3 Shop Coating Requirements When required by equipment Specifications, such equipment shall be primed and finish coated in shop by manufacturer and touched up in field with identical material after installation.

Where manufacturer’s standard coating is not suitable for intended service condition, Engineer may Approve use of a tie-coat to be used between manufacturer’s standard coating and specified field finish. In such cases, tie-coat shall be surface tolerant epoxy as recommended by manufacturer of specified field finish coat. Coordinate details of equipment manufacturer’s standard coating with field coating manufacturer.



3.0 EXECUTION

3.1 GENERAL Contractor furnished items shall be cleaned, prepared and coated as specified herein, unless otherwise Approved by Engineer.

The Contractor shall provide surface treatment, priming, corrosion protection and painting of the equipment furnished. Unless otherwise specified, the surface preparation, coating and recoating, painting and curing shall be carried out in accordance with the latest manufacturer’s written instructions as Approved by Engineer, and these Specifications.

Equipment of standard manufacture shall be shop painted in accordance with the manufacturer's standard practice.

All finished surfaces shall present a neat, pleasing appearance. The Contractor shall supply full details regarding the extent of which cleaning, blasting, priming and painting will be carried out in its workshop (or its subcontractors) and at the Site.

For each painting and coating system, the required surface preparation, prime coat, intermediate coats, and finish coat, thicknesses are specified in the Protective Coatings System Schedule. Contractor shall apply coating systems in accordance to the coating manufacturers recommended dry-film thicknesses (DFT) or the specified minimum thicknesses, whichever is greater. Discrepancies between the specified DFT and the manufacturers recommended DFT shall be brought to the attention of Engineer prior to applying coatings.

Provide materials for the specified painting system, including primer, intermediate, and finish coats by the same manufacturer. Thinners, cleaners, driers and other additives shall be as recommended by the paint manufacturer for the particular coating system.

Deliver paints, whether for shop or field applications, in the original, unopened containers.

Coatings application shall not be performed under adverse ambient conditions as specified by the product manufacturer that may affect the life, performance or appearance of the coating. Follow the recommendations of the coating manufacturer for the selection of spray equipment, brushes, rollers, cleaners, thinners, mixing, drying time, temperature, and humidity of application, and safety precautions.

Demonstrate ambient conditions are within the product manufacturer’s guidelines by recording temperature, relative humidity, etc. from recently calibrated instruments at the time coatings are applied.



The establishment and maintenance of a calibration system to control the accuracy of all measuring and test equipment shall be in accordance with ANSI/NCSL Z540.3 and/or ANSI/ISO/IEC 17025. Calibration interval shall be one (1) calendar year or less, and clearly labeled on each measuring device.

Conform to the requirements of SSPC-PA 1, Shop, Field and Maintenance Painting of Steel.

For coatings subject to immersion, obtain full cure for completed system. Consult coatings manufacturer’s written instructions for these requirements. Do not immerse coating until completion of curing cycle.

The intention of these Specifications is for new, interior and exterior metal and submerged metal surfaces to be painted, whether specifically mentioned or not, except as modified herein. Concealed structural steel surfaces shall receive prime coat only, unless modified herein.

Perform painting in accordance with recommendations of the following: 1. Paint manufacturer’s instructions. 2. Federal, state, and local agencies having jurisdiction.

3.2 ASSESSING COMPRESSED AIR CLEANLINESS Compressed air used for blast cleaning, blow down, and coating spray atomization must be free from oil and moisture contamination. Contaminants of this type are effectively transferred to the surface with the air and blast cleaning media (abrasive) or by mixing it with the coating during application. Adequate moisture and oil traps shall be used on all lines to ensure that the air is dry and oil-free so it does not interfere with the quality of the Work.

Compressed air shall be tested and results interpreted for oil and water in accordance with ASTM D4285. Testing shall be conducted after air compressor(s) have been idle for over 30 minutes, prior to use for the Work. Records of testing shall be kept on file for District review, as requested.

A thorough inspection of the surface after blast cleaning for signs of moisture or oil contamination shall be made, and these results need to be correlated with the results of the blotter test. In addition, the proper functioning of in-line moisture and oil traps shall be evaluated on a comparative basis from the results of the blotter test.

3.3 SURFACE PREPARATION INSPECTION: Inspect and provide substrate surfaces prepared in accordance with these Specifications and printed directions and recommendations of paint manufacturer whose product is to be applied. In event of conflict, more stringent shall apply.



Notify Engineer minimum 7 days prior to start of surface preparation Work or coating application Work. Perform Work only in presence of Engineer, unless Engineer grants prior Approval to perform Work in Engineer’s absence.

Measure the surface profile of the steel to be painted in accordance with ASTM D4417, Test Method C. The surface profile measurements shall be made for each 100 square feet of area as stated in SSPC-PA 2, Part 4.1 – NUMBER OF MEASUREMENTS.

Prepare and submit a report of surface preparation inspections. Failure to provide inspections and reports shall be cause for rejection of the applied coating if there is reasonable doubt, as determined solely by Engineer, that specified surface preparation or paint application procedures were not followed.

Surfaces which do not meet the specified requirements shall be corrected at Contractor’s expense.

3.4 PROTECTION OF MATERIALS NOT TO BE PAINTED Protect all surfaces adjacent to, or downwind of Work area from overspray. Contractor shall be responsible for any damages resulting from overspray.

Protect all materials not requiring painting including but not limited to nonferrous and corrosion-resistant ferrous alloys such as copper, bronze, monel, aluminum, chromium plate, and stainless steel.

Remove, mask, or otherwise protect hardware, lighting fixtures, switchplates, aluminum surfaces, bearings, grease fittings, plastic, rubber materials, glass, nameplates on machinery, and other surfaces not specified elsewhere.

Provide drop cloths to prevent paint materials from falling on or marring adjacent surfaces.

Protect working parts of mechanical and electrical equipment from damage.

Mask openings in motors to prevent paint and other materials from entering the motors.

Do not paint wearing steel surfaces such as the head of the trolley rail, the treads and inner flanges of wheels, nor the grooved portions of sheaves and drum. Do not paint the hoist hooks. Coat these surfaces before shipping with an easily-removable rust-preventative coating similar to Cosmoline or LPS. The rust preventative coatings shall be removed during the field installation phase.

3.5 TOUCH-UP Field touch-up of items left unpainted in the fabricators shop, such as facing surfaces at bolted connections, areas which were masked at field weld joints and surface damage which occurred during shipping and erection shall receive the same coating system



specified herein or as Approved by Engineer. The touch-up coating and painting shall be carried out as per these Specifications and reach the minimum DFT stipulated.

3.6 FIELD SANDBLASTING No field sandblasting will be allowed within the Rocky Reach Powerhouse. Paint preparation work that requires sandblasting shall be done at the Contractor’s facilities.

Perform sandblasting for items and equipment where required to restore damaged surfaces previously shop or field blasted and primed. Materials, equipment, procedures shall meet requirements of SSPC.

3.7 APPLICATION SAFETY Contractor will be solely and completely responsible for conditions of the jobsite, including safety of all persons (including employees) and property during performance of the Work. This requirement will apply continuously and not be limited to normal working hours. Safety provisions will conform to U.S. Department of Labor, Occupational Safety and Health Act, any equivalent state law, and all other applicable federal, state, county, and local laws, ordinances, and codes.

3.8 PREPARATION OF SURFACES 3.8.1 Metal Surface Preparation General:

1. Submit samples prior to surface preparation blasting. 2. Conform to current SSPC specifications as follows:

a. Solvent Cleaning: SP 1. b. Hand Tool Cleaning: SP 2. c. Power Tool Cleaning: SP 3. d. White Metal Blast Cleaning: SP 5. e. Commercial Blast Cleaning: SP 6. f. Brush-Off Blast Cleaning: SP 7. g. Near-White Blast Cleaning: SP 10. h. Power Tool Cleaning to Bare Metal: SP 11. i. High Pressure Waterjetting: SP WJ-1, SP WJ-2, SP WJ-3, SP WJ-4.

3. Where OSHA or EPA regulations preclude standard abrasive blast cleaning, wet- or vacu-blast methods may be required. Follow coatings manufacturers recommendations for wet-blast additives and first coat application.

4. Hand-tool clean areas that cannot be cleaned by power-tool cleaning.

Blast Cleaning Requirements: 1. Comply with applicable federal, state, and local, air pollution and environmental

control regulations for blast cleaning and disposition of spent aggregate and debris.



2. Alternatives to standard abrasive blast cleaning methods subject to Engineer review.

3.9 PAINT MIXING Multiple-Component Coatings:

1. Prepare using contents of container for each component as packaged by paint manufacturer.

2. No partial batches will be permitted. 3. Do not use multiple-component coatings that have been mixed beyond their pot

life. 4. Mix only components specified and furnished by paint manufacturer. 5. Do not intermix additional components for reasons of color or otherwise, even

within same generic type of coating.

Keep paint materials sealed when not in use.

Where more than one coat of material is applied within given system, alternate color to provide visual reference that required number of coats has been applied.

3.10 PAINT APPLICATION 3.10.1 General Inspection: Schedule with Engineer in advance for cleaned surfaces and all coats prior to succeeding coat.

Apply coating in accordance with paint manufacturer’s recommendations. Allow sufficient time between coats to ensure thorough drying of previously applied paint.

Paint units to be bolted together and to structures, prior to assembly or installation.

Place canvas tarps under items to be painted in the field and provide other containment measures as necessary to prevent residue from field surface preparation and painting activities from entering the water.

3.10.2 Shop Primed or Factory Finished Surfaces Inspection: Schedule inspection for compliance with Specifications of shop primed or factory finished items with Engineer in advance of delivery to Site.

Hand or power sand areas of chipped, peeled, or abraded coating, feathering the edges. Follow with a spot primer using specified primer.

For two-package or converted coatings, consult coatings manufacturer for specific procedures as relates to manufacturer’s products.



Prior to application of finish coats, clean shop-primed surfaces free of dirt, oil, and grease and apply mist coat of specified primer, 1-mil DFT.

Areas that require field welding shall be masked 4” on either side of the joint.

After welding, prepare and prime holdback areas as required for specified paint system. Apply primer in accordance with manufacturer’s instructions.

3.10.3 Manufacturer Shop and Factory Applied Paint Systems Handle and install shop-painted metals in a manner that reduces damage to the protective coating. Repair damaged coatings in accordance with this section and the coating manufacturer’s printed directions. Excessive damage to the exterior coating, as determined by District, will require an additional field-applied finish coat to achieve uniform appearance of the coating.

3.10.4 Prime Coats Prime coats found to be incompatible with finish coats or applied to improperly prepared surfaces shall be removed. The prime coat shall be re-applied at no additional cost to District.

Apply prime coat immediately after blast cleaning and before any surface rusting occurs, or any dust, dirt, or any foreign matter has accumulated. Re-clean surfaces by blast cleaning that have surface colored or become moist prior to coating application.

3.10.5 Stripe Coating Stripe coat all welds, edges, angles, and other irregular, difficult to reach surfaces.

Stripe coat shall consist of one coat, brush applied, 3 mils minimum DFT.

Stripe coat color shall contrast primer to allow visual verification of application.

3.10.6 Intermediate and Finish Coats After proper application of the prime coat and stripe coats, apply one (1) full coat of the intermediate coat.

Remove coats found to be incompatible with prime coats or applied to improperly prepared surfaces.

Apply each coating application with paints that differ noticeably in coloration from each other on succeeding coating applications to ensure even coverage by shading or tinting, as appropriate, for the paint material and color. Shading or tinting shall be done by the paint manufacturer.



Finished surfaces shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Verify absence of holidays, pinholes, gaps, etc. by appropriate testing. Recoat and retest any areas failing these tests.

3.10.7 Film Thickness and Coverage Number of Coats:

1. Minimum required, irrespective of coating thickness. 2. Additional coats may be required to obtain minimum required paint thickness,

depending on method of application, differences in manufacturers products, and atmospheric conditions.

Application Thickness: 1. Do not exceed coating manufacturer’s recommendations. 2. Use wet film thickness gauge to measure proper coating thickness during

application.

Film Thickness Measurement and Electrical Inspection of Coated Surface: 1. Perform with properly calibrated instruments. 2. Recoat and repair as necessary for compliance with Specifications. 3. Coats will be subject to inspection by Engineer and coating manufacturer’s

representative.

Give particular attention to edges, angles, flanges, and other similar areas, where insufficient film thickness are likely to be present, and ensure proper millage in these areas.

Apply additional coats as required to complete hiding of underlying coats. Hiding shall be so complete that additional coats would not increase hiding.

3.11 GALVANIZED, ALUMINUM, ALUMINUM ALLOY, OR COPPER SURFACES Where surfaces are specified to be painted, they shall be first solvent cleaned (SP1) and then pretreated with a primer conforming SSPC Paint 27. Surfaces shall receive the first coat of paint after at least 1 hour but not more than 24 hours of drying of the pre-treatment film.



3.12 PROTECTIVE COATINGS SYSTEMS AND APPLICATION SCHEDULE 3.12.1 System No. 1 Existing Bridge Crane Structure— Exposed Metal—Atmospheric

Exterior and Interior – Field Applied

Surface Prep. Paint Material Min. Coats, Cover Solvent Clean (SP 1) Power Tool Clean (SP 3)

High Build Surface Tolerant Epoxy Prime Coat

1 coat, 4 MDFT

Aliphatic Polyurethane Enamel Intermediate Coat (International Interthane 990HS)

1 coat, 3 MDFT

Aliphatic Polyurethane Enamel Top Coat (International Interthane 990HS)

1 coat, 3 MDFT Total 10 MDFT

1. Field apply this system to: a. All exterior surfaces of the existing crane structure with damaged paint or

removed paint due to the crane rehabilitation work. b. As Directed by the District, to other exterior surfaces of the existing crane

structure with damaged paint. c. New conduit with existing painted conduit as part of the conduit run. (Note:

New conduit without any existing conduit as part of the run does not need to be painted).

2. Galvanized conduit to be painted shall be passivated as per paragraph 3.11 of this section.



3.12.2 System No. 2 Exposed Metal—Atmospheric Exterior and Interior – Shop Applied

Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast, (SP 10) High Build Surface

Tolerant Epoxy Prime Coat

1 coat, 4 MDFT

Aliphatic Polyurethane Enamel Intermediate Coat (International Interthane 990HS)

1 coat, 3 MDFT

Aliphatic Polyurethane Enamel Top Coat (International Interthane 990HS)

1 coat, 3 MDFT Total 10 MDFT

1. Shop apply this system to all atmospheric exposed metal surfaces and the

following items or areas: a. Equipment and components such as platforms, walkways, ladders,

handrails, hatch covers, brackets, pedestals, upper block equalizer bar, fabricated pillow blocks, etc.

b. Areas where field repair of shop-applied coating is required due to damage during installation.

2. Solvent Clean (SP1) and Power Tool Clean (SP 3) areas for spot repairs of shop-applied coating in accordance with paint manufacturer’s recommendations.

3.12.3 System No. 3 Re-passivation Repair Methods Stainless steel items shall not be coated. New stainless steel surfaces shall have been uniformly passivated at point of manufacture. Damaged, contaminated, or depassivated surfaces of stainless steel shall be cleaned and the uniform passivation layer restored by the methods listed below.



Degree of surface contamination

ASTM A380/A380M*

Surface preparation method**

ASTM A380/A380M*

Surface inspection procedure

Locally heavy surface contaminated areas:

Contaminated by free iron, oxide scale, or rust related contaminates caused by field welding or cutting.

Method 5. – “Descaling”, General

Method 5.3 – “Mechancial Descaling” by grinding

and/or

Method 6.3 – “Cleaning of Welds and Weld-Joint Areas”

Method 7.2 – “Gross Inspection”

Methods 7.2.5 – “Tests for Free Iron: Gross Indications”

General surface contaminated areas:

Contaminated by free iron, oxide scale, or rust related contaminates.

Method 5. – “Descaling,” General

Method 5.2 – “Chemical Descaling”

Method 5.2.2.(1) – “Chemical Descaling” by swab or spray wetting the surfaces

and/or

Method 5.3 – “Mechanical Descaling” by grinding


7.2.5 – “Tests for Free Iron: Gross Indications”



Degree of surface contamination

ASTM A380/A380M*

Surface preparation method**

ASTM A380/A380M*

Surface inspection procedure

General surface contaminated areas:

Contaminated by grease, oil, residual chemical films, or other non-free iron related contaminates.

Method 6.2.10 – “Water Jetting”

and/or

Method 6.4 – “Final Cleaning, or Passivation, or Both” wiping with a clean, solvent-moistened cloth.


Method 7.2.2 – “Wipe Tests”

Where films are not detectable under white light conditions, use

Method 7.3 – “Precision Inspection”

Method 7.3.2 – “Black Light Inspection”

* The specified surface preparation and surface inspection procedure methods listed are herein for the given “Degree of surface contamination”. Other ASTM A380/A380M methods may also be utilized as required.

** The field cleaning and passivation method used shall not damage attached parts, adjacent parts, or materials in which stainless steel parts are embedded.

1. Items to receive a uniform passivation layer: Stainless steel surfaces.

3.13 QUALITY CONTROL 3.13.1 Testing Equipment Provide magnetic type dry film thickness gauge, to test coating thickness specified in mils, as manufactured by Nordson Corp., Anaheim, CA; Mikrotest.

Provide electrical holiday detector, low voltage, wet sponge type, to test completed coating systems, 20 mils or less MDFT, for holidays and discontinuities as manufactured by Tinker and Rasor, San Gabriel, CA, Model M-1.

Provide high voltage holiday detector for coatings in excess of 20 mils MDFT. Unit as recommended by coating manufacturer.

3.13.2 Testing Thickness and Continuity Testing:



1. Measure coating thickness specified in mils with magnetic type dry film thickness gauge in accordance with SSPC PA 2.

2. Check each coat for correct millage. Do not make measurement within 8 hours, minimum, after application of coating.

3. Test finish coat, 20 mils thick or less DFT, except zinc primer, galvanizing, and elastomeric coatings, for holidays and discontinuities with electrical holiday detector, low voltage, wet sponge type in accordance with NACE SP0188.

4. Holiday detect coatings in excess of 20 mils MDFT with high voltage units recommended by coating manufacturer, and in accordance with NACE SP0188.

5. After repaired and recoated areas have dried sufficiently, retest each repaired area. Final test may also be conducted by Engineer.

3.13.3 Unsatisfactory Application Clean and top coat surfaces found to have improper finish color or insufficient film thickness.

Evidence of runs, bridges, shiners, laps, or other imperfections shall be cause for rejection.

Repair defects in coating system per written recommendations of coating manufacturer.

Leave staging up until Engineer has inspected surface or coating. Replace staging removed prior to Approval by Engineer.

3.13.4 Damaged Coatings, Pinholes, and Holidays Feather edges and repair in accordance with recommendations of paint manufacturer.

Hand or power sand visible areas of chipped, peeled, or abraded paint, and feather edges. Follow with primer and finish coat in accordance with Specifications. Depending on extent of repair and appearance, finish sanding and topcoat may be required.

Apply finish coats, including touchup and damage-repair coats, in a manner, which will present uniform texture and color-matched appearance.

3.14 MANUFACTURER’S SERVICES Coating manufacturer’s representative shall be present at Site as follows:

1. On first day of application of any coating. 2. Minimum of two additional Site inspection visits as required to resolve field

problems attributable to, or associated with, manufacturers product. 3. As required to verify full cure of coating prior to coated surfaces being placed

into immersion service.



3.15 CLEANUP Place cloths and waste that might constitute fire hazard in closed metal containers or destroy at end of each day.

Upon completion of Work, remove staging, scaffolding, and containers from Site or destroy in legal manner.

Completely remove paint spots, oil, or stains from adjacent surfaces and floors and leave entire job clean.

3.16 PURCHASED COMPONENTS PAINTING For the designated commercial items listed below, the specified paint systems need not be applied. Purchase these components with the manufacturer’s best optional coating for outdoor / marine environments, color as selected by District:

1. Limit switches, encoders, resolvers and other electronics 2. Motors 3. Brakes 4. Reducers 5. Control panel and other indoor sheet metal enclosures. 6. Festoon carriers 7. Transformers and switchgear 8. All galvanized surfaces (conduit, conduit fittings).

Contractor shall submit the manufacturer’s recommendation for paint system used from their range of options and manufacturer’s certification that the selected paint system is the best available for the intended use.

3.17 SURFACES NOT REQUIRING PAINTING Unless otherwise stated herein or shown, the following areas or items will not require painting:

1. Nonferrous and corrosion-resistant ferrous alloys such as copper, bronze, Monel, aluminum, chromium plate, atmospherically exposed weathering steel, and stainless steel, except where required for electrical insulation between dissimilar metals.

2. Nonmetallic materials such as glass, plastic, rubber, and porcelain, except as required for architectural painting or color coding.

3. Items specified to be galvanized after fabrication, unless specified elsewhere or subject to immersion.



4.0 LIST OF APPENDICES Appendix 4.1 – Paint System Data Sheet Appendix 4.2 – Paint Product Data Sheet



4.1 PAINT SYSTEM DATA SHEET

Complete this PSDS for each coating system, include all components of the system (surface preparation, primer, intermediate coats, and finish coats). Include all components of a given coating system on a single PSDS.

Paint System Number (from Spec.):

Paint System Title (from Spec.):

Coating Supplier:

Representative:

Surface Preparation:

Paint Material (Generic)

Product Name/Number (Proprietary) Min. Coats, Coverage



4.2 PAINT PRODUCT DATA SHEET

Complete and attach manufacturer’s Technical Data Sheet to this PDS for each product submitted. Provide manufacturer’s recommendations for the following parameters at temperature (F)/relative humidity:

Temperature/RH 50/50 70/30 90/25

Induction Time

Pot Life

Shelf Life

Drying Time

Curing Time

Min. Recoat Time

Max. Recoat Time

Provide manufacturer’s recommendations for the following:

Mixing Ratio:

Maximum Permissible Thinning:

Ambient Temperature Limitations: min.: max.: Surface Temperature Limitations: min.: max.: Surface Profile Requirements: min.: max.:


Exhibit S

Specifications

Bid No. 15-65 Electrical Testing – 26 08 00 Page 1

SECTION 26 08 00

ELECTRICAL TESTING

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 SUBMITTALS ....................................................................................................... 3 1.3 QUALITY ASSURANCE .......................................................................................... 3 1.4 SEQUENCING AND SCHEDULING ............................................................................ 3


3.1 GENERAL ............................................................................................................ 4 3.2 CHECKOUT AND STARTUP .................................................................................... 5 3.3 PANELBOARDS .................................................................................................... 5 3.4 DRY TYPE TRANSFORMERS .................................................................................. 6 3.5 LOW VOLTAGE CABLES AND WIRING, 600 VOLTS MAXIMUM ................................... 6 3.6 SAFETY SWITCHES, 600 VOLTS MAXIMUM ............................................................ 7 3.7 MOLDED AND INSULATED CASE CIRCUIT BREAKERS ............................................... 8 3.8 GROUNDING SYSTEMS ......................................................................................... 8 3.9 LOW VOLTAGE MOTOR CONTROL ......................................................................... 8

Exhibit S

Specifications


SECTION 26 08 00

ELECTRICAL TESTING

1.0 GENERAL


Institute of Electrical and Electronics Engineers (IEEE) 43 Recommended Practice for Testing Insulating Resistance

of Rotating Machinery 81 Guide for Measuring Earth Resistivity, Ground

Impedance, and Earth Surface Potentials of a Ground System (Part 1): Normal Measurements

C2 National Electrical Safety Code (NESC) C37.20.1 Standard for Metal-Enclosed Low Voltage Power Circuit

Breaker Switchgear C37.20.2 Standard for Metal-Clad Switchgear C37.20.3 Standard for Metal-Enclosed Interrupter Switchgear C62.33 Test Specifications for Varistor Surge-Protective Devices

InterNational Electrical Testing Association (NETA) ATS STANDARD FOR ACCEPTANCE TESTING SPECIFICATIONS for

Electrical Power Equipment and Systems

National Electrical Manufacturers Association (NEMA) AB 4 Guidelines for Inspection and Preventive Maintenance of

Molded-Case Circuit Breakers Used in Commercial and Industrial Applications.

PB 2 Deadfront Distribution Switchboards National Fire Protection Association (NFPA)

70 National Electrical Code® (NEC) 70E Standard for Electrical Safety - Safety in the Workplace® 101 Life Safety Code®

Occupational Safety and Health Administration (OSHA) 29 CFR, Part 1910 Occupational Safety and Health Standards

Exhibit S

Specifications


1.2 SUBMITTALS 1.2.1 Informational Submittals Submit 30 days prior to performing inspections or tests:

1. Schedule for performing inspection and tests. 2. List of references to be used for each test. 3. Sample copy of equipment and materials inspection form(s).

Submit test or inspection reports and certificates for each electrical item tested within 48 hours after completion of test.

Operation and Maintenance Data:

1. In accordance with Section 01 45 16.13, Contractor Quality Control. 2. After test or inspection reports and certificates have been reviewed by Engineer

and returned, insert a copy of each in Operation and Maintenance Manual.


Test equipment shall have an operating accuracy equal to or greater than requirements established by NETA ATS.

1.4 SEQUENCING AND SCHEDULING Perform inspection and electrical tests after equipment here in listed has been installed.

Perform tests with apparatus de-energized whenever feasible.

Inspection and electrical tests on energized equipment shall be:

1. Scheduled with District prior to de-energization. 2. Minimized to avoid extended period of interruption to the operating plant

equipment.

Notify District at least 24 hours prior to performing tests on energized electrical equipment.

Exhibit S

Specifications



3.0 EXECUTION

3.1 GENERAL Tests specified in this section shall be performed in accordance with requirements of Section 01 91 14, Equipment Testing and Commissioning.

Tests and inspections shall establish:

1. Electrical equipment is operational within industry and manufacturer’s tolerances and standards.

2. Installation operates properly. 3. Equipment is suitable for energization. 4. Installation conforms to requirements of Contract Documents and NFPA 70 and

IEEE C2.

Perform inspection and testing in accordance with NETA ATS, industry standards, and manufacturer’s recommendations.

Adjust mechanisms and moving parts of equipment for free mechanical movement.

Adjust and set electromechanical electronic relays and sensors to correspond to operating conditions, or as recommended by manufacturer.

Verify nameplate data for conformance to Contract Documents and approved Submittals.

Realign equipment not properly aligned and correct unlevelness.

Properly anchor electrical equipment found to be inadequately anchored.

Tighten accessible bolted connections, including wiring connections, with calibrated torque wrench/screw driver to manufacturer’s recommendations, or as otherwise specified in NETA ATS.

Clean contaminated surfaces with cleaning solvents as recommended by manufacturer.

Provide proper lubrication of applicable moving parts.

Inform Engineer of working clearances not in accordance with NFPA 70.

Investigate and repair or replace:

Exhibit S

Specifications


1. Electrical items that fail tests. 2. Active components not operating in accordance with manufacturer’s

instructions. 3. Damaged electrical equipment.

Electrical Enclosures:

1. Remove foreign material and moisture from enclosure interior. 2. Vacuum and wipe clean enclosure interior. 3. Remove corrosion found on metal surfaces. 4. Repair or replace, as determined by Engineer door and panel sections having

dented surfaces. 5. Repair or replace, as determined by Engineer poor fitting doors and panel

sections. 6. Repair or replace improperly operating latching, locking, or interlocking devices. 7. Replace missing or damaged hardware. 8. Finish:

a. Provide matching paint and touch up scratches and mars. b. If required due to extensive damage, as determined by Engineer, refinish

entire assembly.

Replace fuses and circuit breakers that do not conform to size and type required by the Contract Documents or approved Submittals.

3.2 CHECKOUT AND STARTUP

3.2.1 Equipment Line Current Tests Check line current in each phase for each piece of equipment.

If any phase current for any piece of equipment is above rated nameplate current, prepare Equipment Line Phase Current Report that identifies cause of problem and corrective action taken.

3.3 PANELBOARDS 3.3.1 Visual and Mechanical Inspection Include the following inspections and related work:

1. Inspect for defects and physical damage, labeling, and nameplate compliance with requirements of up-to-date drawings and panelboard schedules.

2. Exercise and perform operational tests of mechanical components and other operable devices in accordance with manufacturer’s instruction manual.

3. Check panelboard mounting, area clearances, and alignment and fit of components.

Exhibit S

Specifications


4. Check tightness of bolted electrical connections with calibrated torque wrench. Refer to manufacturer’s instructions for proper torque values.

5. Perform visual and mechanical inspection for overcurrent protective devices.

3.3.2 Electrical Tests Include the following items performed in accordance with manufacturer’s instruction:

1. Insulation Resistance Tests: a. Applied megohmmeter dc voltage in accordance with NETA ATS,

Table 100.1. b. Each phase of each bus section. c. Phase-to-phase and phase-to-ground for 1 minute. d. With breakers open. e. With breakers closed. f. Control wiring except that connected to solid state components. g. Insulation resistance values equal to, or greater than, ohmic values

established by manufacturer. 2. Ground continuity test ground bus to system ground.

3.4 DRY TYPE TRANSFORMERS 3.4.1 Visual and Mechanical Inspection

1. Physical and insulator damage. 2. Proper winding connections. 3. Bolt torque level in accordance with NETA ATS, Table 100.12, unless otherwise

specified by manufacturer. 4. Defective wiring. 5. Proper operation of fans, indicators, and auxiliary devices. 6. Removal of shipping brackets, fixtures, or bracing. 7. Free and properly installed resilient mounts. 8. Cleanliness and improper blockage of ventilation passages. 9. Verify that tap-changer is set at correct ratio for rated output voltage under

normal operating conditions. 10. Verify proper secondary voltage phase-to-phase and phase-to-ground after

energization and prior to loading.

3.5 LOW VOLTAGE CABLES AND WIRING, 600 VOLTS MAXIMUM 3.5.1 Visual and Mechanical Inspection

1. Inspect each individual cable and wire for: a. Physical damage. b. Proper connections in accordance with wiring diagram. c. Cable bends not in conformance with manufacturer’s minimum allowable

bending radius where applicable.

Exhibit S

Specifications


d. Color coding conformance with Specifications. e. Proper circuit identification.

2. Mechanical Connections for: a. Proper lug type for conductor material. b. Proper lug installation. c. Bolt torque level in accordance with NETA ATS, Table 100.12, unless

otherwise specified by manufacturer. 3. Shielded Instrumentation Cables for:

a. Proper shield grounding. b. Proper terminations. c. Proper circuit identification.

4. Control Cables for: a. Proper termination. b. Proper circuit identification.

3.5.2 Electrical Tests for cables and wiring 1. Insulation Resistance Tests:

a. Applied megohmmeter dc voltage in accordance with NETA ATS, Table 100.1.

b. Each phase of each bus section. c. Phase-to-phase and phase-to-ground for 1 minute. d. With breakers open. e. With breakers closed. f. Control wiring except that connected to solid state components. g. Insulation resistance values equal to, or greater than, ohmic values

established by manufacturer. 2. Ground continuity test ground bus to system ground.

3.6 SAFETY SWITCHES, 600 VOLTS MAXIMUM 3.6.1 Visual and Mechanical Inspection

1. Proper blade pressure and alignment. 2. Proper operation of switch operating handle. 3. Adequate mechanical support for each fuse. 4. Proper contact-to-contact tightness between fuse clip and fuse. 5. Cable connection bolt torque level in accordance with NETA ATS,

Table 100.12. 6. Proper phase barrier material and installation. 7. Verify fuse sizes and types correspond to one-line diagram or approved

Submittals. 8. Perform mechanical operational test and verify electrical and mechanical

interlocking system operation and sequencing.

Exhibit S

Specifications


3.7 MOLDED AND INSULATED CASE CIRCUIT BREAKERS 3.7.1 General Inspection and testing limited to circuit breakers rated 100 amperes and larger and to motor circuit protector breakers rated 100 amperes and larger.

3.7.2 Visual and Mechanical Inspection 1. Proper mounting. 2. Proper conductor size. 3. Feeder designation according to nameplate and one-line diagram. 4. Cracked casings. 5. Connection bolt torque level in accordance with NETA ATS, Table 100.12. 6. Operate breaker to verify smooth operation. 7. Compare frame size and trip setting with circuit breaker schedules or one-line

diagram. 8. Verify that terminals are suitable for 75 degrees C rated insulated conductors.

3.8 GROUNDING SYSTEMS 3.8.1 Visual and Mechanical Inspection

1. Equipment and circuit grounds in motor control center, and panelboard assemblies for proper connection and tightness.

2. Ground bus connections in motor control center, and panelboard assemblies for proper termination and tightness.

3. Effective transformer core and equipment grounding. 4. Accessible connections to grounding electrodes for proper fit and tightness. 5. Accessible exothermic-weld grounding connections to verify that molds were

fully filled and proper bonding was obtained.

3.8.2 Electrical Tests 1. Neutral Bus Isolation

a. Test each neutral bus individually with neutral bonding jumper removed at Service Entrance or separately derived system.

b. Evaluate ohmic values by measuring resistance between ground bus and neutral bus.

c. Investigate values less than 50 megohms.

3.9 LOW VOLTAGE MOTOR CONTROL 3.9.1 Visual and Mechanical Inspection

1. Proper barrier and shutter installation and operation. 2. Proper operation of indicating and monitoring devices. 3. Proper overload protection for each motor.

Exhibit S

Specifications


4. Proper operation of drawout elements. 5. Integrity and contamination of bus insulation system. 6. Check door and device interlocking system by:

a. Closure attempt of device when door is in OFF or OPEN position. b. Opening attempt of door when device is in ON or CLOSED position.

7. Verify current and potential transformer ratios conform to Contract Documents. 8. Check bus connections for high resistance by low resistance ohmmeter and

calibrated torque wrench applied to bolted joints: a. Ohmic value to be zero. b. Bolt torque level in accordance with NETA ATS, Table 100.12, unless

otherwise specified by manufacturer. 9. Check operation and sequencing of electrical and mechanical interlock systems

by: a. Closure attempt for locked open devices. b. Opening attempt for locked closed devices. c. Key exchange to operate devices in OFF-NORMAL positions.

10. Verify performance of each control device and feature furnished as part of motor control center.

11. Exercise active components. 12. Compare overload heater rating with full-load current for proper size.

3.9.2 Electrical Tests 1. Operational test by initiating control devices to affect proper operation.


Exhibit S

Specifications

Bid No. 15-65 Bridge Crane Runway Conductor – 26 25 13 Page 1

SECTION 26 25 13

BRIDGE CRANE RUNWAY CONDUCTOR

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 REFERENCES ...................................................................................................... 2 1.2 SECTION INCLUDES ............................................................................................. 2 1.3 SUBMITTALS ....................................................................................................... 3 1.4 QUALITY ASSURANCE .......................................................................................... 4

2.0 PRODUCTS ......................................................................................................... 4 2.1 GENERAL ............................................................................................................ 4 2.2 SYSTEM GROUND BAR (SCHEDULE B) .................................................................. 4 2.3 RUNWAY CONDUCTOR (SCHEDULE C) .................................................................. 4

3.0 EXECUTION ......................................................................................................... 5 3.1 GENERAL ............................................................................................................ 5 3.2 INSTALLATION ..................................................................................................... 5 3.3 REMOVAL OF EXISTING RUNWAY CONDUCTOR ....................................................... 5

Exhibit S

Specifications


SECTION 26 25 13

BRIDGE CRANE RUNWAY CONDUCTOR

1.0 GENERAL


Crane Manufacturers Association of America (CMAA) No. 70 Top Running and Gantry Type Multiple Girder Electric

Overhead Traveling Cranes (2010 edition) American Institute of Steel Construction (AISC)

AISC 317 Manual of Steel Construction, Vol II: Connections AISC 325 Manual of Steel Construction

InterNational Electrical Testing Association (NETA) ATS STANDARD FOR ACCEPTANCE TESTING SPECIFICATIONS for

Electrical Power Equipment and Systems

National Fire Protection Association (NFPA) 70 National Electrical Code® (NEC) 70E Standard for Electrical Safety - Safety in the Workplace® 101 Life Safety Code®

Occupational Safety and Health Administration (OSHA) 29 CFR, Part 1910 Occupational Safety and Health Standards

1.2 SECTION INCLUDES Work described in this section is applicable to additive alternate Bid Schedules B and C as follows:

1. Additive Alternate 1 – Installation of a Dedicated System Ground for Both Bridge Cranes (Bid Schedule B): a. Modify existing three phase conductor system support brackets to allow

installation of a new ground bar. b. Furnish and install a new system ground for both cranes complete with

collectors and expansion joints as specified. The crane ground system shall be designed for installation adjacent to the existing three-phase crane conductor system.

c. Furnish all on crane wiring, materials, and equipment to connect to the new system ground.

Exhibit S

Specifications


d. Furnish incidental materials, such as structural steel supports, shims, anchors, bolts, nuts, washers, lock washers, etc. as required to completely and correctly install the runway conductor system

2. Additive Alternate 2 – Installation of New Runway Conductor System for Both Bridge Cranes (Bid Schedule C): a. Remove and dispose of the existing three phase conductor system. The

existing conductor support bracket anchors shall remain and be reused. b. Design, fabricate, furnish and install a new runway conductor system. The

new system shall include three-phase conductors, and green insulated ground bar.

c. Furnish incidental materials, such as structural steel supports, shims, anchors, bolts, nuts, washers, lock washers, etc. as required to completely and correctly install the runway conductor system in accordance with the manufacturer’s recommendations and to satisfy all code and regulatory requirements.

1.3 SUBMITTALS 1.3.1 Action Submittals

1. Runway Voltage Drop Calculations: Calculation based on the crane FLA proposed conductors and length of runway.

2. Shop Drawings: General arrangement drawings for runway conductor installation.

3. Catalog Data: Product specifications, descriptive literature, and performance data for items of standard manufacture.

4. Installation instructions. 1.3.2 Informational Submittals Submit 30 days prior to performing inspections or tests:

1. Schedule for performing inspection and tests. 2. List of references to be used for each test.

3. Sample copy of equipment and materials inspection form(s).

4. Submit test or inspection reports and certificates for each electrical item tested within 48 hours after completion of test.

1.3.3 Operation and Maintenance Data:

1. In accordance with Section 01 45 16.13, Contractor Quality Control. 2. After test or inspection reports and certificates have been reviewed by Engineer

and returned, insert a copy of each in Operation and Maintenance Manual.

Exhibit S

Specifications



Apply a system of control that will ensure that the requirements herein have been properly interpreted and transposed to Contractor’s Shop Drawings, material orders, and any written procedures or instructions pertaining to the Work.

2.0 PRODUCTS

2.1 GENERAL To meet the requirements of the NEC the cranes must have a ground. Therefore the Contractor shall provide a ground to the crane. The section 41 22 11.13 requires a grounding shoes to make contact with the building runway rails. However as an option the contractor shall offer pricing for schedules B and C as described below. It is the intention of the District that both systems be designed for ease of maintenance and minimum stocking of spare parts. Schedule C shall be design for a voltage drop of no more than 4%.

2.2 SYSTEM GROUND BAR (SCHEDULE B)

1. Type: Enclosed, finger-safe, insulated type for indoor crane service, UL Listed. 2. Description: Ground for 400 Amp service, center feed where indicated on the

Contract Drawings. The runway ground bar system shall be designed for longitudinal expansion thermally and shall incorporate expansion joints when crossing the powerhouse concrete structure contraction joints. Match the existing system to the extent possible.

3. The system shall include matching collectors with double shoes for crossing expansion joints in the runway conductors without loss of connectivity or disruption to the crane ground system. The assemblies shall feature corrosion resistant pivot pins, impact resistant polycarbonate arms and body that are universally interchangeable, electrically insulated and green in color. The shoes shall be capable of carrying the maximum demand load of the system.

4. Furnish incidental materials, such as structural steel supports, shims, anchors, bolts, nuts, washers, lock washers, etc. as required to completely and correctly install the runway ground bar system in accordance with the manufacturer’s recommendations and to satisfy all code and regulatory requirements

2.3 RUNWAY CONDUCTOR (SCHEDULE C)

1. Type: Enclosed, finger-safe, insulated type for indoor crane service, UL Listed. 2. Description: Electromotive Systems, Inc., Electrobar FS, 400 Amp (larger if required

fto reduce voltage drop) Or Equal, center feed where indicated on the Contract Drawings, three-phase conductors, and green insulated ground bar. The runway

Exhibit S

Specifications


conductor system shall be designed for longitudinal expansion thermally and shall incorporate expansion joints when crossing the powerhouse concrete structure contraction joints.

3. The system shall include matching collectors with double shoes for crossing expansion joints in the runway conductors without loss of power or disruption to the crane drives. The assemblies shall feature corrosion resistant pivot pins, impact resistant polycarbonate arms and body that are universally interchangeable, electrically insulated and safety yellow in color. The shoes shall be capable of carrying the maximum demand load of the system.

4. Furnish incidental materials, such as structural steel supports, shims, anchors, bolts, nuts, washers, lock washers, etc. as required to completely and correctly install the runway conductor system in accordance with the manufacturer’s recommendations and to satisfy all code and regulatory requirements

3.0 EXECUTION

3.1 GENERAL Furnish labor, suitable cranes and/or platforms, slings, and other tackle for handling the runway conductors, as well as incidental materials, torque wrenches and other tools, surveyor’s transits, levels, plumb wires, gauges, and other measurement devices, to facilitate installation

3.2 INSTALLATION Install ground bar or conductor system as shown on the Contract Drawings on the downstream wall below the bridge crane runway rails and in accordance with runway conductor manufacturer’s installation instructions and details and in cooperation with the crane manufacturer’s requirements. Provide support brackets to secure to the downstream wall. The support brackets shall be mounted on “stand-offs” from the wall utilizing the existing embedded anchor bolts used to support the existing crane conductor system.

3.3 REMOVAL OF EXISTING RUNWAY CONDUCTOR For Schedule C Work remove the existing runway conductors located on the downstream wall of the powerhouse and the existing feeder cable. The Contractor shall dispose of all materials removed off site.


Exhibit S

Specifications

Bid No. 15-65 Basic Mechanical Requirements for Bridge Cranes 41 05 13.13 Page 1

SECTION 41 05 13.13

BASIC MECHANICAL REQUIREMENTS FOR BRIDGE CRANES

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 2 1.1 SECTION INCLUDES ............................................................................................. 2 1.2 REFERENCES ...................................................................................................... 2 1.3 MANUFACTURERS................................................................................................ 5

2.0 PRODUCTS ......................................................................................................... 5 2.1 MATERIAL REQUIREMENTS ................................................................................... 5 2.2 MATERIAL STANDARDS ........................................................................................ 5 2.3 MATERIAL TESTS ................................................................................................. 7 2.4 TEST CERTIFICATES ............................................................................................ 8 2.5 NONDESTRUCTIVE TESTS ..................................................................................... 8 2.6 WELDS ............................................................................................................... 8 2.7 PLATE MATERIAL ................................................................................................. 9 2.8 FORGINGS .......................................................................................................... 9 2.9 CASTINGS ........................................................................................................... 9

3.0 EXECUTION ......................................................................................................... 9 3.1 WORKMANSHIP ................................................................................................... 9 3.2 TOLERANCES ...................................................................................................... 9 3.3 MACHINE WORK ................................................................................................ 10 3.4 VIBRATION ........................................................................................................ 11 3.5 NOISE REQUIREMENTS ...................................................................................... 12

Exhibit S

Specifications


SECTION 41 05 13.13

BASIC MECHANICAL REQUIREMENTS FOR BRIDGE CRANES

1.0 GENERAL

1.1 SECTION INCLUDES 1. General requirements applicable to the bridge crane system specified in

Section 41 22 10.13 Bridge Crane Mechanical Rehabilitation. 2. Where more than one (1) choice is available as options for Contractor’s

selection of product, material, or equipment, Contractor shall select an option that is compatible with other products, materials, or equipment.

3. Compatibility shall be a basic, general, performance requirement of product, material, and equipment selections.

4. Contractor is responsible for ensuring equipment is furnished with fittings, accessories, and parts necessary for complete operating installations.

5. Provide items such as shims, fasteners, grout, grease fittings, lubricants, and fluids necessary for installation, start-up, testing and operation of the equipment provided.

1.2 REFERENCES 1. The publications listed below form a part of this specification to the extent

referenced. The publications are referred to in the text by basic designation only.

Acoustical Society of America (ASA) ASA S1.4 Part 1 American National Standard Electroacoustics - Sound Level

Meters - Part 1: Specifications (Same as IEC 61672-1)

ASA S1.4 Part 2 American National Standard Electroacoustics - Sound Level Meters - Part 2: Pattern Evaulation Tests (Same as IEC 61672-2)

ASA S1.4 Part 3 American National Standard Electroacoustics - Sound Level Meters - Part 3: Periodic Tests (Same as IEC 61672-3)

American Society of Mechanical Engineers (ASME) BPVC Section VIII Division 1, Rules for Construction of Pressure Vessels BPVC Section V Nondestructive Examination ANSI/ASME B4.1 Preferred Limits and Fits for Cylindrical Parts ASME B46.1 Surface Texture

American Society of Nondestructive Testing (ASNT) SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing

Exhibit S

Specifications


ASTM International (ASTM)

A27/A27M Standard Specification for Steel Castings, Carbon, for General Application

A36/A36M Standard Specification for Carbon Structural Steel A47/A47M Standard Specification for Ferritic Malleable Iron Castings A48/A48M Standard Specification for Gray Iron Castings A53/A53M Standard Specification for Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless A106/A106M Standard Specification for Seamless Carbon Steel Pipe for High-

Temperature Service A108 Standard Specification for Steel Bars, Carbon, Cold-Finished,

Standard Quality A148/A148M Standard Specification for Steel Castings, High-Strength, for

Structural Purposes A176 Standard Specification for Stainless and Heat-Resisting Chromium

Steel Plate, Sheet, and Strip A216/A216M Standard Specification for Steel Castings, Carbon, Suitable for

Fusion Welding, for High-Temperature Service A217/A217M Standard Specification for Steel Castings, Martensitic Stainless

and Alloy, for Pressure-Containing Parts, Suitable for High-Temperature

A240/A240M Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

A242/A242M Standard Specification for High-Strength Low-Alloy Structural Steel

A264 Standard Specification for Stainless Chromium-Nickel Steel-Clad Plate

A275/A275M Standard Practice for Magnetic Particle Examination of Steel Forgings

A276 Standard Specification for Stainless Steel Bars and Shapes A285/A285M Standard Specification for Pressure Vessel Plates, Carbon Steel,

Low- and Intermediate-Tensile Strength A370 Standard Test Methods and Definitions for Mechanical Testing of

Steel Products A388/A388M Standard Practice for Ultrasonic Examination of Steel Forgings A435/A435M Standard Specification for Straight-Beam Ultrasonic Examination

of Steel Plates A473 Standard Specification for Stainless Steel Forgings A500/A500M Standard Specification for Cold-Formed Welded and Seamless

Carbon Steel Structural Tubing in Rounds and Shapes

Exhibit S

Specifications


ASTM International (ASTM) A501/A501M Standard Specification for Hot-Formed Welded and Seamless

Carbon Steel Structural Tubing A504 Standard Specification for Wrought Carbon Steel Wheels A516/A516M Standard Specification form Pressure Vessel Plates, Carbon

Steel, for Moderate- and Lower-Temperature Service A537/A537M Standard Specification for Pressure Vessel Plates, Heat-Treated,

Carbon-Manganese-Silicon Steel A564/A564M Standard Specification for Hot-Rolled and Cold-Finished

Age-Hardening Stainless Steel Bars and Shapes A572/A572M Standard Specification for High-Strength Low-Alloy

Columbium-Vanadium Structural Steel A576 Standard Specification for Steel Bars, Carbon, Hot-Wrought,

Special Quality A668/A668M Standard Specification for Steel Forgings, Carbon and Alloy, for

General Industrial Use A743/A743M Standard Specification for Castings, Iron-Chromium,

Iron-Chromium-Nickel, Corrosion Resistant, for General Application

A747/A747M Standard Specification for Steel Castings, Stainless, Precipitation Hardening

A992/A992M Standard Specification for Structural Steel Shapes B16/B16M Standard Specification for Free-Cutting Brass Rod, Bar and

Shapes for Use in Screw Machines B21/B21M Standard Specification for Naval Brass Rod, Bar, and Shapes B100 Standard Specification for Wrought Copper-Alloy Bearing and

Expansion Plates and Sheets for Bridge and Other Structural Use B127 Standard Specification for Nickel-Copper Alloy (UNS N04400)

Plate, Sheet, and Strip B584 Standard Specification for Copper Alloy Sand Castings for General

Applications B766 Standard Specification for Electrodeposited Coatings of Cadmium

Crane Manufacturers Association of America (CMAA) CMAA 70-2010 Specification for Top Running Bridge and Gantry Type Multiple

Girder Electric Overhead Traveling Cranes International Organization for Standardization (ISO)

ISO1940-1:2003/ Cor 1:2005

Mechanical Vibration – Balance Quality Requirements for Rigid Rotors (rev 2005)

National Electrical Manufacturer’s Association (NEMA) ANSI/NEMA MG1-2011

Motors and Generators

Exhibit S

Specifications


1.3 MANUFACTURERS 1. All products, materials and equipment shall be standard products of

manufacturers employing the latest and best design and manufacturing practices regularly engaged in the production of the type of equipment and materials specified in the Contract Documents.

2. To the greatest extent possible, provide products, materials, and equipment of a singular generic kind from a single source. Manufacture individual parts to standard sizes and gauges so repair parts can be installed in the field.

3. Furnish interchangeable components of the same manufacturer for similar components.

4. The manufacturer’s name, address, and catalog number shall be permanently displayed on a nameplate securely attached to each major item of equipment.

2.0 PRODUCTS

2.1 MATERIAL REQUIREMENTS 1. Grade of Material: Materials and mechanical equipment shall conform to the

requirements indicated or specified, and if not specified, then materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved shall be furnished.

2.2 MATERIAL STANDARDS 1. Use the following partial list of material specifications, which are acceptable for

the intended purposes, as referenced for selecting standard, types, and grades of materials used by the Contractor unless specified otherwise. Substitutions may be used if approved by Engineer.

Product Material Group Application Specification

Castings

Carbon Steel General applications ASTM A27, Grade 65-35 or better

Carbon Steel Pressure-containing parts and for welding

ASTM A216, Grades WCB and WCC

Low-Alloy Steel High-strength, structural purposes

ASTM A148, Grade 80-50

Alloy Steel Pressure-containing parts ASTM A217, Grades WC4 and WC5

Corrosion-Resistant General applications ASTM A743,

suitable grade

Alloy Steel Precipitation hardening material

ASTM A747, Grade CB7-CU1

Exhibit S

Specifications


Product Material Group Application Specification

Bronze “BRNZ”

General applications (for bearings, wear plates etc.)

ASTM B584, Alloy C932 and C937

General applications (for castings)

ASTM B584, Alloy C903 or C923

Gray Iron General purpose ASTM A48, suitable grade

Malleable Iron General purpose ASTM A47, suitable grade

Shapes, plate and bars

Structural Steel General purpose ASTM A36, A992

High strength, low alloy ASTM A572, A242

Plate

Carbon Steel Pressure-containing parts ASTM A516, Grade 60 or better, Impact tested

Carbon Steel Structures ASTM A516 or A36 or A572

Carbon-Manganese Silicon Steel

Pressure-containing parts ASTM A537, Class 1, Impact tested

Stainless Clad Carbon Steel

Sealing surfaces-not machined

ASTM A264; with A285, Grade C base material and A240, Type 304L cladding for a minimum 20% of thickness

Plate, Sheet and Strip

Corrosion-Resistant Steel “GP-CRES”

General purpose ASTM B766 and A176

Corrosion-Resistant Steel

Fusion-welded pressure-containing parts

ASTM A240, Type 304L

Phosphor Bronze Bearing plates ASTM B100,

Alloy C51100 Nickel-Copper Alloy Monel ASTM B127

Bar Carbon Steel Pins and shafts up to 4-in. diameter ASTM A576

Carbon Steel General purpose ASTM A108

Exhibit S

Specifications


Product Material Group Application Specification Corrosion-Resistant Steel “GP-CRES”

General purpose ASTM A276, Series 300 or A240, Series 300

Hardened Corrosion-Resistant Steel “Mach-CRES”

Shafts and pins Wheel Axles

ASTM A564, Type 630

Rod, Bar and Shapes

Brass General purpose-free machining ASTM B16

Naval Brass Corrosive applications ASTM B21

Forgings

Carbon and Alloy Steel General industrial use ASTM A668

Corrosion-Resistant Steel Corrosive applications ASTM A473

Carbon Steel Crane wheels ASTM A504, Class C

Pipe Carbon Steel General service, handrails, special sizes ASTM A53, Grade B

Tubing Carbon Steel Drums, handrails, general service

ASTM A106, A500, A501

2.3 MATERIAL TESTS 1. Test materials or parts used in the equipment in conformity with applicable

methods prescribed by the ASTM, or such other organization as may be specifically required, and in general accordance with the best commercial methods.

2. Stocked material may be used provided evidence is furnished showing that such material meets the specified requirements, in which case, tests on stocked material may be waived.

3. Contractor shall test and inspect materials used in the Work to suit Contractor’s particular design. As a minimum, the following material testing and inspection requirements shall apply to the Work.

2.3.2 Plate Material

1. Perform material tests on plate materials as specified herein. Unless modified by mutual agreement between Contractor and Engineer, plate materials for major structural or load carrying shall be tested as follows: a. Chemical composition.

Exhibit S

Specifications


b. Tension. 2.3.3 Forged and Cast Material

1. Perform material tests on forged and cast materials as specified herein. Unless modified by mutual agreement between Contractor and Engineer, forged and cast materials for major load carrying parts, such as drive pinions, drive gears, wheel shafts, and wheels, shall be tested as follows: a. Chemical composition. b. Tension and hardness.

2.3.4 Tension and Hardness Tests Perform tension and hardness tests on specified materials in accordance with ASTM A370.

2.4 TEST CERTIFICATES 1. Submit certified material test reports to Engineer as soon as possible after the

tests are made. 2. Test certificates shall identify the component for which the material is to be

used and shall contain all information necessary to very compliance with the specifications.

3. Material certificates and test reports shall be included in the Contractor’s Inspection and Test Plan.

2.5 NONDESTRUCTIVE TESTS 1. Unless otherwise noted or specified, Contractor shall:

a. Determine the specific standard for nondestructive testing applicable to the material and manufacturing method used, and;

b. Determine the extent of examination and the basis for acceptance. 2. Contractor’s Shop Drawings submitted for Engineer review shall define the

areas, extent, type, and method of nondestructive examination and acceptance criteria.

3. Certify that personnel performing and interpreting nondestructive examinations have been qualified as Level 2 or 3 examiners in accordance with ASNT SNT-TC-1A.

2.6 WELDS Perform NDE on welds as specified in Section 05 05 23 Welding.

Exhibit S

Specifications


2.7 PLATE MATERIAL Perform NDE of plate materials as specified herein. Unless modified by mutual agreement between Contractor and Engineer, plate materials for major structural or load carrying elements shall undergo the following NDE:

1. Ultrasonic examination per ASTM A435/A435M.

2.8 FORGINGS Perform NDE on forgings as specified in Section 05 58 10 Forgings. Unless modified by mutual agreement between Contractor and Engineer, forged materials for major load carrying parts shall undergo the NDE specified in Section 05 58 10 Forgings.

2.9 CASTINGS Perform NDE on castings as specified in Section 05 56 00 Castings. Unless modified by mutual agreement between Contractor and Engineer, cast materials for major load carrying parts shall undergo the NDE specified in Section 05 56 00 Castings.

3.0 EXECUTION

3.1 WORKMANSHIP 1. Perform and complete Work in a thorough workmanlike manner, following the

best modern practices in the design and manufacture. 2. Perform and complete Work using personnel skilled in the related professions

and operators. 3. Provide like parts and spare parts to be interchangeable wherever possible.

Machining of fits on renewable parts shall be accurate and dimensions specified so that replacements made to the size shown on the Shop Drawings may be readily installed.

4. Machining of fits on renewable parts shall be accurate and to specified dimensions so that replacements made to size may be readily installed.

3.2 TOLERANCES 1. Tolerances shall be selected by the Contractor to meet the precision required

for the proper operation of the equipment, considering the nature and function of the part. All tolerances shall be indicated on the Contractor’s Shop Drawings and submitted for review.

2. Contractor shall establish finer shop tolerances, if necessary, to meet the specified performance or operational requirements or for interchangeability of spare parts. All tolerances shall be selected with due considerations to the nature and function of the parts and to the corresponding accuracy required to secure proper operation, but shall not exceed the tolerances specified.

Exhibit S

Specifications


3.3 MACHINE WORK 3.3.1 General

1. All tolerances, allowances, and gages for metal fits between plain (non-threaded) cylindrical parts shall conform to ANSI/ASME B4.1 for the class of fit as shown or required.

2. Sufficient machining stock shall be allowed on parts to be machined to ensure true surfaces of solid material.

3. Finished contact or bearing surfaces shall be true and exact to secure full contact.

4. Journal and sliding surfaces shall be polished, and all surfaces shall be finished with sufficient smoothness and accuracy to ensure proper operations when assembled.

5. All drilled holes for bolts which are intended to match other drilled holes shall be accurately located and drilled from templates.

6. No machining shall be done on working surfaces of self-lubricating bronze bushings or washers.

3.3.2 Finished Surfaces:

1. Surface finish of machined parts shall be the most suitable to meet functional requirements.

2. Surface finish qualities shall be adequate for the intended use and shall be indicated on the Contractor’s drawings and shall be in accordance with ANSI/ASME B46.1.

3. Compliance with specified surface will be determined by visual inspection of the work compared to standard roughness specimens, in accordance with the provisions of ANSI/ASME B46.1.

4. Except as otherwise specified or approved, surface roughness shall not exceed 63 microinches for all surfaces in sliding contact; 125 microinches for surfaces in permanent contact where a tight joint is required; 250 microinches for surfaces in contact where a tight joint is not required; and 500 microinches for other machined surfaces. Contact surfaces of shafts or shaft sleeves, which pass through packing boxes and bearings, and all bearings, shall be finished to a surface roughness not to exceed 32 microinches.

3.3.3 Unfinished Surfaces:

1. So far as practicable, all work shall be laid out to secure proper matching of adjoining unfinished surfaces.

2. Where there is a large discrepancy between adjoining unfinished surfaces they shall be chipped and ground smooth, or machined, to secure proper alignment.

3. Unfinished surfaces shall be true to the lines and dimensions shown on the drawings and shall be chipped or ground free of all projections and rough spots.

Exhibit S

Specifications


4. Depressions of the parts may be filled in an approved manner. 3.3.4 Holes for Pins and Dowels

1. Holes shall be bored true to gauges, smooth and straight, and at right angles to the axis of the member.

2. Boring shall be done after the member is securely fastened in position. 3.3.5 Protection of Machined Surfaces

1. Machine-finished surfaces shall be thoroughly cleaned of foreign matter. 2. Finished surfaces of large parts and other delicate surfaces shall be protected

with wooden pads or other suitable means. 3. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant

paper or protected by other approved means. 4. Finished surfaces of ferrous metals to be in bolted contact shall be washed with

a rust inhibitor and given one thin coat of lubricant. 5. Self-lubricating bronze bearings shall be assembled according to the

manufacturer’s written instructions. 3.3.6 Machining Equipment

1. All machines required for carrying out the Work shall be Contractor’s responsibility. All machining tools and equipment including milling and boring machines, lathes and all other required machines and equipment shall be furnished by Contractor as part of their Scope. In addition, Contractor shall furnish: a. Trained and qualified personnel for the installation, calibration, operation,

maintenance, repair, and removal of the machining equipment. b. Supports, platforms and any required jigs or special assemblies required for

the proper and optimal operation of the machining equipment. c. All consumable materials including cutters, milling teeth, cutting heads,

blades, abrasives, drills, etc. required for the proper and optimal use of the machining equipment.

3.4 VIBRATION 1. All rotating mechanical equipment shall not exhibit unfiltered readings in excess

of the following amplitudes: Speed Range Anti-friction Bearings Sleeve Bearings

900 rpm and below 3.0 mils 3.5 mils 901-1800 rpm 2.2 mils 3.0 mils 1801-3000 rpm 1.3 mils 2.5 mils 3001-4500 rpm 1.0 mils 2.0 mils

Exhibit S

Specifications


Speed Range Anti-friction Bearings Sleeve Bearings 4501 and above 0.5 mils 1.6 mils

2. Antifriction Bearings: Measured on bearing housing in vertical, axial, and horizontal direction.

3. Sleeve Bearings: Relative shaft-to-casting motions for both rigid mounted and isolator mounted equipment.

4. Axial shaft vibration displacements (relative to casing) shall not exceed fifty percent (50%) of the maximum lateral shaft vibration displacements (relative to casing existing at any point along the shaft).

5. The above vibration responses are to include the range from 5.0 Hz to 5000 Hz and shall therefore encompass both low and high frequency responses of the subject equipment. The measurements shall be obtained with the equipment installed and operating at any capacity within the specified operating range. In addition to these maximum unfiltered readings, it is also stipulated that no narrow band spectral acceleration component, whether sub rotational, higher harmonic or asynchronous multiple of running speed, shall exceed forty percent (40%) of the synchronous displacement amplitude component without manufacturer's detailed verification of the origin and ultimate effect of said excitation.

3.5 NOISE REQUIREMENTS 1. The maximum permissible "free field" noise level for a complete piece of

mechanical equipment which is to be located within a structure shall not exceed 80 dBA at a distance of three (3) feet from the equipment.

2. For the purpose of this section, "free field" shall be the noise level measured when the equipment shall include the driver, driven equipment and any intermediate couplings, gears and auxiliaries.

3. For a complete piece of mechanical equipment located outside of a structure, the maximum permissible noise level shall comply with the requirements of the OSHA Standard Specifications.

4. Maximum permissible noise levels are in decibels as read on the "A" weighting network of a standard sound level meter (dBA). Measurements of emitted noise levels shall be made on a sound level meter meeting at least the Type II requirements as set forth in all parts of ANSI/ASA S1.4. The sound level meter shall be set on the "A" scale and to slow response.

5. Point of measurement of sound level shall be at the specified distance from any major surface along the entire perimeter and at mid-height of the piece of equipment. If sidelight is not easily determinable, then line of measurement shall be at a height level with the apparent noise source. To assure accuracy, the sound level meter shall be acoustically calibrated with an appropriate instrument, prior to test measurement.

Exhibit S

Specifications


6. Contractor shall furnish for each piece of equipment, prior to shipment to the job site, certified factory noise test reports on the actual equipment to be provided or an unconditional guarantee that the equipment when operating under design conditions will not produce noise exceeding the permissible levels specified.

7. Noise measurements shall be accomplished at the factory or at such other location approved by Engineer prior to shipment of any equipment to the job site. The measurements shall take place in a reverberant or semi reverberant condition, with equipment sitting on a hard reflecting surface or conditions that duplicate the circumstances under which the equipment will operate in this project.

8. At the option of Engineer, noise level measurements shall be taken or observed by an independent acoustical laboratory or consultant retained and paid for by Contractor. Such independent acoustical laboratory or consultant shall be qualified by experience in the acoustical field to take such measurement and shall be responsible for conducting them in accordance with accepted procedures for the measurement of sound. The selection of the laboratory or consultant shall be approved by Engineer.

9. In the event that the noise level is in excess of the allowable limits, appropriate field noise reduction measures shall be undertaken to reduce the noise to the allowable limits. If the noise level is within the allowable limits District will pay Contractor for all expenses incurred in conducting the test.

10. All field noise reduction measures shall be at Contractor's expense and shall be approved by Engineer prior to installation. Rated capacities, operation and normal maintenance procedures of the equipment shall not be affected by the noise reduction measures.



Bid 15-65 Bridge Crane Mechanical Rehabilitation – 41 22 10.13 Page 1

SECTION 41 22 10.13

BRIDGE CRANE MECHANICAL REHABILITATION

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 3 1.1 SECTION INCLUDES ............................................................................................. 3 1.2 REFERENCE SPECIFICATIONS ............................................................................... 3 1.3 RELATED SPECIFICATION SECTIONS ..................................................................... 4 1.4 SUBMITTALS ....................................................................................................... 4

1.4.1 GENERAL ....................................................................................................... 4 1.4.2 PROCEDURES ................................................................................................ 4 1.4.3 DRAWINGS ..................................................................................................... 5 1.4.4 EQUIPMENT AND MATERIAL LISTS ..................................................................... 6 1.4.5 CATALOG DATA .............................................................................................. 6 1.4.6 ENGINEERING DATA ........................................................................................ 7 1.4.7 CALCULATIONS, ENGINEERING DATA, ETC. INCLUDING: ....................................... 7 1.4.8 REPORTS AND DOCUMENTATION ...................................................................... 7

1.5 GENERAL REQUIREMENTS.................................................................................... 8 1.5.1 CONTRACTOR QUALIFICATIONS ....................................................................... 8 1.5.2 DESCRIPTION OF EQUIPMENT ........................................................................... 9 1.5.3 NAMEPLATES, CAPACITY PLATES, AND LABELS ............................................... 10

1.6 DESIGN REQUIREMENTS .................................................................................... 12 1.6.1 GENERAL ..................................................................................................... 12 1.6.2 DESIGN CRITERIA ......................................................................................... 13 1.6.3 DESIGN PARAMETERS ................................................................................... 15

1.7 OPERATING CONDITIONS ................................................................................... 16 1.8 OPERATING REQUIREMENTS .............................................................................. 16 1.9 WARRANTY ....................................................................................................... 17 1.10 QUALITY ASSURANCE ........................................................................................ 17

1.10.1 DRAWINGS ................................................................................................... 17 1.10.2 MATERIALS .................................................................................................. 17 1.10.3 WELDING ..................................................................................................... 17 1.10.4 PAINTING ..................................................................................................... 17 1.10.5 MANUFACTURE AND INSTALLATION ................................................................. 17

1.11 SUBSTITUTIONS ................................................................................................. 18 1.12 MANUFACTURER’S FIELD SERVICE REPRESENTATIVE ........................................... 18

2.0 PRODUCTS ....................................................................................................... 18 2.1 GENERAL MATERIAL REQUIREMENTS ................................................................... 18 2.2 STRUCTURAL FABRICATION ................................................................................ 18 2.3 BRIDGE MODIFICATIONS..................................................................................... 19

2.3.1 GENERAL ..................................................................................................... 19 2.3.2 BRIDGE STRUCTURE ..................................................................................... 19 2.3.3 BRIDGE DRIVE AND IDLER TRUCKS ................................................................. 20

2.4 WALKWAYS, PLATFORMS, AND LADDERS ............................................................. 20



2.5 HORIZONTAL LIFE LINE ...................................................................................... 23 2.6 TROLLEY .......................................................................................................... 23

2.6.2 TROLLEY DRIVE ........................................................................................... 24 2.6.3 TROLLEY RAILS AND LUBRICATORS ................................................................ 24 2.6.4 MISCELLANEOUS FEATURES AND ACCESSORIES ............................................. 24

2.7 BRIDGE BUMPERS AND STOPS ........................................................................... 24 2.8 OPERATOR’S CAB ............................................................................................. 24 2.9 GENERAL HOIST REQUIREMENTS ........................................................................ 25 2.10 LOAD BLOCKS ................................................................................................... 27 2.11 SHEAVES .......................................................................................................... 28 2.12 WIRE ROPE ...................................................................................................... 28 2.13 AUXILIARY HOIST DRUM ..................................................................................... 29 2.14 GEARING .......................................................................................................... 30 2.15 WHEELS ........................................................................................................... 30 2.16 BEARINGS ......................................................................................................... 31 2.17 AXLES, SHAFTS, AND COUPLINGS ....................................................................... 31 2.18 GUARDS AND ENCLOSURES................................................................................ 31 2.19 LUBRICATING SYSTEM ....................................................................................... 32 2.20 ANTI-DRIP PROVISIONS ..................................................................................... 33 2.21 PARKING AND HOLDING BRAKES ......................................................................... 33 2.22 SHOP ASSEMBLY TESTS .................................................................................... 34

3.0 EXECUTION ....................................................................................................... 34 3.1 PREPARATION FOR INSTALLATION ....................................................................... 34 3.2 INSTALLATION ................................................................................................... 35 3.3 FIELD TESTING .................................................................................................. 35 3.4 ADJUSTMENTS AND REPAIRS .............................................................................. 36 3.5 FIELD TRAINING................................................................................................. 36 3.6 SUBSTANTIAL COMPLETION ................................................................................ 36 3.7 ACCEPTANCE .................................................................................................... 37



SECTION 41 22 10.13

BRIDGE CRANE MECHANICAL REHABILITATION

1.0 GENERAL

1.1 SECTION INCLUDES 1. General requirements for performance, manufacturing, painting, shop

assembling and testing, shipping, installing, and field-testing for retrofit and upgrade of the two (2) 250 ton capacity Powerhouse Bridge Cranes.

1.2 REFERENCE SPECIFICATIONS

American Bearing Manufacturers Association (ABMA) STD 9 Load Ratings and Fatigue Life of Ball Bearings STD 11 Load Ratings and Fatigue Life for Roller Bearings

American Gear Manufacturer’s Association (AGMA) 2001-D04 Fundamental Rating Factors and Calculation Methods

for Involute Spur and Helical Gear Teeth ANSI/AGMA 6013-A06 Standard for Industrial Enclosed Gear Drives

American National Standards Institute (ANSI) C80.1 American National Standard For Electrical Rigid Steel

Conduit (ERSC) American Society of Mechanical Engineers (ASME)

B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

B30.10 Hooks B30.20 Below-the-Hook Lifting Devices BTH-1 Design of Below-the-Hook Lifting Devices

ASTM International (ASTM) A668/A668M Standard Specification for Steel Forgings, Carbon and

Alloy, for General Industrial Use B138/B138M Standard Specification for Manganese Bronze Rod, Bar,

and Shapes E709 Standard Guide for Magnetic Particle Testing

American Welding Society (AWS) D14.1/D14.1M Specification for Welding of Industrial and Mill Cranes

and Other Material Handling Equipment Crane Manufacturers Association of America (CMAA)

No. 70 Top Running and Gantry Type Multiple Girder Electric Overhead Traveling Cranes (2010 edition)

International Organization for Standardization (ISO)



1940 Mechanical Vibration – Balance Quality Requirements of Rigid Rotors

1.3 RELATED SPECIFICATION SECTIONS See the following related Specification sections for reference codes and standards for design, materials, material testing, inspection and other requirements for the crane system.

1. 05 05 23 Welding 2. 05 05 24 Fasteners 3. 05 50 00 Metal Fabrications 4. 05 56 00 Castings 5. 05 58 10 Forgings 6. 26 08 00 Electrical Testing 7. 41 05 13.13 Basic Mechanical Requirements for Bridge Cranes 8. 42 22 11.13 Bridge Crane Electrical Rehabilitation

1.4 SUBMITTALS 1.4.1 General

Submit all items in accordance with Section 01 30 00 Administrative Requirements.

Before proceeding with manufacture of the crane rehabilitation system, submit for review and approval Contractor’s Shop Drawings, catalog cut sheets, and engineering documents required to demonstrate fully that all parts will conform to the provisions and intent of this Section and related Sections, and to the requirements related to installation, operation, and maintenance.

1.4.2 Procedures 1. Work plan: Submit detailed Work plans for removal of existing equipment and

components; modifications to existing crane structures; installation of walkway, platform and other access equipment; installation of all electrical equipment and controls; modification of existing bridge drive and travel trucks; and installation of the new hoist and other crane equipment. Work plans shall including a description of work activities, illustrative diagrams, and schedule. Work plan for installation and testing of the modernized crane system shall be complete with Contractor’s Shop Drawings to demonstrate that the proposed design is consistent with the intended approach regarding installation and testing.



2. QA/QC Plan: Before proceeding with manufacture of any crane equipment, Contractor shall submit for review and approval a QA/QC Plan in accordance with Section 01 45 16.13 Contractor Quality Control.

3. Inspection and Test Plan: Before proceeding with manufacture and installation of cranes, submit for review and approval Contractor’s plan of inspection to be performed at key stages of assembly and testing of equipment, with applicable illustrations, diagrams, check sheets, and procedures, for fit-up, dimensional correctness, alignment, and sequential checkout, startup, and operation of equipment. The Shop and Field Inspection and Test Plan shall be in accordance with the requirements of Section 01 45 16.13 Contractor Quality Control, Section 01 91 14 Equipment Testing and Commissioning, and these Specifications.

1.4.3 Drawings 1. Before proceeding with manufacture of any crane equipment, Contractor shall

submit Drawings showing all necessary dimensions and fabrication details, complete Bill of Materials (including the type and grade of materials), details of welded and bolted joint connections, tolerances, surface finishes, nondestructive examinations, and other pertinent details.

2. Detail drawings (including but not limited to): a. General arrangement drawings for the revised crane assembly showing

clearances, capacities, speeds, pertinent dimensions, weights, wheel loads, etc. Drawings shall clearly detail the relationship of new crane equipment with respect to the existing crane and powerhouse features.

b. Crane clearance diagrams similar to District drawings 194/195-1-1E, 0220-61LY-0006

c. In addition to providing the details and assembly drawings required for equipment supplied, Contractor shall redraw the following list of Reference Drawings to reflect changes:

Reference Drawing

Description

PACECO 194/95-1-1E GENERAL ARRANGEMENT 250 TON BRIDGE CRANE 194/95-1-2E TROLLEY - GENERAL ARRANGEMENT: 250 TON BRIDGE

CRANE 194/95-1-3E BRIDGE DRIVE - GENERAL ARRANGEMENT: 250 TON

BRIDGE CRANE 194/95-3-1-E 250 TON BRIDGE CRANE CONDUIT DRAWING 194/95-6-1C BRAKE WHEELS: 250 TON BRIDGE CRANE 194/95-8-1C TROLLEY COLLECTOR ASSEMBLY: 250 TON BRIDGE

CRANE 194/95-8-2C 250 TON BRIDGE CRANE: BRIDGE COLLECTORS 194/95-17-1D BRIDGE DRIVE TRUCK: 250 TON BRIDGE CRANE 194/95-18-1D BRIDGE IDLER TRUCK: 250 TON BRIDGE CRANE 194/95-21-1E 250 TON BRIDGE CRANE: TROLLEY FABRICATION



Reference Drawing

Description

194/95-21-2C 250 TON TROLLEY: BOLTS NUTS & GROOVE PINS 194/95-27-1E MAIN HOIST GEAR; LOAD BRAKE ASSEMBLY (WITH BOM) 194/95-27-4D MAIN HOIST REDUCER LOAD BRAKE DETAILS 194/95-52-1D 250 TON BRIDGE CRANE: WALKWAYS & LADDER

DETAILS EDERER C-40776 BRIDGE DRIVE TRUCK PINION No. TEETH, 17-DP, 3 C-40777 BRIDGE DRIVE TRUCK GEAR No. TEETH, 72/DP 3 C-40783 ROCKY REACH POWERHOUSE 250 TON CRANE DRIVE

TRUCK ASSEMBLY (W/ BOM) M-40775 BILL OF MATERIALS

d. Installation and erection (field assembly) drawings for new crane equipment and accessories.

e. Load diagrams. f. Reeving diagrams. g. Subassembly drawings of revised trolley, hoist, load blocks, bridge trucks,

drives and other subassemblies. h. Details of new crane walkways, ladders, and enclosures. i. Details of new and revised hoist machinery, motors, brakes, speed

reducers, drums, sheaves, couplings, shafts, bearings, etc. j. Details of new traversing motion machinery, motors, brakes, speed

reducers, bearings, bearing cartridges, axles, shafts, wheels, couplings, etc. k. Details of new load blocks, hooks, sheaves, bearings, and wire rope. l. Details of new equipment arrangement in operator’s cab. m. Details of new lubrication systems. n. Match marking drawings. o. Nameplates. p. Other drawings needed to clarify the design.

1.4.4 Equipment and material lists 1. Equipment and material lists shall be provided for all items, pieces, parts and

assemblies to provide a complete listing of all components that make up the refurbished crane system.



1.4.5 Catalog Data 1. Provide product specifications, descriptive literature, and performance data for

items of standard manufacture; including but not limited to gear reducers,



bearings, couplings, and similar mechanical components, and manufacturer’s data sheets for motors, brakes, limit switches, circuit breakers, alternating current variable frequency (ACVF) drives, contactors and similar electrical components, etc.

2. Catalog data shall be submitted for items of standard manufacture, which will consist of the manufacturer’s published catalog; including but not limited to product specifications, descriptive literature and performance data.

1.4.6 Engineering Data 1.4.7 Calculations, engineering data, etc. including:

1. Calculations developed using MathCAD® or Microsoft® Excel shall be submitted in the original software application file formats; PDF (*.pdf) file format will not be accepted except for the final stamped and Approved submittal.

2. Structural design criteria and calculations used in the design of all new crane structural parts, including but not limited to walkways, ladders, handrails, etc.

3. Mechanical design criteria and calculations used in the selection and/or design of mechanical components including but not limited to axle, shaft, hook, drum, frame and pin stresses; wire rope, sheave, coupling wheel and rail selections; bearing life and coupling selection; commercial gear reducer selection and engineered gear ratings. Catalog ratings may be relied upon for components or assemblies (e.g. gear reducer) that are sold in quantity in the USA for general industrial purpose, but detailed calculations must be submitted for the ‘standard products’ of a crane supplier.

4. Calculations to determine rope anchorage capacity. 5. Calculations to determine the torque rating for each brake.

1.4.8 Reports and Documentation 1. Material test certificates (mechanical and chemical properties), in accordance

with requirements of appropriate sections of these Specifications. 2. Shop test report, including shop assembly and inspection check sheets for fit-

up, dimensional correctness, alignment, functional tests, and other checks. 3. Certification Records: Submit copies of all shop and field inspection records and

reports. 4. Hoisting rope pull test documentation. 5. Hook pull test and NDE documentation. 6. Packing and shipping procedures, in accordance with the requirements of

Section 01 61 00 Common Product Requirements. 7. Installation instructions, in accordance with the requirements of Section 01 78

23 Operation and Maintenance Data. 8. Operation and Maintenance Manuals: Submit complete sets of O&M manuals

containing the manufacturer’s operating and maintenance instructions for each



piece of equipment and the integrated crane in accordance with the requirements of Section 01 78 23 Operation and Maintenance Data.

9. Warranties: Manufacturer’s product warranties and additional warranties to be provided by Contractor.

10. Certificates of Compliance and Proper Installation, in accordance with the requirements of Section 01 45 16.13 Contractor Quality Control.

11. Closeout submittals, in accordance with Section 01 30 00 Administrative Requirements.

12. Certification of the factory adjusted torque rating of holding brakes. 13. Field test report, including field assembly and inspection check sheets for fit-up,

dimensional correctness, alignment, functional tests, load tests, and other checks.

1.5 GENERAL REQUIREMENTS 1.5.1 Contractor Qualifications

The Contractor shall be an established crane manufacturer with its own engineering department, or an experienced crane modification supplier, and shall provide a single source of supply throughout all aspects of the Work to provide consistency in design, component selection, manufacturing, and all other aspects of performing the Work furnished under this Contract.

The Contractor for this project shall demonstrate the following minimum qualifications:

1. 10 years experience in design, fabrication, and installation of new custom crane equipment, and/or 10 years experience in the mechanical and electrical modification of high-capacity or high-power overhead bridge or gantry cranes, for hydroelectric facilities. Experience shall show supply or modification of hydroelectric bridge or gantry crane systems of similar complexity to that required by these specifications.

2. The Contractor shall have experience in the electrical refurbishment of existing cranes, or the supply of new cranes. Demonstrate experience with no less than three (3) bridge or gantry cranes within the last ten (10) years that required crane controls with 100 or more installed horsepower (example 50hp main hoist + 25hp aux hoist + 5hp trolley + 20hp bridge = 100hp total installed.)

3. The Contractor shall also have experience in the mechanical refurbishment of existing crane hoists, or the supply of new cranes. Demonstrate experience with no less than three (3) bridge or gantry cranes rated 50 tons capacity or more within the last ten (10) years that required supply and installation of new structure, hoist gears, wire rope and bearings.

4. Site installer of the crane equipment (whether Contractor itself or Subcontractor), shall have experience in modifying crane and hoist equipment.



Installer shall have specific experience with the refurbishment of no less than three (3) hydroelectric-industry powerhouse bridge cranes within the last 10 years and shall have a minimum of 10 years’ experience in mechanical and electrical modification of large gantry or bridge cranes similar to the work specified.

The Contractor shall provide evidence of their qualifications with its Bid in accordance with General Requirements and Instructions to Bidders paragraph, Bidder’s Data. Subcontractors, and suppliers of crane components shall be subject to Approval by the Engineer.

1.5.2 Description of equipment

Contractor shall provide new electrical, mechanical and structural crane equipment and accessories for the refurbishment of the Rocky Reach Powerhouse Bridge Cranes including, but not limited to the following:

1. New motors and brakes. 2. New wiring, reusing existing conduit and wireway as applicable. 3. New rigid conduit where required. 4. New motor controls. 5. New geared limit switches for both the main and auxiliary hoists 6. All-new auxiliary hoist drum, reducer, couplings, lower block and equalizer bar 7. New main hoist reducer 1st and 2nd reduction gear sets with shafts and caps 8. New drum gear and reducer output sets with bearings on the south crane only 9. New bridge drive motor-reducer assemblies with torque arm mounting 10. New bridge drive wheel gears, pinions and extended pinion shafts 11. Modification of existing bridge drive bogies to suit new bridge drives 12. All-new bearings for the entire crane, and their installation, except as noted for

the north crane hoist 13. Crane power system 14. Crane control system with enclosures 15. Crane access modifications (walkways and ladders) 16. Miscellaneous accessories and components. 17. Removal of existing equipment as specified in Sections 02 41 19 Selective

Removal and Modifications.

Equipment supplied shall include and meet with the following requirements:



18. Select standard (off-the-shelf) parts and components to the extent practicable given the performance requirements specified herein.

19. Select parts and components that are readily available and interchangeable to the extent practicable. Select components to minimize the overall number and type of parts to be serviced, repaired, and/or stored in spare parts inventories.

20. Requirements specified herein shall apply to all equipment furnished, except those requirements that are modified elsewhere. All aspects that are not specified in this Section shall be in accordance with the recommendations of applicable industry design standards, and with conservative design practice.

21. Provide a refurbished crane system that is complete with all parts and components specified and/or required for installation, operation, and maintenance.

22. Provide parts and components that can be serviced and repaired directly by firms or agencies located in the United States.

23. Provide all equipment and accessories for handling the supplied equipment including slings and other accessories to form and handle bundles during transportation and for unloading at the job site. The equipment shall also include all supporting elements for transportation of various supplied equipment.

24. All parts, components, and assemblies which are heavier than 50 pounds shall be provided with suitable provisions for handling, such as eyebolts, lugs, hooks, tapped holes for eyebolts, or holes with rounded corners for passing slings. Components that require special access and weight considerations shall be provided with handling provisions and detailed written handling procedures.

25. Provide special handling equipment and other support equipment for installation, if required, which are specific to the Contractor’s design and which cannot be readily purchased.

26. Provide one (1) complete set of erection supplies, including nuts and bolts, electrodes, miscellaneous material, alignment checking instruments, and templates needed for efficient installation of the equipment and for checking the installed equipment. Provide sufficient number and type of fasteners, consumables, and miscellaneous items to ensure timely installation and assembly.

27. Provide spare parts in accordance with Section 01 78 43. All Spare parts shall be readily available through Contractor or directly through suppliers/manufacturers or U.S. representatives.

1.5.3 Nameplates, Capacity Plates, and Labels

1.5.3.1 Crane Identification Nameplates 1. Furnish at least two large nameplates (one for each side of bridge) denoting the

cranes’ rated capacity, manufacturer, serial number and supply / refurbish date.



2. Nameplates shall be fabricated from steel, iron, bronze or aluminum, with porcelain or painted coating. Wood, fabric, plastic or other non-metallic plates, vinyl or other adhesive lettering or logos are not permitted.

3. All nameplates shall be attached to the equipment with corrosion resisting mechanical fasteners.

4. Drawings showing the proposed nameplates, its size, and location on the cranes shall be submitted. Lettering shall be large enough to be readable from deck level.

1.5.3.2 Operator’s Cab Nameplate 1. Provide a manufacturer’s nameplate in the operator’s cab, with the crane name

(Rocky Reach Powerhouse Bridge Crane #1 / #2), capacity, refurbish contractor’s name and addresses, serial number, contract number and supply year.

2. The cab nameplate may be cast, painted metal or engraved phenolic. 3. Cab nameplates shall be attached with corrosion resisting screws.

1.5.3.3 Equipment Nameplates 1. Furnish each piece of equipment (such as motors, gear reducers, holding

brakes, drives, radio controllers, etc.) with identification nameplates that are permanently mounted on each piece of equipment.

2. Nameplates shall show the serial number, the name and address of the manufacturer, rated capacity, speed, electrical characteristics, and other pertinent data as applicable to the component. Nameplates of distributing agents alone will not be acceptable. Mount the nameplates at an appropriate, prominent location on the equipment itself.

3. Submit all proposed nameplate designations to the Engineer for approval. Nameplates shall be of either: a. Twenty (20) gage stainless steel with embossed lettering, b. Laminated plastic with lettering engraved through upper layer, or c. Anodized aluminum, stainless steel, plastic, or other material of equivalent

durability which has engraved or etched lettering filled with enamel of a contrasting color.

4. All nameplates shall be attached to the equipment with corrosion resisting screws.

1.5.3.4 Block Capacity Plates

Provide new capacity plates for both sides of the auxiliary hoist lower blocks. The existing main hoist capacity plates shall be reused. Materials for block capacity plates shall be as specified in paragraph 1.5.3.1.



1.6 DESIGN REQUIREMENTS 1.6.1 General

Unless specified otherwise, the supplied crane equipment shall meet all of the requirements and recommendations of ASME B30.2, OSHA 1910.169 and the NFPA-70 National Electrical Code.

The supplied new equipment shall also be designed in accordance with CMAA No. 70 for Class D Service, except as modified by the detailed requirements in this specification. In addition, any reference to the term “should” in CMAA Specification No. 70, shall be a firm performance requirement, rather than optional for this Contract. Equipment that has been designed using other codes and standards may be used, provided that it meets this Specification’s detailed requirements and the alternate code or standard has been approved by the District Engineer. District Engineer may approve the use of alternate equivalent recognized international standards; however the requirements regarding properties, workmanship, quality and testing specified in the listed standards shall apply for all equivalent standards proposed. See Section 01 42 13 Reference Codes and Standards, for additional details regarding alternate standards and codes.

The overall machinery design factor shall be based on machine stresses no higher than 20% of Ultimate Tensile Strength (UTS) in accordance with CMAA paragraph 1.7.1 and all rotating shafts shall be designed for infinite fatigue life. Reduced basic design factors and limited design fatigue life will not be accepted.

These Specifications are intended to describe performance details and requirements for the crane equipment and are not restrictive as to actual manufacturing details, which shall be determined by Contractor, unless otherwise shown or specified. Contractor may propose alternative configurations and details provided that the design provides a results equivalent to that specified. The design will be subject to Engineer’s review and approval.

The Contract Drawings indicate: the general arrangement of the existing crane; clearances necessitated by the structure or other equipment; maximum overall dimensions, and other pertinent features. Contract Drawings also indicate general arrangement of new crane equipment including new hoist, reducer modifications, new controls and accessories, and crane access. Contract Drawings are not intended to define the detailed design of the equipment to be furnished, but are illustrative in showing conceptual details and requirements.

Requirements specified herein shall apply to all equipment furnished, except those requirements that are modified elsewhere. All aspects that are not specified in this Section shall be in accordance with the recommendations of applicable industry design standards, and with conservative design practice.



1.6.2 Design Criteria

1.6.2.1 General

Design criteria used for the crane shall ensure that all operations can be performed as specified over a 50-year service life with minimal inspection and maintenance, and can be safely operated under the loading conditions specified in the environment for which it is intended.

The following criteria shall apply to the design of all new crane components and equipment:

1. Electrical component certification shall be UL Certified, Or Equal, as approved by the Engineer.

2. The new equipment shall have a service life of 50 years with minimal inspection and maintenance.

3. Design the equipment and the structural reinforcements with special attention to design simplicity.

4. Design the equipment with special attention to ease of access for inspection and maintenance.

5. Design the equipment to operate safely and reliably without binding, vibration, noise or excessive heat.

6. Design the equipment to perform as specified. 7. Select components (e.g., motors, instrumentation, controls, supports, and

accessories) designed to meet the specified design and operating conditions for the environment in which they are installed.

8. Select components based on generous factors of safety and service factors to provide a conservative design.

9. Select components and equipment for indoor crane service. The Rocky Reach Powerhouse is covered, indoors, not climate controlled.

10. Apply appropriate and conservative stress concentration factors where applicable.

1.6.2.2 Allowable Stresses: 1. Structural Design: Per CMAA Specification No. 70, as modified herein and in

related sections. The Design for the revised and new walkway structures shall be reviewed and stamped by a Washington State Professional Engineer.

2. Mechanical Design: Per CMAA Specification No. 70, as modified herein and in related sections. For mechanical items not covered by CMAA, working stresses, bearing pressures, and other design parameters for mechanical components including shafts, pins, and bushings shall be based on



consideration of functional requirements, dynamic loading, impact, and stress concentration effects. Stresses computed for normal load conditions (or rated capacity) shall not exceed 20% of the ultimate strength of the materials used. The working stresses for overload may be increased to 80% of the minimum yield strength or elastic limit, and those for overload caused by stalled conditions may be increased to 90% of the minimum yield strength or the elastic limit of the materials used.

3. Wire Ropes: The size and length of the wire ropes for the main hoist shall be duplicated as specified below. Wire ropes for the new auxiliary hoist shall be selected such that the rated load plus the weight of load block divided by the number of parts of reeving shall not exceed 20% of the nominal breaking strength of the rope per ASME B30.2 and CMAA Specification No. 70.

1.6.2.3 Design of Miscellaneous Components 1. Rolling Elements: New-design rolling element bearings shall be selected to

have an L-10 life of 10,000 hours under rated loading conditions determined in accordance with CMAA #70.

2. Shop Connections: Shop connections shall be designed for assembly by means of welding or by bolting.

3. Welded Connections: Design of new welded connections shall be in accordance with the provisions of Section 05 05 23 Welding.

4. Bolted Connections: All new bolted connections and supplied fasteners shall be as specified in Section 05 05 24 Fasteners. a. Where required to maintain crane components in proper alignment,

structural connections shall utilize tolerance-body bolts in reamed holes. The bolts shall have a light drive fit in the holes. Alternatively, provide bolted connections with locating pins and dowels, as appropriate for the application. Friction-type joints shall not be used.

b. Field splices for the trolley frame, if required, shall utilize structural bolted connections. Field welding of major connections is not acceptable.

5. Balance Requirements: Finished new machinery and rotating parts shall be statically balanced in the shop to meet the requirements of ISO 1940, balance quality grade G6.3.

6. All equipment shall be of the type normally furnished for crane applications and service, unless specified otherwise. All equipment shall be the standard product of manufacturers specializing in the production of this type of equipment as evidenced by the existence of previously published catalog data. Equipment shall essentially duplicate items that have been in satisfactory service for at least two (2) years prior to bid opening.

7. Defective equipment, or equipment or finishes damaged in the course of installation shall be replaced or repaired as approved. Equipment and materials for the same or similar or allied services shall be of the same manufacturer and type, and when of the same rating shall be interchangeable.



1.6.3 Design Parameters

1.6.3.1 Performance Parameters

The principal performance parameters for the bridge cranes are as follows:

1. Number of Cranes: Two (2). Existing bridge cranes are to be refurbished as specified.

2. Type of Crane: Double-girder electric overhead traveling bridge cranes, each with a single trolley. The cranes operate together, periodically in tandem, on existing straight runway integral with the powerhouse structure.

3. Type of Service: Indoor service for handling generators, turbines and supporting equipment, and general material handling within powerhouse.

4. Rated Capacity: a. Main Hoist, Trolley and Bridge: 250 short tons (500,000 pounds) b. Auxiliary Hoist: 25 short tons (50,000 pounds)

5. Lifts: a. Main Hoist: 89’-0”, from 3’-0” BTR (below top of runway rail) to 92’-0” BTR,

measured at center of the hook central lifting hole. b. Aux Hoist: 142’-0”, from 1’-8” BTR to 143’-8” BTR, measured at palm of the

hook 6. Spans:

a. Existing Bridge Span: 83’-0” b. Existing Trolley Gauge: 16’-0”

7. Traveling Speeds: a. Main Hoist:

1) 250 ton load, new design speed = 3.6 FPM at 870 rpm input, using new reducer ratio 100.58 : 1. Existing speed 3.3 FPM using 108.56 : 1 ratio. Drum gear ratio = 115 / 22 = 5.227 : 1.

2) Light load, new express speed = 7.2 FPM maximum, as allowed by existing hoist machinery. Contractor shall adjust the maximum express speed to a lower value if the existing machinery does not operate smoothly at 1800 rpm.

b. Aux Hoist: 1) 25 ton load, new design speed = 22.5 FPM 2) Light load, new express speed = 45 FPM. Contractor is responsible for

designing the new aux hoist to smoothly achieve this speed. c. Trolley: existing speed (to be maintained) = 28.0 FPM at 870 rpm input.

Trolley reducer ratio = 293.5 : 1. d. Bridge: existing speed (to be maintained) = 65 FPM at 1750 rpm input.

Existing wheel gear ratio = 72/17 = 4.235 : 1. 8. Spotting and Traveling Accuracy:

a. Trolley: ± 0.07 inch.



b. Main Hoist: ± 0.03 inch. c. Aux Hoist: ± 0.10 inch. d. Bridge: ± 0.17 inch.

9. Class of Service: Class D, Heavy Duty. 10. Control: Magnetek VG+ Series 4 for Main and Auxiliary Hoists, G+ Series 4 for

Trolley and Bridge

1.6.3.2 Design Temperatures

The range of design temperatures for operating stresses, allowable loads, coefficient of expansion, modulus of elasticity, lubricants, wiring, etc. shall be 40°F to 120°F. The crane equipment shall be designed for indoors operation under normally dry conditions.

1.7 OPERATING CONDITIONS The cranes will be used for material handling inside the powerhouse and primarily for disassembly, reassembly, and maintenance of the turbines, generators, and governors.

Each crane travels on the existing straight runway rails located above the powerhouse generator floor as shown on the Drawings.

The two powerhouse bridge cranes will operate independently on the same runway during routine disassembly, reassembly, and maintenance work; and will work in tandem during handling of the generator rotor.

The existing hook travel limits within the building shall be maintained or improved.

1.8 OPERATING REQUIREMENTS The refurbished crane system shall be designed for operation from the operator’s cab, or from a portable radio control station. A transfer switch with “Cab” and “Radio” positions shall be mounted in the operator’s cab.

The powerhouse operators will normally utilize the portable radio control station “bellybox” for daily crane service. The operator’s cab will be used during tandem crane operations, for crane maintenance, and in the event that the radio control system is out of service.

The existing crane-to-crane links for tandem operation shall be reused as-is; limit switches shall be added as specified in Section 41 22 11.13

The new auxiliary hoist shall be designed for true vertical lift, so that the center of lift does not shift in any direction throughout the full lift of the hoist. The center of the hoist shall be offset from the center of the trolley gauge, at the same position as the existing hoist.



Indicating lights, and displays for the crane operation shall be provided on the crane bridge, visible from the operators cab and from the powerhouse floor, as specified in Section 41 22 11.13.

1.9 WARRANTY The Contractor shall warrant all materials and equipment in accordance with the requirements of General Conditions, Paragraph GC-18.

1.10 QUALITY ASSURANCE 1.10.1 Drawings

Contractor shall apply a system of control to ensure that the requirements of these Specifications and Contract Drawings have been properly interpreted and transposed to Contractor’s Shop Drawings, material orders, and fabrication and inspection procedures.

1.10.2 Materials

In accordance with Section 01 45 16.13 Contractor Quality Control, the Contractor shall ensure the requirements and standards for analysis and testing of materials shall be as specified in this section and additional related sections elsewhere in these Specifications. The Contractor shall be responsible for inspection to ensure such analyses and tests are performed and that the results are certified in conformance with the specified acceptance criteria.

1.10.3 Welding

Perform welding, inspecting, and testing of welded parts in accordance with the requirements of Section 05 05 23 Welding.

1.10.4 Painting

Perform painting, inspecting, and testing of painted parts in accordance with the requirements of Section 09 90 04, Painting.

1.10.5 Manufacture and Installation

In accordance with Section 01 45 16.13 Contractor Quality Control, the Contractor shall apply quality control systems throughout all aspects of the manufacturing and installation Work. The Contractor shall ensure that the materials, dimensions, and all other requirements called for in Shop Drawings, inspection plans, procedures, and specifications are fully correct and in compliance with these Specifications.



Fabrication work subcontracted to workshops other than the manufacturer’s own facilities shall be disclosed to the Engineer in a timely manner prior to the start of fabrication. Workshops shall be subject to approval by the Engineer.

1.11 SUBSTITUTIONS If the Specification requirements differ from the manufacturer’s standard design, submit sufficient information to allow Engineer to determine that the item or material proposed is essentially equivalent to or satisfies the intent to that specified. The submittal process shall be utilized, as specified in Section 01 30 00 Administrative Requirements.

Material and equipment substitutions shall be in accordance with Section 01 25 13 Material and Equipment.

Substitutes for materials and technical standards defined according to other national standards (e.g., Canadian or DIN standards) may be substituted for U.S. standards provided the materials and standards are comparable or equivalent to, or superior to those specified. Substitutes for materials and technical standards shall be subject to approval by the Engineer.

1.12 MANUFACTURER’S FIELD SERVICE REPRESENTATIVE Contractor shall provide qualified and experienced field service representative(s) to supervise installation, testing, instruct personnel in the operation and maintenance of the refurbished bridge cranes, training, and related activities in accordance with Section 01 43 33 Manufacturers Field Services. The Contractor’s field service representative(s) shall be direct employee(s) of the Contractor authorized to make contract decisions.

2.0 PRODUCTS

2.1 GENERAL MATERIAL REQUIREMENTS All materials furnished as part of this Contract shall be new, and both workmanship and materials shall be of first-class quality. Where indicated by these Specifications, material classification and grades shall be as designated herein. For material specifications not specifically indicated herein provide the material according to specifications in Section 41 05 13.13 Basic Mechanical Requirements for Bridge Crane.

Structural materials and materials in mechanical equipment shall conform to the requirements indicated or referred to herein, and when not covered thereby, materials and equipment of the best commercial grade quality suited for the intended use and as Approved shall be furnished.

2.2 STRUCTURAL FABRICATION 1. All plate and structural steel shall be accurately fabricated, free of injurious

laminations or other defects, true to line, and free from warp or twist.



2. Drill metalwork, chamfer, and countersink holes as required for attaching hardware or other materials.

3. Grind cut edges smooth and straight. Round sharp edges to small uniform radius. Grind burrs, jagged edges, and surface defects smooth.

4. Sheared edges of all stress-carrying plates over 5/8-inch thick shall be planed at least 1/8-inch.

5. Fit and assemble in largest practical sections for delivery to site. 6. Material not specifically designated shall be subject to Approval by Engineer. 7. Material specifications shall comply with the latest specifications of the ASTM or

equal. 8. Clearly identify material specifications or standards, including grade, class or

type, for each component on Contractor’s Shop Drawings. 9. Fabrications to be galvanized shall be as specified in Section 05 50 00 Metal

Fabrications, unless otherwise indicated.

2.3 BRIDGE MODIFICATIONS 2.3.1 General

Existing crane equipment and components to be removed and disposed of off-site shall be as specified in Section 02 41 19 Selective Removal and Modifications and as specified herein. Abatement, removal and disposal of any equipment containing asbestos shall be in accordance with Section 02 82 13.01 Class II Asbestos Abatement. Removal of existing lead based coating shall be in accordance with Section 02 83 33.13 Lead Based Paint Removal and Disposal.

2.3.2 Bridge Structure

The existing bridge girders, trolley rails, end ties, travel truck saddles, and pins shall be reused as-is.

Contractor shall provide removal and inspection of weld traces from prior attachments of angles and other structural items that were roughly removed from the bridge girder web plates, as Directed by the District. Payment for removal of weld attachments shall be based on the actual number of locations repaired and the final Contract Price shall be increased or decreased accordingly using the Unit pricing for removal of weld attachments included in the Bid Form. Work shall include abatement of LBP, grinding to base metal of the girder web plates, NDE of the affected area and touch-up painting. NDE inspections shall be in accordance with Section 05 05 23, Welding. If NDE reveals flaws or indications in the base metal, Contractor shall submit repair procedures to the District for Approval. Payment for weld repairs, if required, shall be in accordance with General Conditions paragraph GC-40, Changes in the Work- Field Work Order/Change Orders.



Contractor shall provide additional touch-up paint repairs, in areas not affected by the specified Work, as directed by the District. Payment for additional touch-up paint repair shall be based on the actual number of locations repaired and the final Contract Price shall be increased or decreased accordingly using the Unit pricing for additional touch-up paint repairs included in the Bid Form. Each location shall be for up to 8 square feet of paint repair. All field touch-up paint repairs shall be performed in accordance with Section 09 90 04, Painting. Additional touch-up paint repairs will not be counted for repair of existing crane coatings in areas where the coatings were damaged, removed, or otherwise disturbed to facilitate installation of new equipment or Work as specified.

2.3.3 Bridge Drive and Idler Trucks

The existing single-motor, cross-shaft bridge drive design shall be removed, and replaced with a new “dual A-4” design providing four drive motors, with each motor driving the outboard wheel on each runway rail. The design modification and re-assembly work shall include:

1. The existing bridge wheels, axles, and bearing cartridge assembles shall be re-used as-is.

2. The wheel gears, pinions, and pinion drive shafts shall be replaced in-kind, except that the wheel gear ratio may be changed to modify the pinion diameter, while maintaining the existing overall bridge speed. The pinion shaft shall be designed by the Contractor to suit the new bridge reducer.

3. The two existing drive truck bogie frames shall be modified as required to allow the wheel gear pinion to be removed through the inboard flanged cartridge bearing bore. The pinion diameter may be reduced, or the bearing size and bore increased, or both, to allow that removal. New flanged cartridge bearings shall be supplied.

4. Two existing idler truck bogie frames shall be modified to match the drive trucks’ design, with new pinion drive shafts and flanged cartridge bearings supplied to match.

5. The existing wheel bearings shall be replaced in-kind; a total of thirty-two (32) 22226-size spherical roller bearings are required per crane, sixty-four (64) bearings total.

6. Details of the existing drive truck assemblies and equipment are shown on the Reference Drawings.

2.4 WALKWAYS, PLATFORMS, AND LADDERS 1. Expand the upstream end of the existing A-girder bridge walkway to provide at

least 30” of clearance between the inside of its handrail and the doors of the new control panels, or so that it equals the 58” nominal width of the platform segment at the center of the span, whichever is greater. That new walkway



width shall extend between the cab segment and the center-span segment, as a minimum, and shall be similar in design to the existing walkway segments.

2. Provide a new crossover platform at the upstream (cab) end of the bridge, with new boarding ladders on each end that allow safe access from the cab-side bridge walkway to the festoon maintenance platform. The crossover platform walking width shall be 30” checkerplate placed at the top of the girders and end tie, with space allowed for the trolley rails and wheel stops, which shall be left in place. The platform shall be placed as close to the upstream building wall as possible, while maintaining a 3” clearance when the crane is centered on the runway rails. The crossover platform shall have full handrails on its ends and outboard (upstream) edge, and be open to the inside edge except for a 6” high toeboard. The crossover platform shall be equipped with a horizontal lifeline as specified in paragraph 2.5 of this section. The platform shall not interfere with the trolley close approach, and shall be suitable for use as a trolley inspection platform when the trolley is near the end of its travel.

3. Provide new checkerplate platforms on the B-girder and caged ladders to access those platforms, to provide safe maintenance access to both bridge drives on that side of the crane, and to the trolley festoon carriers when the trolley is in the upstream position. The downstream platform shall have handrails on each open edge, while the inboard handrail on the upstream platform may have an opening, as small as possible, for passage of the festoon loops. Provide gathering guides that allow the festoon cables to pass through that opening without snagging.

4. Expand the trolley handrail perimeter in a manner similar to that shown on the Contract Drawings, to accommodate the boarding ladder described in item (5) below, provide access around the new reducer-mounted hoist holding brakes, and to provide an access path to other crane platforms, as applicable. Provide checkerplate walking surfaces similar to the bridge walkways in the expanded areas.

5. Supply new, caged trolley boarding ladders with design similar to the existing system, but with the rungs aligned in the same plane. Provide common, standard spacing spanning between the on-bridge rungs and the on-trolley rungs. Provide a hinged, spring-return safety gate at the top of the trolley ladder.

6. If multiple boarding ladders lead from the trolley they shall be positioned so a single trolley parking location may be designated. All ladders to be aligned when trolley is parked.

7. Replace the existing cab access ladder and modify access opening. The existing cab access opening shall be enlarged to meet the clearance requirements of WAC 296-870-500. Contractor shall also provide new handrail and safety gate around the enlarged cab access opening.

8. Replace the existing ladder accessing the runway conductor service platform. Redesign and extend the existing bridge walkway platform and provide a ladder



cage, side guards, safety gate, and handrails. Contractor shall modify existing bridge cross-over walkway supports as necessary.

9. Platforms and walkways shall have sufficient area to provide safe access to all specified areas. Platforms and walkways shall: a. Provide a stable, safe working area meeting all state and federal safety

requirements. b. Avoid ladders that require that the climber ‘back over” an edge whenever

possible. c. Be properly proportioned for total ladder length, rung spacing, hand and toe

clearance, handrail height, and cage dimensions. d. Provide back and/or guarding for ladders that extend from elevated

platforms 10. Fabricate ladders with rails, rungs, landings, and cages to meet applicable

requirements of WAC 296-876-500, OSHA, CFR Part 1910.27, and ALI A14.3. a. Concentrated load of 300 pounds loads imposed by persons occupying the

ladder shall be considered to be concentrated at such points as will cause the maximum stress in the structural member being considered.

b. The weight of the ladder and attached appurtenances together with the live load shall be considered in the design of rails and fastenings.

c. Maximum rung deflection of l/360. d. Concentrated load of 250 pounds plus 30% impact between consecutive

attachments. e. New ladder rungs shall be 1 or 1.05 - inch diameter, with a permanently

textured surface that is comfortable for an ungloved hand. The texture may be achieved by knurling, by permanently attaching grit-impregnated rung caps, or by use of SlipNOT® or similar solid rungs.

f. Self-closing gates at landings. Access safety gates shall be designed in accordance with ANSI A1264.1 and installed in accordance with the manufacturer’s instructions.

11. A structural engineer, licensed in the State of Washington, shall design the platforms and walkways and meet, as a minimum, the following requirements: a. Platforms, walkways and their components shall be capable of supporting

without failure at least four (4) times the maximum intended load. b. Minimize tipping caused by personnel movement on platforms and

walkways by having an appropriate suspension/stabilization system. c. Keep personnel, tools, materials, and equipment from falling off the

platforms and walkways by having a standard guardrail system and toe board.

d. Contractor shall provide permanent marking plate that clearly indicates the platform’s rated load capacity or maximum intended load. All rough edges on the platform must be ground smooth to prevent injuries to employees.

e. The anchorage for the platforms and walkways shall be sound, rigid, and capable of carrying the maximum intended load without settling or displacement. Bolts used in the construction of platform shall be of



adequate size and in sufficient numbers at each connection to develop the designed strength of the platforms and walkways.

12. Construction: Rigid construction, consisting of square tube or pipe-construction handrails, toe board, and non-slip grating.

13. Walkway and Handrail Design Load: Live load of 75 pounds per square foot (psf), and a 200 pound lateral point load on the handrail, except that the crossover platform handrail shall be designed for use as a fall restraint as specified above.

2.5 HORIZONTAL LIFE LINE Contractor shall install a new Horizontal Life Line (HLL) along the new crossover platform at the upstream (cab) end of the bridge. The HLL is part of a fall arrest sub-system consisting of flexible wire spanned horizontally between two end anchorages and shall meet the following requirements:

1. Design of the HLL system shall meet the requirements of WAC 296 155 Part 1C, Fall Protection Requirements for Construction and all applicable requirements of ANSI Z359, Fall Protection Code.

2. HLL shall be designed to be located inside of the crossover walkway handrail at an elevation of 6 – feet above the walkway surface without impairing handrail access or use.

3. Synthetic or natural fiber ropes shall not be used for the HLL. 4. The HLL shall be designed for indoor use and environment. 5. The HLL shall be designed, installed, tested, and certified for use under the

supervision of a Qualified Person for Fall Protection as part of a complete fall arrest system that maintains a minimum factor of safety of 2.

6. The design shall include drawings, required clearance, instructions on proper installation and use, proof testing reports and inspection requirements.

7. All HLL anchorages shall be designed by a registered professional engineer in the State of Washington qualified in designing HLL systems.

8. The HLL and HLL anchorages to be used for attachment of personal fall arrest equipment shall be designed for a minimum of two (2) workers using the system at the same time.

9. HLL anchorages shall be independent of any anchorage used to support walkways or platforms and shall be directly connected to the crane end tie.

2.6 TROLLEY The existing trolley frame structure shall be used as-is, except that:

1. The existing auxiliary hoist machinery mounting supports shall be removed, flush to the main supporting structure or to the top of the walkway surface.



2. The existing main hoist motor and brake mounting supports shall be removed, flush to the main supporting structure or to the top of the walkway surface.

3. The main hoist drum reducer-end plow block shall be made adjustable, or removed and replaced with an adjustable design.

4. The walkway and handrail system on the trolley shall be expanded as described in paragraph 2.4 Walkways, Platforms, and Ladders of this section.

2.6.2 Trolley Drive 1. Replace the existing trolley motor as specified in Section 41 22 11.13. 2. Replace the existing trolley parking and holding brake as specified in paragraph

2.20 of this section. In addition, the existing motor coupling shall be replaced with a shrouded-bolt flanged geared coupling similar to the existing unit.

2.6.3 Trolley Rails and Lubricators

The existing trolley rails shall be re-used as-is. Add graphite-stick lubricators to both ends of the trolley frame to lubricate the wheel flanges.

2.6.4 Miscellaneous Features and Accessories 1. Provide new rail sweeps for the trolley. 2. The existing trolley bumpers, bumper stops and wheel stops shall be re-used

as-is. Add safety cables to the existing bumpers. 3. Avoid placing conduit or other obstructions on the trolley deck or floor in the

existing and new walking areas. 4. Provide new, substantial mounting supports for the new, geared limit switches

specified in Section 41 22 11.13. 5. Improve the routing of cables to the new main hoist and auxiliary hoist limit

switches specified in Section 41 22 11.13 so that the weight (or a new block-actuated structure) is mounted on the standing rope leading to the equalizer, with a clear path to the limit switch lever

2.7 BRIDGE BUMPERS AND STOPS 1. The existing bridge spring bumpers and stop shall be reused as-is, except that

safety cables shall be added to the bumper heads to prevent parts falling from the crane in case of breakage.

2.8 OPERATOR’S CAB 1. The existing operator’s cab structure shall be re-used as-is. The existing

master switches and the stand-up console to which they are mounted shall also be re-used. Add selector switches and pushbuttons to that console as specified in Section 41 22 11.13.



2. Remove other electrical equipment from the back wall of the operator’s cab as specified in Section 02 41 19 Selective Removal, and replace those components as specified in Section 41 22 11.13.

3. Place the indicator lights and load cell displays specified in Section 41 22 11.13 so that they are visible from the operator’s cab.

4. Cover the cab floor with seamless ribbed rubber sheeting with a minimum thickness of 1/4-inch, bonded to the floor with adhesive.

5. Provide one freestanding operator chair. Chair shall be barstool-type and place the operator at a height roughly equivalent to standing. The chair shall able to swivel 360 degrees, have a padded vinyl seat and backrest, adjustable in height from approximately 29 – 33 inches, and a footrest.

2.9 GENERAL HOIST REQUIREMENTS 1. The existing main hoist design shall largely be reused, including the complete

lower block, upper block load sheaves, drum, drive shaft, and the reducer housing. All-new gears and pinions shall be provided, except that the existing drum gear and its pinion, and the output gear and its pinion, shall be reused on the North crane. Those components shall be replaced on the South crane. New components shall be provided and installed for both bridge cranes, unless otherwise noted, as follows: a. Wire ropes b. A new equalizer bar, mounted in the position of the existing equalizer

sheave. c. A new double-extended input shaft assembly, including integral pinion (G1),

bearings, and a new open bearing cap with seal, all designed by Contractor to match the existing reducer housing and allow an outboard holding brake. The existing gear tooth form, width, material and hardness shall be copied from the design shown on Reference Drawing 194/95-27-3D-1, but the number of G1 pinion teeth shall be increased from 15 to 16. Provide a hex drive or other means to allow attachment of a torque wrench for checking brake torque.

d. A new 1st intermediate shaft assembly, including integral pinion (G3), input gear (G2), bearings, and a new closed bearing cap, all designed by Contractor to eliminate the existing mechanical load brake and suit the existing reducer housing. The existing gear tooth form, width, material and hardness shall be copied from the design shown on Reference Drawing 194/95-27-3D-2 and 194/95-27-3D-3, but the number of G2 gear teeth shall be reduced from 85 to 84.

e. On the north crane only, a new G4 gear, for mounting on the existing 2nd intermediate shaft G5. The existing gear tooth form, width, material and hardness shall be copied from the design shown on Reference Drawing 194/95-27-3D-4.

f. On the south crane only, a new G4 gear, for mounting on a new 2nd intermediate shaft G5. The existing gear tooth form, width, material and



hardness shall be copied from the design shown on Reference Drawings 194/95-27-3D-4 and 194/95-27-3D-5.

g. On the north crane only, all-new hoist bearings, seals, and gaskets in the reducer except for the output shaft. Note that the existing sheave bushings, drum bearing, output shaft bearings and seals shall be reused as-is.

h. On the south crane only, all-new hoist bearings, seals, and gaskets in the reducer including the output shaft and drum bearings. Note that the existing sheave bushings shall be reused as-is.

i. On north crane only all other main hoist gears (G5 through G8) shall be reused as-is.

j. On south crane only, a new main hoist drum gear pinion G7, for mounting on the existing reducer output shaft. The existing gear tooth form, width, material and hardness shall be copied from the design shown on Reference Drawing 194/95-1-2E-2.

k. On the south crane only, a new main hoist drum gear G8, for mounting on the existing main hoist drum. The existing gear tooth form, width, material and hardness shall be copied from the design shown on Reference Drawing 194/95-1-2E-1.

l. Motor m. Coupling n. The motor foundation and drum idler pillow block pedestal shall be fitted

with locking jack screw assemblies to allow precision alignment of couplings and drum gear mesh. The idler pillow block pedestal may need to be modified or replaced to allow the adjustment.

o. Holding Brakes (minimum of two (2) required) p. Limit switches q. Accessories

2. The existing auxiliary hoist shall be removed in its entirety and replaced with all-new components, including, but not limited to the following: a. A new 25 ton capacity two-sheave load block with new forged single-barb

hook, b. A new equalizer bar, mounted in the position of the existing equalizer

sheave, and including a load cell pin. c. Wire ropes. d. Hoist drum. e. Foot-mounted reducer with a hex drive or other means on the input shaft to

allow attachment of a torque wrench for checking brake torque. f. Motor g. Coupling h. Holding Brakes (minimum of two (2) required) i. Limit switches j. Accessories

3. Hoist Drive a. The general arrangement of the main hoist drive shall remain as-is.



b. For the new auxiliary hoist design, the hoist drive shall consist of a single electric motor mechanically connected through a gear reducer and shafts to drive and rotate the hoist drum. The hoist motor shall be connected to a self-contained, foot mounted enclosed gear reducer through an all-steel geared flexible coupling. Torque-arm-mounted hoist reducers are NOT acceptable. The output shaft of the gear reducer shall be connected directly to the hoist drum via an all-steel flexible coupling that is designed for hoisting drum service. All hoist shafts shall be keyed to their gears and couplings; relying on press fits or compression couplings will NOT be acceptable.

c. After final alignment the position of the auxiliary hoist reducer shall be secured using permanently-welded shear bars or at least four tapered drive pins. The motor foundation and drum pillow block pedestals shall be fitted with locking jack screw assemblies to allow precision alignment of couplings.

4. Hoist Reeving a. The auxiliary hoist shall use four part double reeving, with two lower block

sheaves. To minimize the possibility of block spin, right-hand (RH) and left-hand (LH) lay ropes shall be used, spooled on the RH & LH drum grooving per the manufacturer’s recommendations.

b. The main hoist shall use the existing 16-part reeving design, except that the equalizer sheave shall be replaced by an equalizer bar. Wire rope of a single hand lay may be used for the main hoist.

2.10 LOAD BLOCKS 1. The auxiliary hoist shall be provided with a lower block of the long-form type,

with a hot-rolled or forged steel swiveling trunnion that is separate from the sheave pin, with a central hole for mounting of a freely-rotating forged steel hook. The trunnion shall freely swivel without load about a horizontal axis by at least 90 degrees, and the design shall allow easy access to the top of the hook nut.

2. The existing main hoist lower block shall be reused as-is. 3. The new auxiliary hoist load block shall be fully enclosed with structural or sheet

metal guards, designed for maximum personnel safety in accordance with OSHA and CMAA Specification No. 70.

4. The new aux hoist load block hook shall comply with all mandatory requirements of ASME B30.10, including a documented factory proof load test at 200% of the rated capacity. Documentation of the test and NDE performed before and after the load test shall be provided as noted in Specification Section 01 91 14 Equipment Testing and Commissioning.

5. The new aux hoist hook shall be standard single barb, carbon or alloy steel, forged per ASTM A668/A668M.



6. Safety latch: Provide the new aux hoist hook with a spring loaded safety latch designed to preclude inadvertent displacement of slings from the hook saddle. The safety latches shall be connected to the hook shanks via a forged-in boss or closely-fitting collars that engage a shallow groove in the hook shank. Collars that are merely friction-fitted will not be accepted. No welding shall be performed on the hook.

7. Hook nut: The aux hoist hook shank shall be threaded, and fitted with a mating threaded nut. The threads shall be designed to not gall upon repeated removal and re-installation of the nut for inspection. Each hook nut shall be secured to its hook shank with a removable set screw or other similar fastener, and shall not be welded. Locking collars such as the Crosby Split-Nut Retention System are acceptable alternatives to a threaded nut.

8. Hook rotation: The aux hoist hook shall be free to rotate through 360° when supporting the rated load. The hook nut bearing shall be of the anti-friction type, selected to allow free rotation of a full test load by hand. The bearing’s rated static capacity shall be at least 125% of the hook load.

9. Block rotation: Rotation of the lower blocks from “square” from the crane axes due to the lay of the rope is not important to the application, but to minimize the possibility of aux hoist block spin, it shall be delivered with RH and LH lay ropes.

10. Guards: Provide close-fitting continuous guards or other suitable devices to prevent ropes from becoming wedged in small openings when the ropes are momentarily unloaded and to guide the rope back into the groove when the load is re-applied. The guards shall be fitted close to the periphery of the sheaves within the load block; it shall be possible to push a rope through the block when re-reeving.

2.11 SHEAVES 1. The main hoist sheaves shall be re-used as-is. For the auxiliary hoist, sheaves

shall be cast, forged, rolled, or welded steel with a minimum groove hardness of 320 BHN. Sheave grooves shall be accurately machined, finished smooth, and free of surface defects, with a groove radius that is at least 5% greater than the nominal rope radius. Groove angles may follow the manufacturer’s standard design. Running sheaves shall be statically balanced.

2. Pitch Diameter: The pitch diameter of new running sheaves shall be no less than 24 times the diameter of the wire rope. Equalizer sheaves shall not be used, supply an equalizer bar for each hoist. The District recognizes that these dimensions exceed the requirements of CMAA Specification No. 70 for Class D service; smaller sheaves will not be accepted.

2.12 WIRE ROPE 1. Construction: Regular lay, standard inch size, preformed, bright, factory

lubricated, 6 x 37 classification with independent wire rope core. Wire rope



designs using more than six strands can be used, but they shall have flexibility equivalent to a 6x36WS or 6x41WS actual construction, which will be measured by having more than 300 wires in the cross-section, not including filler wires. Seale Filler Wire (SFW) constructions shall not be used.

2. For the main hoist, provide 1-3/8” diameter EIPS or XXIPS grade, two ropes with calculated length less than 870 feet each, 1740 feet total. The final length shall be confirmed and ropes trimmed to suit by Contractor.

3. Grade: The auxiliary hoist design shall be based upon the future replacement of the original ropes with inch-size Extra Improved Plow Steel (EIPS) or Extra-Extra Improved Plow Steel (XXIPS) grade ropes. The hoist design shall not be based upon use of higher rope breaking strength ratings.

4. Fleet Angle: The maximum fleet angle between the drum axis and the sheave, and between sheaves, shall be no greater than 3.5 degrees throughout the rated lift range. The fleet angle as the rope leads into the drum rope groove shall be no greater than 3 degrees; greater fleet angles will not be accepted.

5. Rope Anchor: Anchor the aux hoist rope ends by clamps securely attached to the drum, so that the connection provides a safety factor of not less than five (5) with only two (2) wraps of rope on the drum (rated load with the load block in the lowest position).

6. Rope Sockets and U-bolt Clips: In accordance with clip or rope manufacturer’s recommendations, and of equal or greater strength than the rope strength.

7. Dead Wraps: Not less than two (2) wraps of rope remaining on drum at each anchorage point on drum when the hook is located at its extreme low position (lower than over travel limit switch position).

2.13 AUXILIARY HOIST DRUM 1. The new aux hoist drum shall be made of cast steel or welded steel of sufficient

strength to sustain the combined crushing and bending loads of the rope pull. Allowance shall be made for fabrication and machining tolerances to assure adequate drum shell thickness under the machined grooves. Grooves shall be smooth and well rounded and shall have a minimum depth of 0.375 times the rope diameter. The grooves shall be smoothly machined to accept a single layer of rope. Multiple layers of rope are not acceptable.

2. The minimum groove pitch shall be the rope diameter plus 1/8-inch, or the rope diameter times 1.14, whichever is smaller. The drum shall be designed so that not less than two (2) wraps of each part of hoisting rope will remain in the grooves when the load block is at the lowest position for the lift specified, and so that at least 3/4 reserve turn is available, without overlapping of the rope, when the block is in the uppermost position.

3. The drum shall be designed so that the maximum rope spread at the drum face shall be 88-inches or less when the hook is at its lowest position.



2.14 GEARING 1. Gear Reducers: Designed, manufactured, and rated in accordance with

AGMA 6013-A06, or other equivalent standard, as Approved by Engineer. Gear reducers shall be standard items of manufacturers regularly engaged in the design and manufacture of gear reducers for crane service. The new aux hoist and bridge gear reduction units shall be fully enclosed, oil lubricated in oil-tight housing.

2. Gear Types: Helical, bevel, herringbone, or spur designed in accordance with AGMA, or other equivalent standard, as approved by Engineer. High speed gears shall be helical or herringbone type. Slow speed gears shall be helical or spur type. Herringbone gearing shall be of the continuous type.

3. Gear Housings: Oil-tight and provided with fill ports and drain plugs, bellows breathers (with plug for shipping), and clear oil level sight gauges . Gear housing shall be constructed of cast steel or welded steel for hoist drives and cast iron or ductile iron for travel drives. Travel drives may utilize a torque arm mount assembly. Housings shall have Minimess® oil sampling ports, or Engineer approved equal. Oil sampling port locations shall be approved by Engineer.

4. Gear Strength and Durability: Manufactured and proportioned to give optimum gear life and performance for the crane service class specified. Aux hoist and bridge reducer gears shall be AGMA 2001-D04 Quality Class 11 or better, or other equivalent standard, as approved by Engineer. All new and replacement gears for the main hoist shall be Quality Class 10 or better. Bridge replacement wheel gears and pinions may be Quality Class 8 or better.

5. Gear operation shall be smooth and quiet. 6. Gear Reducers: Standard catalog products of manufacturers which are

distributing AGMA rated gear reducers in the United States. Service factor shall be 1.25 for new aux hoist reducer and 1.5 for new bridge reducers. Catalog data for reducers shall be submitted and shall include manufacturer’s assembly drawing(s) and parts list(s). Gear tooth counts shall be provided.

As an alternative to a gear reducer of standard manufacturer for the aux hoist and bridge travel, the crane manufacturer may provide their own reducer design. Design shall be based on CMAA for Class E Duty. Crane manufacturer shall submit all calculations and detail drawings of all parts for District review and all final approved calculations and drawings shall become part of the final contract closeout record drawings.

2.15 WHEELS 1. The existing trolley and bridge wheels shall be re-used as-is. 2. All of the existing trolley and bridge wheel bearings shall be removed and

replaced in-kind with new bearings, using the existing axles and cartridge



assemblies. Replace seals, lubrication fittings and relief fittings as applicable. There are eight (8) 22226-size bearings for each 4-wheel trolley, 16 total. There are thirty-two (32) 22226-size bearings on each 16-wheel bridge, 64 total.

3. Two of the four bridge drive wheel assemblies shall be removed from their inboard position at the A-girder walkway, and placed at the outboard position at the B-girder, to create a “dual-A4” drive assembly – four motors geared independently to four wheels. Modify two idler bogie frames and supply two additional pinion shafts to suit, as specified in paragraph 2.3.3 above.

2.16 BEARINGS 1. New bearings shall be anti-friction type, except bearings that are subject only to

small rocker motion, selected to provide an L-10 life expectancy at full rated speed as required by the crane service class specified.

2. Lubrication: modify the existing trolley and bridge assemblies to include provisions to re-lubricate bearings from the walkways, four positions for the bridge and no more than three positions for the trolley. Extend grease tubing to centralized location(s) with identification tags to facilitate greasing. All lubrication tubing shall be stainless steel, guarded by structure away from walking surfaces, and lengths of runs should be minimized.

3. New hoist bearing housings shall be cast steel or welded steel construction with seals. If welded steel or heavy plate bearing housings are used, they shall be fully stress relieved before machining.

4. New designs shall include machined seats for each bearing to be installed in and contained by. The use of self-aligning bearings held to un-machined surfaces is not acceptable.

2.17 AXLES, SHAFTS, AND COUPLINGS 1. New axles and shafts, as applicable: Machine shafts to close tolerances at

bearing and gearing fits. Shafting shall be of rolled or forged steel and amply supported to prevent excessive deflection. Angular deflection in shafts shall not exceed one-tenth degree (0.1°) per foot of shaft length at full load motor torque. The maximum spacing between shaft bearings shall be in accordance with CMAA Specification No. 70.

2. Couplings: The existing trolley low-speed couplings shall be reused. In all other positions provide suitable couplings throughout trolley, hoist, and bridge drives for connecting shafts. Shaft couplings shall be aligned to the equipment manufacturer’s requirements; hoist couplings shall be laser aligned.

2.18 GUARDS AND ENCLOSURES 1. Guards

a. All exposed moving parts such as main wheels, gears, set screws, projecting keys, etc. shall be provided with guards in accordance with the applicable safety requirements. Such safety devices shall meet or exceed



federal, state and municipal requirements. The Contractor shall furnish equipment with suitable guards and safety devices designed to protect persons against contact with moving parts and hazardous surfaces.

b. Fabricate guards of 14-gauge (minimum) steel, 1/2-inch opening in expanded metal screen to provide visual inspection of moving parts without removal of the guard.

c. Guards shall be painted after fabrication and shall be designed to be readily removable to facilitate maintenance of moving parts.

d. The existing drum gear guard, shall be modified to have an inspection opening that exposes entire pinion and at least eight (8) drum gear teeth.

e. Openings shall be provided in the guard for access to the lubricating fittings and may require provisions to extend lube fittings through guards.

f. Cut-outs and holes through guard screen shall be reinforced. 2. Enclosures: Parts subject to wear or damage caused by dust and moisture shall

be totally enclosed in dustproof, weatherproof housings. 3. Access Openings and Hatches: Provide openings and moveable hatches in

guards and enclosures for inspection and maintenance access. Provide openings and hatches as large as possible.

2.19 LUBRICATING SYSTEM 1. All lubricants shall be of types recommended by the applicable equipment

manufacturer. Contractor, subject to the approval of the equipment manufacturer, shall limit lubricants to the least number or types required for normal maintenance of all equipment. In addition, Contractor shall confer with Engineer to limit the number and type of lubricants, to the extent practicable, to those presently in use at the Project.

2. Not less than 60 days before the date scheduled for field testing of the equipment, Contractor shall provide Engineer with three (3) copies of a listing indicating all lubricants required for each item of supplied equipment.

3. Properly lubricate and protect equipment and appurtenances prior to operation. Furnish and install oil, grease, and protective fluids required for initial operation. Contractor shall provide all equipment with a sufficient supply of correct lubricant for start-up, testing, and initial 20 day trial operation period.

4. Unless otherwise noted, all grease lubrication fittings shall be of an approved standard hydraulic type and shall be grouped together as specified in paragraph 2.15.2 of this section. Cover and protect installed equipment from damage or contamination by ongoing construction work and the elements. Label excess lubricants and deliver to Engineer upon completion of Work.

5. Provide proper lubrication of all moving parts, as required. All high-speed gears and pinions shall be provided with oil lubrication. Low-speed gears shall be lubricated by tacky lubricant or as recommended by the gear manufacturer.



2.20 ANTI-DRIP PROVISIONS Design the new auxiliary hoist to preclude leakage of lubricants onto decks, and other surfaces below the crane. Provide suitable drip pans for equipment and components, which cannot be made leak proof. Design drip pans to permit removal of collected lubricant. Construct drip pans using steel of suitable gauge.

2.21 PARKING AND HOLDING BRAKES 1. Shoe-type for each hoist drive, and disc-type for each travel drive, as specified

herein. 2. Thermal Capacity: Ample thermal capacity suitable for the class, service, and

frequency of operation specified herein to prevent overheating. 3. Features:

a. Unitized construction. b. Totally enclosed, self-aligning. c. Provisions for adjustment for torque setting and lining wear. d. Manual release with automatic reset. e. Enclosure: dust-tight and waterproof for outdoor crane service. f. Class B or Class H insulation where required for high temperature

applications. g. Brake Design: Per CMAA Specification No. 70 and ANSI/ASME B30.2, as

applicable. 4. Trolley and Bridge Brakes.

a. Provide one (1) motor-mounted disc brake for each drive motor. b. The disc brakes shall have a stationary DC release electromagnet and a

spring-set armature plate. c. Brake Operation: Brake shall become effective when the power to the brake

is cut off. d. Braking Distance: Size brakes for stopping trolley and bridge within a

distance equal to the distance traveled in six (6) seconds when traveling at rated speed with rated load and design wind load, as applicable.

e. Torque rating: 5. Hoist Holding Brakes.

Provide two (2) shoe-type holding brakes. Mount one (1) brake on the motor shaft and the other on the opposite side of gear reducer. Alternate the application and release of the brakes as described in Section 41 22 11.13, paragraph 2.4.2(4) Control of Brakes.

a. Shoe brakes shall be rated for NEMA standard wheel size and torque. b. Torque rating: Catalog rating of 150% of full-load motor torque or greater,

and capable of being adjusted to less than 130% motor torque. c. Braking system shall be designed to have zero (0) hook lowering motion

when a raise motion is initiated.



d. Each brake shall be capable of holding the rated load with zero (0) hook drift.

e. Duty: Designed for continuous duty. Magnets for all brakes shall be rated for continuous duty.

f. A brake release limit switch with 1 NO (normally open) & 1 NC (normally closed) contact, shall be incorporated into the control system to provide positive feedback that the brake is released.

6. Hoist Control Brake: Regenerative type. 7. Brake Lining Material: Asbestos free. 8. Brake Wheel Material: Cast iron.

2.22 SHOP ASSEMBLY TESTS Perform shop inspections and tests in accordance with Section 01 91 14 Equipment Testing and Commissioning.

3.0 EXECUTION

3.1 PREPARATION FOR INSTALLATION 1. Install equipment as specified herein, as shown on the Drawings, and in

accordance with Approved Shop Drawings. In case of conflict between the Contract Documents and the crane manufacturer’s Shop Drawings, Engineer shall issue clarification in writing.

2. Ensure that the assembly match-marks on delivered equipment are consistent with those shown of the crane manufacturer’s field assembly drawings.

3. Furnish suitable cranes, slings, and other equipment and tackle for handling the equipment, as well as incidental materials, welding equipment, torque wrenches and other tools, surveyor’s transits, levels, plumb wires, gauges, and other measurement devices, to facilitate erection, installation, inspection, and testing of the equipment.

4. Ensure that equipment used for handling is equipped with lifting lugs or has other suitable sling attachment points for safe and appropriate handling and placing of equipment.

5. Lubricate and grease components as required. Apply lubricants in accordance with the manufacturer’s instructions and/or as deemed necessary by field representative.

6. Special tools, if any, shall be provided by Contractor and shall become the property of the District after completion of the Work. Repair or replace any tools used by Contractor that are damaged beyond further usefulness during performance of installation at no expense to District.



7. Furnish equipment, labor, and materials such as scaffolding, ladders, and blocking, necessary for installation, all in conformance with governing safety regulations.

8. Establish sequence of operations and methodology for installing the equipment in conformance with requirements set forth in the manufacturer’s installation instructions.

9. Become familiar with the problems involved in the installation and with the fact that certain erection and installation operations, particularly those that cannot be readily corrected and are fundamental to successful functioning of the equipment, will require levels of accuracy and iterative assembly and inspection procedures that exceed ordinary practices in construction.

10. Provide installation crew with experience in the installation of similar equipment, in accordance with Section 01 11 00 Summary of Work.

3.2 INSTALLATION 1. Installation shall conform to the requirements specified herein. Crane and

appurtenant items shall be assembled for installation in strict accordance with the installation drawings, and shop match-marking drawings.

2. Preliminary Checks: a. Examine crane equipment for damage that may have occurred during

shipment. b. Examine crane equipment for rain or moisture damage to motors and

panels, inadequate painting, accumulation of dirt and rubbish, and oil leaks. 3. Thoroughly clean and lubricate all bearing surfaces requiring lubrication before

assembly and installation with an approved lubricant. 4. Perform crane assembly, erection, and testing under the supervision of the

Contractor’s Superintendent. 5. During installation, repeated checks of the tolerances shall be made so that the

equipment is installed within the specified tolerances. 6. Alignments: Align all structural and mechanical subassemblies erected in the

field in accordance with manufacturer’s instructions.

3.3 FIELD TESTING Perform field inspections and tests in accordance with Section 01 91 14 Equipment Testing and Commissioning.

Contractor shall provide the services of Test Engineer(s) to direct field testing. Perform all tests under the direction of the Test Engineer(s).



3.4 ADJUSTMENTS AND REPAIRS Adjust travel limiters, switches, controls, and other operating devices as required. After adjustments have been made, re-test functions to ensure correct functioning.

3.5 FIELD TRAINING 1. Contractor shall conduct a field training course for District’s operating staff, as

described: a. Field training for District’s operating staff shall be carried out on site by

qualified individuals familiar with the installation, operation, and maintenance of the cranes modified under this Contract.

b. An individual from the crane hoist / equipment manufacturer and the motor controller manufacturer shall conduct the training.

c. Training shall be required for 12 District employees during two (2) sessions of approximately eight (8) hours for each session.

2. Field Training Operations and Maintenance (O&M) Manuals shall be: a. Provided for each employee participating in the training. b. Created and assembled as described in Section 01 78 23 Operation and

Maintenance Data. 3. The District reserves the right to record such training for future use. 4. Training shall include:

a. Classroom activities b. Hands-on type training with the actual equipment. c. Operation d. Troubleshooting the equipment to return it to service, e. All required maintenance activities, including

1) Preventative Maintenance 2) Corrective procedures.

3.6 SUBSTANTIAL COMPLETION 1. When Contractor considers the crane Substantially Complete, as defined in

General Conditions, Contractor shall notify Engineer in writing and request that Engineer issue a notification of Substantial Completion.

2. The Engineer and Contractor shall make an inspection of the crane to determine the status of completion within a reasonable time (two (2) weeks) after receipt of written notice from Contractor.

3. The Contractor shall be given notification in writing, by Engineer for the following: a. Fixing the date of Substantial Completion, if Engineer considers the Work

substantially complete. A punchlist of minor items to be completed or corrected before Substantial Completion notification shall be included, or;

b. If Engineer does not consider the Work substantially complete, a punchlist of those items to be completed or corrected in order for the Work to be considered substantially complete shall be included.



4. Contractor shall continue to submit requests for Substantial Completion inspection, as required.

5. The trial operation period shall begin upon issuance of written notice of Substantial Completion by the District.

6. Upon written notice from Contractor that the entire Work is complete, The Engineer shall make a final inspection with Contractor and shall notify Contractor in writing of any remaining or additional punchlist items. Contractor shall immediately take such measures as are necessary to complete or correct the punchlist items prior to 100% progress payment.

3.7 ACCEPTANCE 1. In addition to the requirements set forth in General Conditions. Final

Acceptance of the Work shall not be given until Contractor has successfully completed all testing operations, corrected all material and equipment deficiencies, made all proper operational adjustments, and provided all required, Approved submittals.



Bid 15-65 Bridge Crane Electrical Rehabilitation- 41.22 11.13 Page 1

SECTION 41 22 11.13

BRIDGE CRANE ELECTRICAL REHABILITATION

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 4

1.1 SECTION INCLUDES ............................................................................................. 4 1.2 REFERENCE SPECIFICATIONS ............................................................................... 4 1.3 RELATED SPECIFICATION SECTIONS ..................................................................... 6 1.4 SUBMITTALS ....................................................................................................... 6

1.4.1 GENERAL ....................................................................................................... 6

1.4.2 PROCEDURES ................................................................................................ 6

1.4.3 DRAWINGS ..................................................................................................... 7

1.4.4 EQUIPMENT AND MATERIAL LISTS ..................................................................... 8 1.4.5 CATALOG DATA .............................................................................................. 8

1.4.6 ENGINEERING DATA ........................................................................................ 8 1.4.7 REPORTS AND DOCUMENTATION .................................................................... 10

1.5 GENERAL REQUIREMENTS.................................................................................. 10 1.5.1 CONTRACTOR QUALIFICATIONS ..................................................................... 10 1.5.2 DESCRIPTION OF EQUIPMENT ........................................................................ 11

1.5.3 EQUIPMENT NAMEPLATES ............................................................................. 12 1.5.4 EQUIPMENT LABELS ...................................................................................... 12

1.6 DESIGN REQUIREMENTS .................................................................................... 13 1.6.1 GENERAL ..................................................................................................... 13

1.6.2 DESIGN CRITERIA ......................................................................................... 13 1.7 OPERATING CONDITIONS ................................................................................... 15

1.8 OPERATING REQUIREMENTS .............................................................................. 16 1.9 QUALITY ASSURANCE ........................................................................................ 16

1.9.1 DRAWINGS ................................................................................................... 16

1.9.2 MATERIALS .................................................................................................. 17 1.9.3 WELDING ..................................................................................................... 17

1.9.4 PAINTING ..................................................................................................... 17 1.9.5 MANUFACTURE AND INSTALLATION ................................................................. 17

1.10 SUBSTITUTIONS ................................................................................................. 17 1.11 MANUFACTURER’S FIELD SERVICE REPRESENTATIVE ........................................... 18

2.0 PRODUCTS ....................................................................................................... 18

2.1 GENERAL MATERIAL REQUIREMENTS ................................................................... 18

2.2 MOTORS ........................................................................................................... 18

2.3 TROLLEY CONDUCTORS ..................................................................................... 19 2.4 MOTOR DRIVES ................................................................................................. 19

2.4.1 MOTOR CONTROLLERS (AC DRIVES) – OPEN LOOP SYSTEM ........................... 19 2.4.2 MOTOR CONTROLLERS (AC DRIVES) – CLOSED LOOP SYSTEM ....................... 22

2.5 INSTRUMENTATION AND CONTROLS ..................................................................... 24 2.5.1 GENERAL ..................................................................................................... 24 2.5.2 BRIDGE ....................................................................................................... 24



2.5.3 MAIN HOIST ................................................................................................. 25 2.5.4 AUXILIARY HOIST .......................................................................................... 25 2.5.5 TROLLEY ..................................................................................................... 26 2.5.6 TANDEM MODE OPERATION .......................................................................... 26

2.6 OPERATOR’S CAB INSTRUMENTS AND CONTROLS ................................................ 27 2.6.1 PUSHBUTTONS AND SWITCHES ...................................................................... 27 2.6.2 DISPLAY AND INDICATION .............................................................................. 27 2.6.3 MASTER SWITCHES ...................................................................................... 28

2.7 OTHER INDICATING DEVICES (NOT IN OPERATOR’S CAB) ....................................... 28

2.7.1 VISUAL INDICATING LIGHT STACK ................................................................... 28 2.7.2 VISUAL INDICATING LIGHTS – MECHANICAL LINKS ........................................... 28 2.7.3 AUDIBLE INDICATION ..................................................................................... 28 2.7.4 WEIGH SYSTEM DISPLAY .............................................................................. 29

2.8 RADIO CONTROL ............................................................................................... 29 2.8.1 GENERAL ..................................................................................................... 29

2.8.2 TRANSMITTER .............................................................................................. 29 2.8.3 RECEIVER: ................................................................................................... 31

2.9 GROUNDING ...................................................................................................... 32

2.10 REACTORS ....................................................................................................... 32 2.11 ISOLATION TRANSFORMER ................................................................................. 33

2.12 MAIN DISCONNECT ............................................................................................ 33 2.13 CONTROL PANELS ............................................................................................. 33 2.14 PROTECTIVE EQUIPMENT ................................................................................... 34

2.15 LIMIT SWITCHES ................................................................................................ 34 2.15.1 GENERAL ..................................................................................................... 34

2.15.2 TRAVEL LIMITS ............................................................................................. 35 2.15.3 MAIN AND AUXILIARY HOIST LIMITS ................................................................ 35

2.16 LIGHTING .......................................................................................................... 35 2.16.1 FLOODLIGHTS .............................................................................................. 35

2.16.2 OPERATOR’S CAB LIGHTING .......................................................................... 36 2.16.3 LIGHTING LEVELS ......................................................................................... 36

2.17 SWITCHES, INDICATING LIGHTS, AND NAMEPLATES............................................... 36

2.18 MAIN POWER .................................................................................................... 36 2.19 ACCESSORY POWER.......................................................................................... 37

2.20 CONVENIENCE OUTLETS .................................................................................... 38 2.21 CONDUIT AND WIRING ........................................................................................ 38 2.22 WIRING ACCESSORIES ....................................................................................... 41 2.23 TERMINAL BLOCKS ............................................................................................ 42

2.24 MISCELLANEOUS ELECTRICAL EQUIPMENT .......................................................... 42 2.25 SHOP ASSEMBLY TESTS .................................................................................... 43

3.0 EXECUTION ....................................................................................................... 43

3.1 PREPARATION FOR INSTALLATION ....................................................................... 43 3.2 INSTALLATION ................................................................................................... 44 3.3 FIELD TESTING .................................................................................................. 44 3.4 ADJUSTMENTS AND REPAIRS .............................................................................. 44 3.5 FIELD TRAINING................................................................................................. 44



3.6 SUBSTANTIAL COMPLETION ................................................................................ 45 3.7 ACCEPTANCE .................................................................................................... 45



SECTION 41 22 11.13

BRIDGE CRANE ELECTRICAL REHABILITATION

1.0 GENERAL

1.1 SECTION INCLUDES

1. General requirements for removal of all electrical controls, equipment, and wiring on the two (2) 250 ton capacity bridge cranes in the Rocky Reach Hydroelectric Project’s powerhouse.

2. The design, fabrication, furnishing, and installation of electrical and control equipment and associated systems.

1.2 REFERENCE SPECIFICATIONS

American Institute of Steel Construction (AISC) AISC 317 Manual of Steel Construction, Vol II: Connections AISC 325 Manual of Steel Construction

Association for Iron and Steel Technology (AIST) AISE Report No. 11 Brake Standards for Mill Motors

ASTM International (ASTM) B3 Soft or Annealed Copper Wire B8 Concentric-Lay-Stranded Copper Conductors, Hard,

Medium-Hard, or Soft B33 Tinned Soft or Annealed Copper Wire for Electrical

Purposes B172 Rope-Lay-Stranded Copper Conductors Having Concentric-

Stranded Members, for Electrical Conductors B173 Rope-Lay-Stranded Copper Conductors Having Bunch-

Stranded Members, for Electrical Conductors B174 Bunch-Stranded Copper Conductors for Electrical

Conductors

Crane Manufacturers Association of America (CMAA) No. 70 Top Running and Gantry Type Multiple Girder Electric

Overhead Traveling Cranes (2010 edition)

International Code Council IBC 2012 2012 International Building Code

International Organization for Standardization (ISO) 1940 Mechanical Vibration – Balance Quality Requirements of

Rigid Rotors

IEEE Standards Association (IEEE) C2 National Electric Safety Code (NESC) C62.41.1 IEEE Guide on the Surge Environment in Low-Voltage



(1000 V and Less) AC Power Circuits C62.41.2 IEEE Recommended Practice on Characterization of

Surges in Low-Voltage (1000 V and Less) AC Power Circuits

519 IEEE Recommended Practice and Requirements for Harmonic Control in Electric Power Systems

112 IEEE Standard Test Procedure for Polyphase Induction Motors and Generators

383 Class 1E Electrical Cables, Field Splices, Connections for Nuclear Power Generating Stations

National Electrical Manufacturer’s Association (NEMA) NEMA C80.1 Rigid Steel Conduit; Zinc Coated ANSI/NEMA FB 1 Fittings, Cast Metal Boxes and Conduit Bodies for Conduit,

Electrical Metallic Tubing, and Cable NEMA ICS 1 General Standards for Industrial Controls and Systems NEMA ICS 2 Controllers, Contactors and Overload Relays Rated 600 V NEMA ICS 3 Medium Voltage Controllers Rated 2,001 to 7,200 V AC NEMA ICS 4 International Control and Systems; Terminal Blocks NEMA ICS 5 International Control and Systems; Control Circuit and Pilot

Devices NEMA ICS 6 International Control and Systems; Enclosures NEMA ICS 8 International Control and Systems; Crane and Hoist

Controllers NEMA MG 1 Motors and Generators NEMA OS 1 Sheet-Steel Outlet Boxes, Device Boxes, and Box Supports NEMA ST 20 Dry-Type Transformers for General Applications NEMA PB 1 Panelboards NEMA WC 57-2014/ ICEA S-73-532-2014

Standard for Control, Thermocouple Extension, and Instrumentation Cables

NEMA WC 70-2009/ ICEA S-95-658-2009

Power Cables Rated 2,000 V or Less for the Distribution of Electrical Energy

NEMA WD 6 Wiring Devices – Dimensional Specifications NEMA 250 Enclosures for Electrical Equipment (1,000 V Maximum)

National Fire Protection Association (NFPA) 70 National Electrical Code® (NEC)

Underwriters Laboratories (UL) 1 Flexible Metal Conduit 6 Rigid Metal Conduit 44 Rubber-Insulated Wires and Cables 62 Safety Flexible Cord and Fixture Wire 66 Fixture Wire 98 Enclosed and Dead-Front Switches 360 Standard for Liquid-Tight Flexible Metal Conduit 467 Grounding and Bonding Equipment 489 Molded-Case Circuit Breakers, Molded-Case Switches and



Circuit-Breaker Enclosures 508 Standard for Industrial Control Equipment 514A Metallic Outlet Boxes 514B Conduit, Tubing, and Cable Fittings 870 Wireways, Auxiliary Gutters, and Associated Fittings 886 Outlet Boxes and Fittings for uses in Hazardous Locations 1449 Transient Voltage Surge Suppressors 1581 Reference Standard for Electrical Wires, Cables, and

Flexible Cords 1686 Pin and Sleeve Configurations

State of Washington – Washington Administrative Code (WAC) WAC 296-46B-903 Electrical Safety Standards, Administration, and Installation

1.3 RELATED SPECIFICATION SECTIONS

See the following related Specification sections for reference codes and standards for design, materials, material testing, inspection and other requirements for the crane system.

1. 26 08 00 Electrical Testing

2. 41 22 10.13 Bridge Crane Mechanical Rehabilitation

1.4 SUBMITTALS

1.4.1 General

Submit all items in accordance with Section 01 30 00 Administrative Requirements.

Before proceeding with manufacture of any equipment for the crane system, submit for review and Approval Contractor’s Shop Drawings, catalog cut sheets, and engineering documents required to demonstrate fully that all parts will conform to the provisions and intent of this Section and related Sections, and to the requirements related to installation, operation, and maintenance.

1.4.2 Procedures

1. Work Plans: Submit detailed Work Plan for installation of the electrical rehabilitation work. Work plans shall including a description of work activities, illustrative diagrams, and schedule. Work Plans for installation and testing of the new crane system shall be complete with Contractor’s Shop Drawings to demonstrate that the proposed design is consistent with the intended approach regarding installation and testing.

2. QA/QC Plan: Before proceeding with manufacture of any crane equipment, Contractor shall submit for review and Approval a QA/QC Plan in accordance with Section 01 45 16.13 Contractor Quality Control.



3. Inspection and Test Plan: Before proceeding with manufacture and installation of crane, submit for review and Approval Contractor’s plan of inspection to be performed at key stages of assembly and testing of equipment, with applicable illustrations, diagrams, check sheets, and procedures, for fit-up, dimensional correctness, alignment, and sequential checkout, startup, and operation of equipment. The Shop and Field Inspection and Test Plan shall be in accordance with the requirements of Section 01 45 16.13 Contractor Quality Control, Section 01 91 14 Equipment Testing and Commissioning, and these Specifications.

1.4.3 Drawings

1. Before proceeding with manufacture of any crane equipment, Contractor shall submit Drawings showing all necessary dimensions and fabrication details, complete Bill of Materials (including the type and grade of materials), details of welded and bolted joint connections, tolerances, surface finishes, nondestructive examinations, and other pertinent details.

2. Detail drawings (including but not limited to): a. Electrical drawing index. b. Details and equipment arrangement in operator’s cab. c. Details of crane and trolley power control and instrumentation electrification

systems. d. Details of crane lighting. e. Detailed list of limit switches, control devices and other instrumentation with

all settings delineated. f. Locations and layout of all electrical equipment, including cabinets, motors,

brakes, controls, and interconnection conduits. Drawings shall include detailed locations of all drilling required in structural members. Weights of items shall be included.

g. Locations and layout of remote radio control receivers, transmitters, and antennas, including: assigned license frequencies, estimated signal strength of remote in operation area, clarification of signal path blockages, and transmitter/receiver coordination study.

h. Each cabinet or equipment housing, with locations and sizes of external equipment, conduit drilling, cabinet mounting means, hinges, latches, and locks.

i. Conduit type and size; locations of the conduits, fittings, splice and junction boxes; and the number and the sizes of conductors in each conduit.

j. Conduit and Cable Schedules; both as drawing and MS Excel (.xls) spreadsheet to include but not be limited to: conduit number blank (to be filled in by the Engineer), conduit size, conductors (number, size, insulation type, shield type, drain wire size), Cable usage (power, control, instrument), cable source, cable number (to be determined by the Engineer), and destination. Schedules shall include list of conductor identifications utilized in each cable, including spares, and assigned color codes. Conduit shall be sized in accordance with NFPA 70.

k. Controls arrangements and components



l. Electrical schematics for the power, control and instrumentation systems, showing all component interconnects for power, control, monitoring, and protective circuits. Schematics shall include truth tables defining the crane operations.

m. Control panel wiring diagrams shall indicate the wiring for individual items of equipment within all panels and equipment items, terminal board connections, wire designations, and sizes and types of wire. The wiring diagrams shall also show all connections between individual panels, and between panels and separately located items.

n. Wiring interconnection diagrams showing interconnecting cable between each piece of equipment and termination details for each of the cables including wire designations, wire color and sizes and types of wire. Interconnection drawings shall be furnished for all control and power cable to be installed by the contractor. Termination details for each of the cables including pin number / letter or other terminal connection point shall be provided.

o. Dimensioned outline drawings detailing placement, conductors, and operation of trolley festoon system.

p. Nameplates. q. Other drawings needed to clarify the design.

1.4.4 Equipment and material lists



3. BOM shall include quantity, manufacturer, manufacturer’s part number and description of material being provided.

1.4.5 Catalog Data

1. Provide product specifications, descriptive literature, and performance data for electrical items of standard manufacture; including but not limited to manufacturer’s data sheets for motors, brakes, transformers, limit switches, circuit breakers, ACVF drives, contactors and similar electrical components, etc.

2. Catalog data shall be submitted for items of standard manufacture, which will consist of the manufacturer’s published catalog; including but not limited to product specifications, descriptive literature, and performance data.

1.4.6 Engineering Data

Calculations, engineering data, etc., in accordance with the detailed provisions of each specifications section, including but not limited to:



1. Calculations developed using MathCAD® or Microsoft® Excel shall be submitted in the original software application file formats; PDF (*.pdf) file format will not be accepted except for the final stamped and Approved submittal.

2. Electrical design criteria and calculations used in the selection and/or design of electrical components including but not limited to wire sizing, circuit breaker and other protection selection, heating / cooling loads, etc.

3. Complete descriptive specification of each type motor to be furnished, with necessary catalog cuts, photographs, and drawings to clearly indicate the construction, the treatments used to prevent corrosion of parts, bearing construction and type of insulation and treatment on the windings. Full NEMA standard nameplate data and dimension sheets shall be furnished.

4. Routine motor test reports for all motors. Motor testing to be performed in accordance with NEMA MG 1-2011 and IEEE-112.

5. Motor characteristic curves or tabulated data (test or calculated) of each motor to be furnished indicating the speed, power factor, efficiency, current, and kilowatt input, all plotted and tabulated against percent rated motor torque or percent rated motor load, in accordance to IEEE Standard 112.

6. Characteristics of the position encoders furnished with the motors.

7. Complete descriptive data covering each type of brake to be furnished with necessary catalog cuts, photographs, and drawings to indicate clearly the construction of the brake and the materials used. Means of release, and torque adjustment of holding brakes, specifications and characteristics, including range of torque adjustment of holding brakes, input current, minimum voltage at which brake will release, rectifier or hydraulic control unit specifications and characteristics, and all other features.

8. Calculations of current and voltage harmonic components on line side of filtering equipment. Calculations shall be made for different loads and speeds, including minimums and maximums, and those combinations of load and speed which may produce maximum waveform distortions.

9. Electrical load tables, feeder sizing, voltage drop calculations, and conduit/raceway sizing to satisfy NEC requirements for power and control circuits.

10. Circuit protection coordination curves.

11. Complete engineering data sheets, catalog information and instruction booklets for variable speed drive systems.

12. Complete data for crane radio controls systems, including frequency allocation for final Approval after reviewing the frequencies already in service and assistance with any required FCC licensing.



1.4.7 Reports and Documentation

Reports and documentation in accordance with the detailed provisions of each specifications section, including but not limited to:

1. Shop test report, including shop assembly and inspection check sheets for fit-up, dimensional correctness, alignment, functional tests, and other checks.

2. Certification Records: Submit copies of all shop and field inspection records and reports.

3. Packing and shipping procedures, in accordance with the requirements of Section 01 61 00 Common Product Requirements.

4. Installation instructions, in accordance with the requirements of Section 01 78 23 Operation and Maintenance Data.

5. Operation and Maintenance Manuals: Submit complete sets of O&M manuals containing the manufacturer’s operating and maintenance instructions for each piece of equipment and the integrated crane in accordance with the requirements of Section 01 78 23 Operation and Maintenance Data.

6. Warranties: Manufacturer’s product warranties and additional warranties to be provided by Contractor.

7. Certificates of Compliance and Proper Installation, in accordance with the requirements of Section 01 45 16.13 Contractor Quality Control.

8. Closeout submittals, in accordance with Section 01 30 00 Administrative Requirements.

9. Certification of the factory adjusted torque rating of holding brakes.

10. Field test report, including field assembly and inspection check sheets for fit-up, dimensional correctness, alignment, functional tests, load tests, and other checks.


1.5.1 Contractor Qualifications

The Contractor shall provide evidence of its qualifications with its Bid in accordance with General Requirements and Instructions to Bidders paragraph ITB-16, Bidder’s Data. Subcontractors, and suppliers of crane components, shall be subject to Approval by the Engineer.

In addition, all aspects of the electrical field installation work shall be performed under the direction of a licensed electrician. There shall be a minimum of one (1) licensed electrician on site during all field wiring and electrical work.

See Section 41 22 10.13, Bridge Crane Mechanical Rehabilitation, for additional Contractor qualifications.



1.5.2 Description of Equipment

Contractor shall provide bridge crane equipment and accessories for the refurbishment of the two (2) Rocky Reach Powerhouse Cranes including, but not limited to the following:

1. Mainline conductors modifications as specified.

2. Isolation transformer.

3. Trolley conductor system.

4. Crane control system with enclosures

5. New geared limit switches for both the main and auxiliary hoists

6. Other limit switches

7. New motors and brakes.

8. Radio control system.

9. Operator’s cab refurbishment equipment.

10. New wiring, reusing existing conduit and wireway as applicable.

11. New rigid conduit where required.

12. Wire, conduit, and any needed appurtenances for installation.

13. Miscellaneous accessories and components.

14. Removal of existing equipment as specified in Section 02 41 19 Selective Removal and Modifications.

Equipment supplied shall include and meet with the following requirements:

15. Select standard (off-the-shelf) parts and components to the extent practicable given the performance requirements specified herein.

16. Select parts and components that are readily available and interchangeable to the extent practicable. Select components to minimize the overall number and type of parts to be serviced, repaired, and/or stored in spare parts inventories.

17. Requirements specified herein shall apply to all equipment furnished, except those requirements that are modified elsewhere. All aspects that are not specified in this Section shall be in accordance with the recommendations of applicable industry design standards, and with conservative design practice.

18. Provide a refurbished crane system that is complete with all parts and components specified and/or required for installation, operation, and maintenance.

19. Provide parts and components that can be serviced and repaired directly by firms or agencies located in the United States.



20. Provide all temporary equipment and accessories for handling the supplied equipment including slings and other accessories to form and handle bundles during transportation and for unloading at the job site. The equipment shall also include all supporting elements for transportation of various supplied equipment.

21. All parts, components, and assemblies which are heavier than 50 pounds shall be provided with suitable provisions for handling, such as eyebolts, lugs, hooks, tapped holes for eyebolts, or holes with rounded corners for passing slings. Components that require special access and weight considerations shall be provided with handling provisions and detailed written handling procedures.

22. Provide spare parts in accordance with Section 01 78 43. All Spare parts shall be readily available through Contractor or directly through suppliers/manufacturers or U.S. representatives.

1.5.3 Equipment Nameplates

1. Furnish each piece of equipment (such as motors, gear reducers, holding brakes, drives, radio controllers, etc.) with identification nameplates that are permanently mounted on each piece of equipment.

2. Nameplates shall show the serial number, the name and address of the manufacturer, rated capacity, speed, electrical characteristics, and other pertinent data as applicable to the component. Nameplates of distributing agents alone will not be acceptable. Mount the nameplates at an appropriate, prominent location on the equipment itself.

3. Submit all proposed nameplate designations to the Engineer for Approval. Nameplates shall be of either: a. Twenty (20) gage stainless steel with embossed lettering, b. Laminated plastic with lettering engraved through upper layer, or c. Anodized aluminum, stainless steel, plastic, or other material of equivalent

durability which has engraved or etched lettering filled with enamel of a contrasting color.

4. All nameplates shall be attached to the equipment with corrosion resisting screws.

1.5.4 Equipment Labels

1. Provide each electrical circuit breaker, fuse block, contactor, relay, control, with an identification label directly adjacent to or on the device

2. Equipment label shall show the name of the device as shown on the schematic and wiring diagrams.

3. Provide engraved phenolic labels that are attached to the enclosure backsheet using screws.



1.6 DESIGN REQUIREMENTS

1.6.1 General

Unless specified otherwise, the supplied crane equipment shall meet all of the requirements and recommendations of ASME B30.2, OSHA 1910.179 and the NFPA-70 National Electrical Code.

The supplied equipment shall also be designed in accordance with CMAA Specification #70 for Class D Service, except as modified by the detailed requirements in this specification. In addition, any reference to the term “should” in CMAA Specification #70, shall be a firm performance requirement, rather than optional for this Contract.

All electrical equipment and installation shall be in accordance with NFPA 70 and IEEE C2 except where otherwise specifically indicated on the Contract Drawings or called for in the Contract specifications. Where equipment is specified to conform to the requirements of any code or standard such as UL, NEMA, etc.; the design, fabrication, and installation shall conform to the code. Omission of details on the Drawings or in these Specifications shall not be construed as permitting deviations from code requirements. NEMA rated and UL listed equipment has been specified when available. Equipment shall meet NEMA and UL construction and rating requirements as specified. No equivalent will be acceptable without District Approval. The Contractor shall immediately notify the District of any requirements of the Specifications or of Contractor proposed materials or assemblies that do not comply with UL or NEMA. International Electrotechnical Commission (IEC) rated equipment will not be considered an acceptable alternative to specified NEMA ratings.

See Section 41 22 10.13, Bridge Crane Mechanical Rehabilitation, for details of additional design requirements.

1.6.2 Design Criteria

1.6.2.1 General

Design criteria used for the crane shall ensure that all operations can be performed as specified over a 50-year service life with minimal inspection and maintenance, and can be safely operated under the loading conditions specified in the environment for which it is intended.

See Section 41 22 10.13, Bridge Crane Mechanical Rehabilitation, for additional design criteria that apply to the design of all new bridge crane components and equipment.

1.6.2.2 Design of Electrical Components

1. Electrical component certification shall be UL Certified, Or Equal, as Approved by the Engineer.



2. The Contractor shall verify all dimensions and site conditions prior to sending applicable submittals for District review. Space available for placement of electrical equipment and enclosures is limited to the dimensions of the existing platforms and structural members unless otherwise shown or indicated in these Specifications or on the Drawings.

3. All electrical equipment shall operate on power supplied at the crane. Equipment shall be able to tolerate variations in voltage source of +/- 10%, and variations in line frequency of +/- 2% with no degradation of performance or lifespan.

4. Power, communication, control, and safety equipment shall be rated for ambient environmental conditions of 40ºF to 122ºF dry bulb and 10% to 95% relative humidity, non-condensing. Shielding of equipment, cables, and components shall be provided as required to prevent mis-operation of the equipment due to external or internal interferences to the control systems.

5. All equipment connected to ac circuits shall be protected from power surges. Equipment shall meet the requirements of IEEE C62.41.1 and IEEE C62.41.2. Fuses shall not be used for surge protection. Surge protection devices shall be comprised of single components designed to dissipate the surge energy. Paralleling of devices to achieve the energy dissipation level is not acceptable.

6. The controls shall operate within the guidelines of IEEE 519 for general systems, including the following: 5% voltage distortion factor, and 22,800 volt-microseconds commutation notch area, as seen by the power source to the crane. Crane drives and other internal systems shall be able to withstand harmonic distortion and notching as defined in IEEE 519 for dedicated systems, that is: 10% voltage distortion factor and 36,500 volt-microseconds commutation notch area. The Contractor shall provide line reactors, isolation transformers, filters, and other items as needed to comply with these requirements. a. The District uses a low energy radio system, the PIT (Passive Integrated

Transponder) tagging system, for tagging and monitoring of fish movements. The system operates on a center frequency of 134.2 kHz. The crane harmonic suppression systems shall effectively block radiation of interfering frequencies in the band from 120 kHz to 150 kHz. Shielding, isolation, and harmonic filtering on the crane shall prevent any interference with the PIT tagging system or the crane shall be modified as required to eliminate interference to the PIT tagging system at no cost to the District.

7. Electrical work shall be in accordance with the National Electrical Code (NEC) and the National Electrical Safety Code (NESC), except where otherwise specifically indicated on the Contract Drawings or called for in these Specifications. Omission of details from the Drawings or Specifications shall not be construed as permitting deviations from Code requirements.

8. All equipment shall be of the type normally furnished for crane applications and service, unless specified otherwise. All equipment shall be the standard



product of manufacturers specializing in the production of this type of equipment as evidenced by the existence of previously published catalog data. Equipment shall essentially duplicate items that have been in satisfactory service for at least two (2) years prior to bid opening.

9. Defective equipment, or equipment or finishes damaged in the course of installation shall be replaced or repaired as Approved by the District. Equipment and materials for the same or similar or allied services shall be of the same manufacturer and type, and when of the same rating shall be interchangeable.

1.6.2.3 Performance Parameters

See Section 41 22 10.13, Bridge Crane Mechanical Rehabilitation, for details of principal performance parameters for the bridge cranes.

1.6.2.4 Seismic Loading

Mounting of all electrical components and attachments to the existing crane shall be designed to resist seismic loads determined in accordance with the International Building Code, ASCE 7-10, and 2008 USGS mapped accelerations.

1. Seismic Design Category D

2. Ss=.479g, S1=.2g, SDS=.319g, SD1=.134g

3. Importance Factor: 1.5

1.7 OPERATING CONDITIONS

The cranes will be used for material handling inside the powerhouse and primarily for disassembly, reassembly, and maintenance of the turbines, generators, and governors.

The crane equipment shall be designed for indoors operation under normally dry conditions and a temperature range of 40ºF to 122ºF.

Each crane travels on the existing straight runway rails located above the powerhouse generator floor as shown on the Drawings.

The two powerhouse bridge cranes will operate independently on the same runway during routine disassembly, reassembly, and maintenance work; and will work in tandem during handling of the generator rotor.

Electric power supply to the bridge cranes is 460 VAC, ungrounded, 3-phase. Runway conductors (feedrail) and accessories specified in Section 26 25 13 shall be furnished and installed by the Contractor. The District will furnish and install supply conductors, sized for the cranes, to a centrally located termination point on the crane runway conductors.



1.8 OPERATING REQUIREMENTS

The refurbished crane system shall be designed for operation from the operator’s cab, or from a portable radio control station. A transfer switch with Cab and Radio positions shall be mounted in the operator’s cab.

The powerhouse operators will normally utilize the portable radio control station “bellybox” for daily crane service. The operator’s cab will be used during tandem crane operations, for crane maintenance, and in the event that the radio control system is out of service.

Tandem mode control selector switches shall be provided on the radio controls and in the operator cab on the south crane. The selector switches shall have three (3) positions: “North”, “South”, and “Both”. When the selector switch is in the “Both” position, and the umbilical cable specified in paragraph 2.5.6 is connected, tandem operation shall be enabled from the active (cab/radio) south crane control station.

The existing crane-to-crane mechanical links for tandem operation shall be reused as-is. New limit switches shall be provided on the south crane to indicate the crane-to-crane links are in the tandem operation position.

Indicating lights, and displays for the crane operation shall be provided on the crane bridge, visible from the operators cab and from the powerhouse floor, as specified in paragraph 2.7.

Interlocks shall be provided for the “Hoist Overload” condition as follows:

1. Main Hoist Overload: Interlock provided will interrupt hoist motion and provide an alarm signal when an electrical signal from the variable frequency drive indicates the load is above a predetermined load trip setting in accordance with paragraph 2.5.3.

2. Auxiliary Hoist Overload: Interlock provided will interrupt hoist motion and provide an alarm signal when an electrical signal from the load pin and weighing system indicates the load is above a predetermined load trip setting in accordance with paragraph 2.5.4.


1.9.1 Drawings

Contractor shall apply a system of control to ensure that the requirements of these Specifications and Contract Drawings have been properly interpreted and transposed to Contractor’s Shop Drawings, material orders, fabrication, and inspection procedures.



1.9.2 Materials

In accordance with Section 01 45 16.13 Contractor Quality Control, the Contractor shall ensure the requirements and standards for analysis and testing of materials shall be as specified in this section and additional related sections elsewhere in these Specifications. The Contractor shall be responsible for inspection to ensure such analyses and tests are performed and that the results are certified in conformance with the specified acceptance criteria.

1.9.3 Welding

Perform welding, inspecting, and testing of welded parts in accordance with the requirements of Section 05 05 23 Welding.

1.9.4 Painting

Perform painting, inspecting, and testing of painted parts in accordance with the requirements of Section 09 90 04, Painting.

1.9.5 Manufacture and Installation

In accordance with Section 01 45 16.13 Contractor Quality Control, the Contractor shall apply quality control systems throughout all aspects of the manufacturing and installation Work. The Contractor shall ensure that the materials, dimensions, and all other requirements called for in Shop Drawings, inspection plans, procedures, and specifications are fully correct and in compliance with these Specifications.

Fabrication work subcontracted to workshops other than the manufacturer’s own facilities shall be disclosed to the Engineer in a timely manner prior to the start of fabrication. Workshops shall be subject to Approval by the Engineer.

1.10 SUBSTITUTIONS

If the Specification requirements differ from the manufacturer’s standard design, submit sufficient information to allow Engineer to determine that the item or material proposed is essentially equivalent to or satisfies the intent to that specified.

Material and equipment substitutions shall be in accordance with Section 01 25 13 Material and Equipment.

Substitutes for technical standards defined according to other national standards (e.g., Canadian or DIN standards) may be substituted for U.S. standards provided the standards are comparable or equivalent to, or superior to those specified. Substitutes for technical standards shall be subject to Approval by the Engineer, in accordance with specification Section 01 42 13, References Codes and Standards.



1.11 MANUFACTURER’S FIELD SERVICE REPRESENTATIVE

Contractor shall provide qualified and experienced field service representative(s) to supervise installation, testing, instruct personnel in the operation and maintenance of the refurbished bridge cranes, training, and related activities in accordance with Section 01 43 33 Manufacturers Field Services.

2.0 PRODUCTS

2.1 GENERAL MATERIAL REQUIREMENTS

All materials furnished as part of this Contract shall be new, and both workmanship and materials shall be of first-class quality. Where indicated by these Specifications, material classification and grades shall be as designated herein. For material specifications not specifically indicated herein provide materials and equipment of the best commercial grade quality suited for the intended use and as Approved by the District.

2.2 MOTORS

1. Voltage: 460 VAC, 3-phase, 60 Hz.

2. Type: AC motor rated for use with IGBT variable frequency drives (VFD) for crane and hoist duty. a. Bridge motors (quantity 4) shall be equipped with brake. b. Trolley motor shall be equipped with brake. c. Hoist motors (main and auxiliary hoist) shall be equipped with encoder.

3. Speed Range Capability, 1000:1 when applied with closed loop control, 40:1 when applied with open loop control.

4. Design: Conform to the requirements of NEMA MG-1, Design B. CMAA Class D rated. 1.0 Service Factor for pulse width modulated (PWM) drives.

5. Certification: Provide routine motor test report in accordance with NEMA MG-1 as required by Specification 01 45 16.13 Contractor Quality Control.

6. Insulation: NEMA Class F, applied with NEMA Class B temperature rise. 50°C ambient rating.

7. Thermal Rating: a. Bridge: 60 minute (one (1) hour) b. Trolley: 60 minute (one (1) hour) c. Hoists: 60 minute (one (1) hour)

8. Enclosure: Totally enclosed non-ventilated (TENV).

9. Accessories and Features: a. Encoders, when specified or required for the application.

1) Encoder Type: Zero (0) speed, magneto-resistive sensing type optimized for motors used with VFDs in crane and hoist service.

2) Encoder Construction: Modular, non-contact, bearingless design.



b. Inspection and service covers with gaskets. c. Corrosion resistant hardware. d. Drain holes with plugs at low points. e. Motor heaters, with heaters energized when the motor is de-energized. f. Three (3) Class F, thermostats (klixons), one (1) per phase, embedded in

motor windings. The thermal devices and associated circuitry shall serve as alarms activating an amber indicating light at the control stations when motor temperature becomes excessive. The thermal device and associated circuitry shall automatically reset.

g. Foot mounted hoist and trolley motors. NEMA C-face mounting with double shaft for travel brakes and hoist encoders, as required for the specific application.

2.3 TROLLEY CONDUCTORS

Trolley conductors shall be of the festooned (looped) insulated wire type, providing a power, control and instrumentation connection between trolley and bridge. The festoon cables shall be flexible (minimum Class K stranding), rated for indoor festoon service, and shall be arranged for maximum separation between power and instrumentation cables, not less than six (6) inches. Power, control, and instrumentation circuits shall be segregated and terminated in separate junction boxes. The festoon cables shall be as short as reasonably possible, and shall have ring terminals on each end of all wires, that connect on strips and lugs in terminal boxes that are mounted at the edge of the trolley and the end of the girder. Shielded instrument cables shall have individual terminal blocks for each shield drain wire; no sharing of terminal blocks for shield drains will be permitted. In no case shall a power conductor be used as a common conductor for more than one circuit.

The multiple loop system shall consist of a support rail, electric cables, junction boxes, cable cars, and all accessories required to completely and correctly install the conductor system in accordance with the manufacturer’s recommendations and to satisfy all code and regulatory requirements. The trolley festoon system hardware shall be corrosion resistant steel. The trolley festoon system shall be maintainable from the upstream maintenance platform.

2.4 MOTOR DRIVES

The drive systems including drives, DBUs, resistors and other associate equipment shall be designed for the maximum hoist and travel distances at rated speed.

2.4.1 Motor Controllers (AC Drives) – Open Loop System

1. Type a. Variable frequency drive (VFD) for controlling 460 VAC motor speeds as

follows: 1) Bridge: AC VFD “open loop” system, as specified below. 2) Trolley: AC VFD “open loop” system, as specified below.



2. Performance (Open Loop Vector Mode) a. Speeds: Control capable of varying the motor's speed between 1/100th and

two (2) times rated motor speed. b. Torque: Control motor to develop full load rated torque at all speeds

between 1/100th rated speed and rated motor speed. c. Speed Regulation: No-load and full-load speeds shall not differ by more

than (3.0%) over the entire frequency range. d. Load Sensitivity: Near zero (0).

3. Motor Speed Control Method: The following types of motor control shall be available in the motor controller. Types 1 and 2, as listed below, shall operate with 120 VAC control circuits. a. Type 1: Fixed Speed Steps for 2 to 5 Speed Points:

1) A programmable number of speed points are operator selectable using control station stepped levers or stepped pushbuttons.

2) Each speed point individually selected by input of dry contact closures to the controller.

3) Fixed speeds are digitally programmed via a user-friendly keypad affixed to the controller.

4) Acceleration and deceleration are independently programmable and independent of each other. Braking action is programmable.

b. Type 2: Infinitely Variable Speed Steps: 1) Levers or pushbuttons are operated to indicate accelerate, hold speed,

decelerate or stop. Speed can be adjusted to any speed at any time by the operator by using only the control levers.

2) These systems shall be capable of being operated using either 2-step or 3-step pushbuttons or levers

3) Acceleration and deceleration rates are independently programmable. Braking action is programmable.

c. Type 3: Infinitely Variable Proportional Control: 1) Through operation of a spring loaded joystick, the crane will accelerate

in the indicated direction to a speed proportional to how far the lever is moved.

2) Ramp rate is programmable. Braking action is programmable.

4. Control of Brakes: a. Type: Electrically released, spring set brake which is released by means of

an electro-mechanical contactor that supplies full voltage to the brake coil when a directional command is issued.

b. Brake Operation: Upon release of a directional command, one of the following sequences shall occur: 1) Brake sets immediately due to de-energizing of the brake contactor and

the controller immediately goes to zero (0) output. 2) Controller decelerates the motor to zero (0) speed using dynamic

braking over a programmable time ramp and then sets the holding brake by de-energizing the brake contactor.

c. Selection of either of the above brake operating methods is programmable.



5. Motor Control System Components: a. Digital, variable speed drive, sized for the application and motor parameters

including motor full load current rating. b. Drive features and capabilities:

1) Phase-to-phase short circuit and ground fault protection. 2) ACCEL range of 0.0 to 25.5 seconds with optional S-curve. 3) DECEL range of 0.0 to 25.5 seconds with optional S-curve. 4) Stall prevention during ACCEL and constant running. 5) Brake operation selection. 6) Direct current (dc) injection braking. 7) Automatic torque compensation (voltage boost) circuitry. 8) Completely digital software driven circuitry and all digital adjustments. 9) Programming capability for all drive characteristics such as: maximum

frequency, minimum frequency, maximum output voltage, voltage boost, volts to hertz relationship, etc.

10) Dry contact output to indicate drive is outputting frequency. 11) Speed search function which allows bumpless starting into a coasting

load. 12) Speed setting via dry contact closure inputs. 13) On-board frequency, current, dc bus voltage and output voltage meters,

elapsed time, number of run commands. 14) Electronic thermal overload protection. 15) Input voltage rating of 460 VAC ±10% at 60 Hz ±5%. 16) Programmable load check overload (weight) available with counter. 17) Automatic overspeed up to 120 Hz (programmable) under light or no

load conditions. 18) Safe Operating Windows to reduce the possibility of programming the

drive with unsafe values. 19) Reverse Plug Simulation for traversing motions. 20) Micro Positioning feature for reduced speed range operation. 21) Selectable password protection. 22) Three (3) selectable jump frequencies with up to a 20 Hz bandwidth. 23) Run Inching Function available. 24) Multi motor two (2) V/F patterns to use one (1) inverter with two (2)

motions. 25) Fault history on flash ROM of the last five (5) faults with trace feature

for the current fault. 26) Keypad display in English, plain language LCD. 27) Auto-Tune for Open Loop Vector Built-in. 28) Dynamic Braking Transistor Built-in (for drives rated up to 34 Amps,

460 VAC). 29) Alternate deceleration ramp used when forward/reverse command

removed (Quick Stop). 30) UL Listed/CSA Approved/CUL Listed. 31) Drive output - asynchronous PWM (Pulse Width Modulated) control

method with a carrier frequency of up to 15 kHz.



32) Motor slip compensation feature. 33) 0 to 10 VDC analog output proportional to output frequency, output

current, output voltage, dc bus voltage, or frequency reference. 34) Ability to verify, using keypad display on drive, presence of input

directional and speed reference signals and output signals. 35) Drive input and output phase loss detection. 36) Fault diagnostics: CPF (central processor failure), EF (external fault), dc

bus fuse, ground fault, input and output open phase, overcurrent, inverter and motor overheat, inverter and motor overload, overtorque, keypad failure, overvoltage, undervoltage, internal braking transistor and resistor.

37) Serial Communications built in for linkage among various peripherals, including radio remote crane controls.

38) Optional data logger for troubleshooting with history of 1024 drive run events and 512 alarm and fault events. A trace function allows viewing of pre-fault conditions.

39) Interface Control Circuits shall provide the following: a) Electrical isolation between control switches and drive. b) Directional signals to the drive by means of solid state outputs. c) Speed reference signals to the drive by means of solid state

outputs. d) Interface control circuit shall be an integral part of the drive.

c. Manufacturer: MAGNETEK, Impulse G+ Series 4.

2.4.2 Motor Controllers (AC Drives) – Closed Loop System

The closed loop system shall include the same capabilities or features as the open loop system with the following additional capabilities or features.

1. Type a. Flux vector variable frequency drive (VFD) for controlling 460 VAC motor

speeds as follows: 1) Hoist: AC VFD “closed loop” system.

2. Performance (Closed- Loop Vector Mode) a. Speeds: Control capable of varying the motor's speed between 1/1,000th

and two (2) times rated motor speed. b. Torque: Control motor to develop full load rated torque at all speeds

between zero (0) and rated motor speed. c. Speed Regulation: No-load and full-load speeds shall not differ by more

than 0.1% over the entire frequency range. d. Load Sensitivity: Near zero (0).

3. Motor Speed Control Method a. Same as open loop controller.

4. Control of Brakes



a. Type: Electrically released, spring set holding brakes which are released by means of two (2) electro-mechanical contactors that each supply full voltage to one brake coil. Command for brake release will coincide with a directional command being issued. Contactors will alternate which brake – primary or secondary – is delayed by one (1) second for the release and application to check the torque of both brakes regularly.

b. Brake Operation: Application type as listed below is selectable at the drive keypad.

c. Hoist Applications: 1) Upon input of a run command from the operator station, both holding

brakes release via brake contactor when sufficient torque is produced to suspend the load. If sufficient torque is not produced, the drive shuts off and a pulsating alarm contact shall activate.

2) Upon removal of a run command from the operator station, the motor is quickly decelerated, the motion stopped by dynamic braking, and the load suspended, establishing a drive set-point. The drive de-energizes the brake contactor, output frequency and voltage goes to zero (0) and operation stops. If the brakes fail to set or cannot hold the load, the drive shall continue to output at zero (0) speed and a “steady” alarm contact shall be activated. The detection of a brake failure shall reduce hoist raising speed to 2 ft/min and illuminate brake failure indicating light.

d. Traverse Applications: 1) Upon input of a run command from the operator station, the holding

brake releases via brake contactor. 2) Upon removal of a run command from the operator station, the motor

shall quickly decelerate and the motion stopped by dynamic braking action. The drive de-energizes the brake contactor.

5. Motor Control System Components a. Flux Vector Drive, sized for the application and motor parameters including

full load current rating. b. Drive features and capabilities: Same as open loop motor controller with

additional capabilities as noted below. 1) Load float capability which allows hoist load to be held aloft at zero (0)

speed or a traverse operation to stop without setting the holding brake. Load float shall be timed operation after removal of raise, lower or directional command with an initial setpoint of 10 seconds load float before setting the holding brake.

2) Slack Cable Detection identifies slack or broken cable conditions. 3) Weight Measurement within ±2.5% accuracy with 0-10 VDC output. 4) Anti-swing control for acceleration and deceleration of delicate loads. 5) Interface Control Circuits: same as open loop controller.

c. Manufacturer: MAGNETEK, Impulse VG+, Series 4.



2.5 INSTRUMENTATION AND CONTROLS

2.5.1 General

To integrate the new controls into the existing system each axis of control shall have its own control panel with flange mounted disconnect which actuates the circuit breaker protecting the drive for that axis of motion. When verifying the existing equipment dimensions the contractor should make note of the conduit entrance locations which are to be reused. The walkway modifications are intended to accommodate the deeper panels while still providing 30 inches of clearance in front of the control panels as required by OSHA & the NEC.

To facilitate ease of troubleshooting for maintenance personnel, the control systems shall be provided with hardwired interlocking 120 VAC circuits. Both the radio control and master switches shall have relay contact outputs. The interlocking logic described within this specification shall be used to provide the forward, reverse, speed, and all safety commands to the variable frequency drives (VFDs). The five speed points shall be initially set at 2.5%, 11%, 33%, 66% and 100% of full load motor speed. Provide Coarse/Fine speed selector switch which will provide speeds rated at 10% of the five speed points specified above.

The contacts of relays, contactors, and other current switching control devices shall be rated in accordance with NEMA ICS-2 and shall have current making, carrying and interrupting ratings 10% greater than the requirements of the circuits to which they switch, at voltages equal to or greater than those of the circuits to which they are connected.

All electrical panels shall be UL508 or as required in WAC 296-46B-903 Equipment standards. See paragraph 2.13.4 for air conditioning requirements.

Hoist, trolley and bridge control panels shall be fitted with elapsed time meters, which run when the individual motions’ brakes are released.

2.5.2 Bridge

Normal Bridge Operation shall be provided using a VFD as described in paragraph 2.4.1 connected to squirrel cage motors described in paragraph 2.2 Motors, controlled from either the cab or radio control with interlocks as described below.

1. Bridge primary stop signal for bridge end-of-travel on the north and south ends of runway. Type: Limit switches.

2. Bridge primary slowdown (10% of full speed) signal for bridge slowdown on the north and south ends of runway. Type: Limit switches

3. Limit Switch Trip Device: Located on the upstream rail to trip the switch before the bumpers are contacted.



4. When travel switches are tripped, the switches shall permit travel opposite the direction of stop and then automatically reset after return to “set” condition.

5. Crane-to-crane mechanical link limit switches: Provide heavy duty industrial limit switches mounted on South crane upstream and downstream mechanical links. Provide local indicating lights which illuminate when links are not properly connected and tandem mode (“BOTH”) is selected.

6. Bridge motor brakes shall be designed to set immediately upon loss of power.

2.5.3 Main Hoist

Normal Main Hoist Operation shall be provided using a Flux Vector Drive (FVD) as described in paragraph 2.4.2 connected to a squirrel cage main hoist motor described in paragraph 2.2 Motors, controlled from either the cab or radio control with interlocks as described below.

1. Upper and Lower Travel Limits: Hoist primary stop signal for hook end-of-travel. Type: Geared, rotary limit switches.

2. Upper Overtravel Limit: Weight-type to prevent the hoist from rising beyond a safe limit. Backup to geared limit switches.

3. Upper Slowdown Limit: Hoist slowdown signal, set one (1) foot below the upper travel limit, 10% of full speed. Type: Geared, rotary limit switches.


5. Roll Back Detection: Included with hoist motor controls.

6. Overload Detection: Provide overload detection using the flux vector drive specified in paragraphs 2.4.2. When overload is detected: a. Prevent further hoisting but allow lowering. b. Illuminate warning light specified in paragraph 2.7.

2.5.4 Auxiliary Hoist

Normal Auxiliary Hoist Operation shall be provided using a Flux Vector Drive (FVD) as described in paragraph 2.4.2 connected to a squirrel cage auxiliary hoist motor described in paragraph 2.2 Motors, controlled from either the cab or radio control with interlocks as described below.

1. Upper and Lower Travel Limits: Hoist primary stop signal for hook end-of-travel. Type: Geared, rotary limit switches.

2. Upper Overtravel Limit: Weight-type to prevent the hoist from rising beyond a safe limit. Backup to geared limit switches.

3. Upper Slowdown Limit: Hoist slowdown signal, set one (1) foot below the upper travel limit, 10% of full speed. Type: Geared, rotary limit switches.




5. Roll Back Detection: Included with hoist motor controls.

6. Overload Detection: Provide weighing system with overload detection for the Auxiliary hoist hook. The weighing system accuracy shall be ±5% of total capacity. a. Permit the hoist to lift a freely suspended load with its rated capacity but

prevents lifting of an overload greater than 25 Tons on the hook. b. The lifted load value will be displayed as specified in paragraph 2.7.

2.5.5 Trolley

Normal Trolley Operation shall be provided using a VFD as described in paragraph 2.4.1 connected to the squirrel cage trolley motor described in paragraph 2.2 Motors, controlled from either the cab or radio control with interlocks as described below.

1. Trolley Travel Limits: Trolley primary stop signal for trolley end-of-travel on the upstream and downstream ends of runway using existing limit switches

2. Limit Switch Trip Device (use existing): Located on both ends of the trolley runway to trip the switch before the bumpers are contacted.

2.5.6 Tandem Mode Operation

The two powerhouse bridge cranes will normally operate independently on the same runway as described above. In addition, the cranes shall be designed to operate in tandem mode from the south bridge crane operator control cab or radio control ‘bellybox”. Provide an Umbilical cord, located at the upstream crossover platform for connection of the south crane to a junction box mounted on the north crane, with the following features:

1. Conductors: a. Main Hoist: Raise, Lower, (4) speed points (from south crane to north

crane). b. Bridge: North, South, (4) speed points (from south crane to north crane). c. Trolley: Upstream, Downstream, (4) speed points (from south crane to north

crane). d. Energize mainline contactor: from south crane to north crane. e. Drive faults: from main hoist, bridge, and trolley (from north crane to south

crane). f. Umbilical connection signals: (between both cranes).

2. Multiconductor cable(s) a. Connectors: Cable strain relief style in accordance with MIL-DTL-38999 b. Kellems-type grips: External Cable Grip: Woven wire-mesh type made of

high-strength, galvanized-steel wire strand, matched to cable diameter, and with attachment provision designed for corresponding connector.



3. Features a. South Crane (when not in tandem mode operation): umbilical cord shall be

plugged into to a socket mounted on the south crane that shall allow single crane operation.

b. North Crane (when not in tandem mode operation): the socket shall have a plug(s) installed that shall allow single crane operation. Plug shall be attached to the junction box by a cable or chain retainer.

2.6 OPERATOR’S CAB INSTRUMENTS AND CONTROLS

2.6.1 Pushbuttons and Switches

1. Emergency stop pushbuttons (Maintained type): one (1) cab.

2. Off/On/Start selector switch: Off (left position) – Maintained, On (center position) – Maintained, Start (right position) – Momentary spring return to center

3. Warning alarm (auditory indication), pushbutton (Momentary type).

4. Transfer switch: Radio-Cab control selector (Maintained type)

5. Speed mode selector switch: two position, maintained, “Coarse” and “Fine”

6. Tandem mode selector switch (south crane only): three position, maintained, “North”, “South”, and “Both”.

7. Flood lights on/off switch: (floodlights shall be fully controllable from both the operator’s cab and the radio control “bellybox”).

8. An “open disconnect” pushbutton will be provided on the back wall of the operators cab to shunt trip the circuit breaker type disconnect.

9. Pushbutton and switch type: heavy duty, dust, and oil-tight type in accordance with NEMA ICS 2.

2.6.2 Display and indication

1. Motor Thermal Overload Indication: Warning lights (color amber) for all motors including: a. Bridge b. Trolley c. Main hoist d. Auxiliary hoist

2. Main Hoist Brake Failure Indication: Indicating light (amber).

3. Auxiliary Hoist Brake Failure Indication: Indicating light (amber).

4. Main Hoist Overload: Indicating light (red).

5. Auxiliary Hoist Overload: Indicating light (red).

6. Power Circuit Indicating Lights a. Power Indication: Indicating light (white). b. Main Line Contactor Energized Indication: Indicating light (blue).



2.6.3 Master Switches

Service and reuse existing master switches for bridge, hoists, and trolley.

Service shall include:

1. Clean and lubrication of cams

2. Vacuum the enclosures

3. Inspect contacts

4. Any master switch repairs, if necessary, shall be the responsibility of the District.

2.7 OTHER INDICATING DEVICES (NOT IN OPERATOR’S CAB)

2.7.1 Visual Indicating Light Stack

Supply a column type group of lights for 360 degree viewing of:

1. Power On Indication: Warning light (white).

2. Main Line Contactor Energized Indication: Warning light (blue).

3. Brake Failure Indication: Warning light for main and auxiliary hoists, located on underside of bridge walkway structure, visible from the operator cab and generator floor area (amber)

4. Load Indication: Warning light for main and auxiliary hoists located on underside of bridge walkway structure, visible from the operator cab and generator floor area, when main hoist load exceeds 250 tons or auxiliary hoist load exceeds 25 tons (red).

2.7.2 Visual Indicating Lights – Mechanical Links

On south crane provide local indicating lights near the upstream and downstream mechanical link used for tandem operation. Lights will illuminate when links are not connected and tandem (“BOTH”) operation is selected (red).

2.7.3 Audible Indication

1. Bridge Travel Warning Alarm: Audible indication, located on the downstream girder end tie structure.

2. Main or Auxiliary Hoist Brake Failure or Overload: Audible indication, located on the downstream girder end tie structure. This warning shall be audible to personnel on the powerhouse floor to a distance of at least 200 feet, during regular full-load operation of the crane. If the hoist with the failed brake is isolated from its power source by maintenance personnel (lockout/tagout), then that hoist shall no longer sound the alarm.



2.7.4 Weigh System Display

Auxiliary hoist load indication shall be located on the downstream sill beam structure and visible from the operator cab and generator floor area. Display shall be mounted within a NEMA 4 enclosure. Display shall be LED or equal. Digits shall be viewable from 100 feet, minimum letter height shall be four inches. Display in XX.X tons for auxiliary hoist hook.

2.8 RADIO CONTROL

2.8.1 General

Type: “Hands-free,” portable, “bellybox” type, battery operated transmitter unit, and a fixed station receiver unit. The transmitter shall be the manufacturer's current commercial product completely assembled, wired, factory tested, and delivered ready for installation and operation. The transmitter shall have an internal battery power source and internal antenna and shall be capable of generating and transmitting all control signals necessary for operation of the system. Total weight shall not exceed six (6) pounds, including battery.

The District uses a low energy radio system, the PIT (Passive Integrated Transponder) tagging system, for tagging and monitoring of fish movements. The system operates on a center frequency of 134.2 kHz. The crane harmonic suppression systems shall effectively block radiation of interfering frequencies in the band from 120 kHz to 150 kHz. Shielding, isolation, and harmonic filtering on the crane shall prevent any interference with the PIT tagging system or the crane shall be modified as required to eliminate interference to the PIT tagging system at no cost to the District.

2.8.2 Transmitter

1. Radio Frequency (RF) output impedance shall be 50 ohms. The transmitted spurious harmonic emissions shall be less than minus sixty -60 dB. Frequency stability shall be a maximum of 0.0005% over the operating temperature range as specified herein. The transmitter shall be designed to maintain minimum field strength of 30 microvolts within entire operating range. Its operating range shall be a minimum of 300 feet. The maximum RF power output shall be one (1) Watt.

2. The transmitters shall operate on a frequency range of 450-470 MHz. The transmitter-receiver pair shall operate from a different assigned frequency from other equipment in the area. Contractor shall implement the existing District (FCC) licensed frequencies. a. North Crane: 451.5625 MHz b. South Crane: 456.5625 MHz

3. The transmitter shall transmit a distinct identity code number as part of all signals emanating from the transmitter. The identity code shall allow for no less



than a seven (7) digit code selection. Transmitter coding telemetry shall be pulsed digital data.

4. The transmitter unit shall be NEMA 4 (IP-65) construction and furnished with accessory neck strap. The control devices shall be arranged in accordance with CMAA Specification #70.

5. Transmitter Accessories and Features (completely labeled and identified): a. On-Off Switch: Key operated. b. Start Pushbutton c. Main Hoist Control: Lever switch: spring return to center, 5 speed. d. Auxiliary Hoist Control: Lever switch: spring return to center, 5 speed. e. Trolley Control: Lever switch, spring return to center, 5 speed. f. Bridge Control: Lever switch, spring return to center, 5 speed. g. Warning Bell Pushbutton. h. Emergency Stop Pushbutton. i. On Indicator: Red LED. j. Battery Monitor: Red LED (lighted when battery charge low). k. Speed mode selector switch, two position, “Fine” and “Coarse” l. Tandem control mode selector switch (South crane only), three position,

“North”, “South”, “Both”. m. Flood lights on/off switch: switch or pushbutton type, flood lights shall

remain illuminated when the radio controller times out.

6. The transmitter unit shall operate from a rechargeable sealed Nickel-metal hydride or lithium-ion battery or set of batteries that will maintain adequate voltage to provide a minimum of eight (8) hours of continuous operation. Battery replacement shall be accomplished by removal of no more than two (2) screws or latches. The transmitter shall constantly monitor and supervise its own battery powered supply. A low battery condition shall be indicated when battery capacity falls below 20% of rated capacity. Two (2) spare batteries or sets of batteries shall be provided for each transmitter provided.

7. A storage cabinet with provisions for wall or ceiling mounting and for a minimum 3/4-inch conduit connection shall be furnished for the crane. The District will locate and install the cabinet. The cabinet shall contain an electronically regulated battery charger with LED indicating lights for “Charging” and “Fully Charged”. Incoming ac power shall be provided with a standard 120VAC GFCI specification grade outlet. Storage space for the remote control box and for the spare battery or battery set, while at least one (1) additional battery or battery set is being charged. The cabinet shall be as specified in paragraph 2.12 of this section. A terminal for one (1), #12 AWG grounding conductor shall be provided inside the cabinet.

8. Transmitter quantities: Each crane shall be supplied with two (2) radio transmitters (one spare).



2.8.3 Receiver:

1. Crane mounted receiver shall receive digital frequency modulated (FM) radio coded signals from the control transmitter/encoder, accurately decode them, and operate solid state output devices that are capable of driving their associated crane control components. Each output shall be isolated type without a common return. The contacts of output relays shall be rated in accordance with NEMA ICS-2 and shall have current making, carrying and interrupting ratings 10% greater than the requirements of the circuits to which they switch, at voltages equal to or greater than those of the circuits to which they are connected. Output or input devices shall be plug in type, with a hold down screw or latch and color coded by function and operating voltage range. The control panel shall be a programmable microprocessor based controller. The decoding computer shall provide system troubleshooting and diagnostics. The decoding computer shall analyze and evaluate incoming digital messages and output devices, as well as on-board watchdog timers and discrete hardware.

2. One (1) radio receiving system compatible with the transmitter frequency shall be provided. The system shall be completely assembled, wired, factory tested, and delivered ready for installation and operation. Receivers shall be solid-state design and shall use frequency modulation pulsed signal. a. Input impedance at the head end of the receiver section shall match a

50 ohm antenna. The receiver shall receive the transmitted signal on a frequency assignment between 450-470 MHz. The sensitivity of the receiver shall be a minimum of one-half (0.5) microvolts, producing a 20 dB quieting of the receiver output noise.

b. Receiver shall have: 1) Spurious response rejection not less than a minimum 75 dB, 2) No more than 5% audio distortion measured at 1,000 Hz, 3) A hum and noise level not greater than -50 dB below the signal level. 4) Output compatible with the associated device.

c. The receiver shall be selected and installed with adequate gain margin, and adequate gain margin shall be allowed for signal fading and equipment aging. Receiver shall provide for error checking of the transmitted information, to ensure all information is received as intended. An error rate of less than five (5) errors per 1,000,000 commands shall be maintained. Error rate shall be determined end-to-end from transmitter through receiver to decoder output.

3. The receiver unit shall consist of: a. RF receiver module. b. Microprocessor based control module. The control module shall provide

constant supervision of the operating conditions. Indicators shall be provided for each major component, and an audible signal shall be produced in the event of failure of any major component. Panel shall provide for fail-safe condition and all crane functions shall cease when a failure occurs.



c. Output relay/control modules. d. Power supply. e. Modular design shall be provided to allow interchange of components for

maintenance purposes.

4. The antenna system shall utilize vertical polarization antennas and matching networks as needed for proper coverage. The antenna system shall be omni-directional. The antenna system and cabling shall be furnished to provide adequate system gain. The receiver antenna location shall be carefully selected as determined by existing clearances and structural features around the crane.

2.9 GROUNDING

The Contractor shall furnish and install the following crane grounding system as part of its Base Bid (Bid Schedule A) for the crane refurbishment Work. For details and requirements of alternative crane grounding systems (Bid Schedules A and B), see Specifications Section 26 25 13.

1. Ground all electrical systems and equipment in accordance with NEC Article 250.

2. Bond and ground all exposed, non-current carrying, metal parts to the system grounding conductor in accordance with NEC article 610.

3. Furnish each power conduit with an equipment grounding conductor sized in accordance with the NEC article 250.

4. Add a least two grounding shoes to the bridge that will make contact with the bridge rail to provide a ground to the bridge, and connect the grounding shoes to the crane ground system. Verify that the runway rails are continuously connected with a properly sized ground wire, and connected the rail to the supply grounding system. If the runway rails are found to not be continuously grounded, the work to correct same will be the responsibility of the District. The grounding shoes shall be brass and rated at 200 Amps. Suggested grounding shoe is VAHLE, INC. part # GSV 2/ Ms.

2.10 REACTORS

1. Furnish properly sized filter reactors on each VFD drive input and output to minimize affects of harmonics, to prevent interference with other drives, and to avoid return of harmonics to the 460 VAC station power system. Reactors shall be UL listed, rated for full load motor current and installed to meet the requirements of NEC. Performance of the reactors shall be as required by the drive manufacturer.



2.11 ISOLATION TRANSFORMER

1. The existing 460 VAC power system at the Rocky Reach Dam is an ungrounded delta system. Provide an isolation transformer rated 480 VAC (delta) to 480 VAC grounded wye.

2. Mount isolation transformer in a convenient location on the crane. Final location of isolation transformer shall be Approved by Engineer.

3. The drive isolation transformer shall be rated to carry the maximum demand load plus approximately 20% over capacity. These calculations shall be submitted for Approval by the Engineer.

4. Provide indoor weatherproof, dry-type transformers.

2.12 MAIN DISCONNECT

1. In accordance with OSHA 1910.179 provide a circuit breaker type disconnect mounted between the runway power feed collectors and the isolation transformer on the upper walkway, in a location near the existing disconnect.

2. An “open disconnect” pushbutton will be provided on the back wall of the operators cab to shunt trip the circuit breaker type disconnect.

2.13 CONTROL PANELS

1. Control panels located in protective indoor locations shall be fabricated of solid steel designed and constructed to conform to requirements of NEMA 250, type 12/13. Control panels shall be finished ANSI Z55.1, #61 gray color or manufacturer’s standard color for exterior surfaces and white for interior surfaces.

2. Manufacture of cabinets and enclosures, including custom-fabricated enclosures, shall be UL Certified in the manufacture of industrial enclosures. Cabinets and enclosures must meet the requirements of Underwriters Laboratories Inc. The UL Mark on the enclosure will be accepted as evidence of compliance.

3. Thermostatically controlled heaters (maximum rating 100 Watts) shall be furnished to keep enclosure temperatures at or above 50°F (must be above dew point).

4. Provide a single window-type commercial air conditioning unit that is plugged into a convenience outlet adjacent to the control panels. The air conditioning unit shall be installed in a divided plenum that directs cool air coming from the evaporator coils into the control panels, and directs return air towards the coils. The plenum shall be designed to allow easy future replacement of the air conditioner with a different unit. Provide a stainless steel or galvanized drip tray suitable for evaporating condensate.

The control panel interior air shall be a closed system. The panels shall be either directly interconnected or connected using ducts, to create a cross-flow of



cool air across the control panel components. An air ducting system with a circulating blower shall direct return air back to the air conditioner plenum. The circulating blower shall run continuously when the crane is energized; the air conditioner shall be thermostatically controlled. Individual panel air conditioners are NOT acceptable.

Providing oversize control panels and electrical components, to limit panel interior temperatures via natural convection, is an acceptable alternative to supply of the air conditioning system. Complete calculations and component temperature ratings shall be provided if this option is selected.

5. Control panel doors shall be hinged, gasketed, and fitted with operator handles and a three-point latch capable of being latched closed. Door swings shall be a minimum 170 degrees. Doors shall be sized so they can be mounted on the crane. Panels shall contain the necessary panel stiffeners and equipment mounting panels to maintain the integrity of the enclosure system.

6. LED bulbs rated at least 800 lumens with a color temperature of less than 4,000 Kelvin, with “A” type bases shall be provided inside each control panel. The lighting circuit shall include a limit switch on the door on the panel to toggle the lighting on and off.

7. A 120 VAC duplex convenience specification grade outlet shall be provided in each panel.

8. Electrical components shall be located and mounted in panels so they are easily accessible for inspection and maintenance.

9. All main wiring runs within panels shall be contained in wireways, according to manufacturer’s recommendations.

2.14 PROTECTIVE EQUIPMENT

Protection shall be not less than that required by NEMA ICS 3, CMAA Specification #70, and ANSI/NFPA 70. All short circuit protection shall be by circuit breakers. Circuit breakers shall be 600V, three poles, 42kA symmetrical minimum, manually operated, molded-case circuit breaker having suitable continuous rating, subject to District Approval.

2.15 LIMIT SWITCHES

2.15.1 General

1. Geared Limit Switches: Heavy duty quick-break, double-pole, double-throw type, conforming to NEMA ICS 2. The geared limit switch interruption of a motion in one (1) direction shall not prevent the opposite motion. Geared limit switches shall reset automatically.

2. Other types of limit switches (proximity or mechanical arm type): oil-tight with cover gaskets.



3. Limit Switch Enclosures: NEMA 250, type 4.

4. Except as Approved by the Engineer (as practical to provide), all limit switches shall have a minimum of one (1) spare isolated, Normally-Open and Normally-Closed set of contacts. Where possible, limit switches shall be provided with a fixed number of contacts to simplify orders and minimize spare parts stock.

2.15.2 Travel Limits

1. Trolley Travel: service and reuse the existing trolley travel limit switches. Service shall include inspection, cleaning, vacuuming, and lubrication.

2. Bridge Travel: Normally-Closed, momentary contact, lever-arm type, limit switches. When the first limit is reached the traveling speed shall slow down to 10% speed. If the contractor desires, one (1) slowdown limit can be used for both directions with two (2) separate targets. The crane shall stop when the second limit is reached, and the switches shall be adjusted so that the end stops are not contacted, but all operational areas are accessible. Targets shall be located on upstream bridge runway rail to trip the switch before the bumpers are contacted. Limit switches shall be mounted so that switches can be adjusted to stop and slowdown limits.

2.15.3 Main and Auxiliary Hoist Limits

1. Hoist Weighted Upper Limit: Normally-closed, momentary contact, weighted-lever type, actuated directly by the blocks to halt upward hoisting. The bale of the weight shall be placed on one of the wire ropes that is part of the equalizer sheave or the fixed end of the rope. The switch shall de-energize the mainline contactor. To reset, the maintenance crew will need to manually hold the weight and slowly lower the hoist to operating range. Lever and weighted-lever type limit switches for hoist shall be direct-acting, equal to Square D Class 9007 Hoist Overtravel Type CLS1 with reset weight and chain.

2. Hoist Upper and Lower Rotary Limit: Normally-closed, rotating-cam rotary type, driven by adapter on drum shaft. The input shafts of rotary limit switches shall couple to shafts on drum axles using zero-backlash couplings. The rotary limit switch shall slow the hoisting speed down to 10% speed. The upper limit shall stop the hoist before the weighted upper limit. Limit switch shall be capable of resetting travel to full speed by reversing the movement of the hoist. Rotary limit switch shall be used for upper slowdown, upper stop, and lower stop functions.

2.16 LIGHTING

2.16.1 Floodlights

1. Type: High pressure sodium or LED with a color temperature of less than 3,500 Kelvin, and UL listed.

2. Floodlight Operation: Floodlight system shall be designed to be controlled by on/off switches located in the operator’s cab and on the radio control. The floodlights shall not turn off when the radio controller times out.



3. Description of Floodlight Fixtures: a. Housing of corrosion resistant aluminum with baked acrylic enamel finish. b. Watertight gasketed housing with tempered glass lens. c. Mogul base shock resistant lampholder and shock resistant lamp supports

for reducing the effects of shock and vibration. d. UL 595 compliant.

4. Floodlights: Located on trolley and bridge structure.

5. Floodlights shall be designed with the ballast located remotely from the light fixture to facilitate replacement of parts. The floodlight fixture shall be conveniently located on the crane structure to facilitate bulb replacement without special access equipment. Unless otherwise Approved by Engineer, light fixtures shall be fixed to hinged deck or walkway plates for ease of access from above.

2.16.2 Operator’s Cab Lighting

1. Dimmable LED bulbs rated at least 800 lumens with a color temperature of less than 3,500 Kelvin, with “A” type bases and industrial fixtures and shall be spaced to provide adequate lighting. Cab lighting shall be controlled by conveniently located dimmer switch near the point of access.

2.16.3 Lighting Levels

Light fixtures shall be sized and located to furnish the following lighting levels:

1. Floodlights: 50 foot-candles at the working surface at the turbine floor level (EL 630).

2. Operator’s Cab: 50 foot-candles at floor area.

2.17 SWITCHES, INDICATING LIGHTS, AND NAMEPLATES

1. Operating pushbuttons shall be heavy-duty, dust and oil tight type with distinctly felt operating positions, which meet requirements of NEMA ICS 2.

2. Indicating lights shall be transformer type, press-to-test, heavy-duty, dust and oil-tight type, which meet requirements of NEMA ICS 2.

3. Nameplates shall be provided adjacent to each pushbutton and indicating light. Nameplates shall be engraved phenolic white with black lettering. Nameplates shall be screw retained.

2.18 MAIN POWER

1. Incoming power will be supplied to the crane electrification conductors or cables at 460 VAC, 3-phase, ungrounded, as indicated on the Contract Drawings, which indicate the desired arrangement of main line contactor, isolation transformer, main power panel, and accessory power. Power consumption shall be limited to 200 Amps per crane. The mainline contactor shall be controlled manually by start/reset and emergency stop switches in the



operator’s cab and by remote radio control. Fuses shall not be used unless Approved by the District.

2. Main Power Panel: a. The main power panel shall be located on the bridge walkway. b. Main power circuit breaker shall be actuated by an external handle which

shall be lockable in the “Off” position. c. Provide circuit breakers as shown on the Contract Drawings and as

required to protect all electrical components.

3. Main Line Contactor: a. Furnish and install a NEMA-rated mainline contactor that disconnects

power to all drive functions of the crane. b. The main line contactor shall be rated to carry the maximum demand load

plus approximately 20% over capacity margin. c. The main line contactor shall have a 120 VAC coil.

4. Phase monitor: Furnish and install a phase monitor. Phase monitor shall provide protection against phase unbalance, phase loss, phase reversal, undervoltage, and overvoltage. Upon sensing fault, the protector shall de-energize the main-line contactor. The protector shall use a combination of voltage and phase-angle sensing to detect phase loss even when regenerated voltages are present. The protector shall have an adjustable line voltage trip level, adjustable trip delay, and both automatic and manual reset. Protector operation shall have repeatability of +1% of set point, maximum, and a dead band of 2% maximum. Protector shall have green indicator to show normal status and red indicator to show tripped status. Protector shall be easily replaceable.

2.19 ACCESSORY POWER

1. Single phase, 120/240 VAC power shall be supplied to crane circuits via a 460 VAC accessory main circuit breaker and accessory power transformer from the line side of the mainline contactor for, motor heaters, space heating, and other accessory circuits on the crane.

2. Accessory Main Circuit Breaker: a. The 460 VAC accessory main circuit breaker shall be furnished with a

thermal-magnetic trip and have a NEMA Type 12 enclosure. b. The enclosure shall have provisions for locking the breaker in the “Off”

position. c. The circuit breaker assembly shall be UL listed. d. The minimum circuit breaker interruption rating is 42 kA. The circuit

breaker trip rating shall be selected to carry the maximum demand load plus approximately 20% over capacity margin.

3. Accessory Transformer: a. A new single phase, dry type transformer shall be furnished for stepping

down the 460 VAC from the circuit breaker to 120/240 VAC.



b. The transformer shall be sized to carry the maximum demand load and have approximately a 20% over capacity margin.

4. Accessory Panelboard: a. A new panelboard shall be fed from the Accessory Transformer. b. Accessory Panelboard shall be a 120/240 VAC UL listed main lug only

circuit breaker panelboard. Minimum circuit breaker interruption rating shall be 22 kA.

c. The 120/240 VAC circuit breaker panelboard shall supply branch circuits for utilization of various accessories such as receptacles, lighting, panel heaters, motor heaters, radio receiver, etc. Supply and install spare circuit breakers (120/240 VAC, various currents) to provide the 20% over capacity margin as described in paragraph 4d below.

d. The panel shall be sized to carry the maximum demand load and have approximately a 20% over capacity margin.

e. GFCI circuit breakers shall be used for all convenience outlet circuits.

5. Locations: The 2-pole, 460 VAC, accessory main circuit breaker; the accessory transformer; and the 120/240 VAC accessory panelboard shall be located on the bridge walkway.

2.20 CONVENIENCE OUTLETS

Convenience outlets shall be single phase, 120 VAC, 20 Amp, duplex type, specification grade or better. All receptacles will be located indoors, but shall be weatherproof type. Convenience outlets shall be provided in the following locations: one installed at the downstream end of the walkway, one at the center of the bridge, one in each control panel, and one in the operator’s cab. A dedicated convenience outlet and accessory circuit breaker shall be provided for the control panel air conditioning system, if provided.

2.21 CONDUIT AND WIRING

All existing wiring shall be removed and disposed of by the Contractor. Prior to demolition, the Contractor shall test the existing wiring for the presence of asbestos. Any wiring found to contain asbestos shall be removed in accordance with Section 02 82 13.01, Class II Asbestos Abatement.

The existing conduit system which is internally mounted and integral to the crane structure shall be reused. All existing conduits left in-place and in which asbestos containing wiring was installed, shall be thoroughly cleaned to remove all asbestos materials. Asbestos removal and disposal work shall be in accordance with Section 02 82 13.01, Class II Asbestos Abatement.

New conduit installations shall be submitted for District Approval. New Conduit systems shall be in accordance with the following:

1. Conduit and wiring installation shall conform to ANSI/NFPA 70 (NEC).



2. Wiring between equipment units or components, except where flexible conduit is allowed by NFPA 70, shall be installed in rigid galvanized steel (RGS) conduit with threaded conduit fittings, and zinc-coated NEMA 250, Type 4 outlet and pull boxes. Conduit connections to motors, brakes, limit switches, wheel trucks, and other similar devices where flexible connections are required at the end of a conduit run shall be made using lengths of less than 3-feet of liquid-tight flexible conduit. Flexible conduit shall not be used for any other purpose.

3. The conduit shall be securely mounted and fastened to the crane framework, and shall be installed in a neat and workmanlike manner. Conduit may be attached to the machinery and structure using Unistrut-style channel and fittings. Conduit shall not be added to any walkway surfaces. The channel shall be 12 gauge minimum thickness, and shall not be welded directly to the structure. If used, the support channel shall be bolted to steel stand-off angles, bars or studs that are structurally welded to the trolley / crane structure and painted using the systems specified in 09 90 04 Painting.

4. Change of direction of a conduit run shall be made by means of threaded conduit fittings or sweeps and the conduit shall be installed to fit close to the crane framework. Conduit unions shall be used where standard couplings cannot be used to join conduits or as required to permit dismantling for shipment. No running threads will be permitted. Ends of conduits shall be carefully reamed and free of burrs and rough edges. All conduit ends shall be fitted with hubs. All sheet metal pull boxes and junction boxes shall be NEMA Type 4.

5. Separate conduit systems shall be provided for power (greater than 120 Volts), control (greater than 24 Volts), and instrumentation (less than 24 Volts) circuits. The entire conduit system shall be grounded in accordance with NEC and shall be installed so that any moisture will be drained from terminal boxes and equipment. The conduit system shall be installed in the shop, complete and ready for installing wire, and after inspection shall be dismantled as necessary for shipment to the site.

6. Conduit: a. Rigid Conduit: RGS conduit shall conform to ANSI C80.1, UL Listed.

Conduit shall be zinc-coated (galvanized) both inside and outside by the hot-dip method.

b. Liquid-tight, flexible conduit: liquid-tight, flexible conduit shall conform to UL 360, CID A-A-55810, be UL Listed, and shall have a hot-dipped galvanized steel core, copper ground wire, and a waterproof extruded PVC cover.

c. Fittings for rigid and flexible conduit shall conform to NEMA FB 1, UL 467, and UL 514B. Fittings for rigid conduit shall be threaded.

d. Cast boxes and covers shall conform to UL 514A and UL 886. All cast boxes shall be supplied with integral cast hubs or with factory-brazed hubs. All hubs shall be factory threaded.

7. Insulated Wire and Cable:



a. Single conductors for installation in conduit shall be a NEC recognized, UL Listed wire type, Approved for the intended used. Single conductors larger than #2 AWG shall be type XHHW. Wiring exposed to heat shall have flame retardant, heat and moisture resistant insulation.

b. All conductors shall be copper with insulation rated for 600 V. Conductors shall be properly sized in accordance with NEC using 75°C temperature basis, but with minimum conductor size and stranding as in accordance with the following table:

APPLICATION MINIMUM AWG STRANDING

Power Circuits #12 Class B or C

Control Circuits #14 Class B or C

Lighting #12 Class B

Exposed to Heat #10 Class K

Control Panel hinge wiring #14 Class K

Instrumentation wiring #16 Class B or C

c. Multiple Conductor Cables. Materials, construction, and tests, unless otherwise specified, shall conform to the applicable requirements of NEMA WC 57 or NEMA WC 70, as applicable.

d. Insulation: 1) Insulation shall be cross-linked polyethylene (XLPE) or ethylene

propylene rubber (EPR). Color coding for control cable shall exclude the colors white and green, and shall be physical colors of insulation rather than printed color names.

2) An outer jacket with a minimum flame rating of VW-1 of a synthetic thermosetting non halogen material shall be applied over multiple-conductor cables. Single-conductor cables and individual conductors of a multiple-conductor cable require a jacket if: a) insulation is EPR or, b) Insulation is XLPE and a lower insulation class (thickness) than

indicated in the table (5.b.) above, in accordance with NEMA WC 57 or WC 70, is supplied.

e. Jackets shall be tightly and concentrically formed around cable cores. f. Instrumentation cable shall be shielded with proper drain wire to insure that

interference in signals is properly eliminated. Multi-conductor control cable shall also be shielded if required to prevent interference of signals.

g. Insulation of power circuit conductors shall be colored brown/orange/yellow for 460 VAC three-phase circuits and black/white for 120 VAC or otherwise identified in accordance with NEC requirements.

8. Control Panel Wiring: Control panel wiring shall be stranded, copper, SIS switchboard wire with 600 Volt insulation. Hinge wire shall be used between stationary and hinged equipment, and shall be formed in wire loops or bundles at least two (2) feet long, which shall provide rotation around the longitudinal axis of the conductors.



9. Wire connecting to resistors, space heaters, or otherwise exposed to heat shall be fixture wire type SF2, 600V, 200°C, and in accordance with UL 66. Insulation shall be silicone rubber (SR) and jacket shall be fiberglass braid.

10. Low Voltage Instrumentation Wiring: All connection to instrumentation such as encoders and weigh systems shall be made using twisted shielded pairs.

11. Terminations and Continuity: All conductor connections, except for splices in lighting conductors (which are made in junction boxes), shall be terminated at terminal studs or terminal blocks using Approved compression or indented terminal ring tongue connectors. Splices shall be permitted only in accordance with NFPA 70 (NEC), as Approved by the Engineer.

12. Grounding Conductors a. Provide bare stranded soft-drawn, annealed copper wire with stranding

conforming to ASTM B 138, Class A or AA. b. Use #2/0 AWG, Class AA for riser cables and 250 MCM Class A for primary

grid conductor, unless otherwise shown on the Drawings. c. Connect exposed cable-to-cable and cable-to-equipment connections using

only silicon bronze fittings, bolts, and lock washers. Connect cable-to-steel support members using servit® post connectors, Burndy KC, K2C or equal.

13. Spare Conductors a. Trolley mounted festoon J-box to trolley: 5 - 12 AWG single conductor

wires routed in the control conduit, labeled “SPARE1” through “SPARE5” and attached to spare terminal blocks on each end. 2 – 16 AWG twisted shielded pair routed in the instrumentation conduit, labeled “SPARE6/7” and “SPARE8/9” attached to spare terminal blocks on each end with drain wire attached.

b. Bridge mounted festoon J-Box to Cab: 5 - 12 AWG single conductor wires routed in the control conduit, labeled “SPARE11” through “SPARE15” and attached to spare terminal blocks on each end. 2 – 16 AWG twisted shielded pair routed in the instrumentation conduit, labeled “SPARE16/17” and “SPARE18/19” attached to spare terminal blocks on each end with drain wire attached.

c. Bridge mounted festoon J-Box to Main Control Panel: 5 – 12 AWG single conductor wires routed in the control conduit, labeled “SPARE21” through “SPARE25” and attached to spare terminal blocks on each end. 2 – 16 AWG twisted shielded pair routed in the instrumentation conduit, labeled “SPARE26/27” and “SPARE28/29” attached to spare terminal blocks on each end with drain wire attached.

2.22 WIRING ACCESSORIES

All cables and conductors shall be marked on both ends with the number corresponding to the identifying number on the schematic and interconnecting drawings.

1. Cable and Conductor Markers



a. Legible, permanently coded, tubular white heat shrink polyolefin tubing. b. Marking: Permanent, machine printed in black with the cable or conductor

coding, as Approved by Engineer.

2.23 TERMINAL BLOCKS

1. 600 Volt Power and Control: Modular blocks rated 600 Volts, current capacity equal to or greater than terminated conductor, screw-type for ring lug to secure conductor.

2. Mounting: Screwed to back panel or, if DIN rail, then securely held on mounting rail with end clamping device.

3. Termination: No more than two (2) wires on each terminal. Jumpers as required shall be provided by metal strips Approved for the purpose.

4. Arrange terminal blocks to facilitate wiring and maintenance. Provide a minimum of four (4) inches clear space on each side of each terminal strip. Terminal blocks shall not be located within 12 inches of the bottom or top of any enclosure without prior Approval of the Engineer.

5. Provide terminal blocks for analog instrument loops with test points for monitoring voltage or current within the loop. Separate terminal blocks for analog instrumentation loops from dc and ac control circuits.

6. Terminal blocks at different voltage levels, AC and DC circuits shall not be mixed on a single rail. Different voltage levels and AC/DC circuits may be on the same rail with sufficient space between the different levels to be easily distinguishable.

7. Provide separate terminal blocks for termination of instrument and control cable shields and drain wire. Shields shall be grouped and grounded at the termination cabinet ground bus.

8. Install spare terminals for crane in terminal block assemblies in quantities of not less than 10% of the total terminals used for control and 600 VAC power circuits. Submit calculations for determination of spares for review by Engineer.

2.24 MISCELLANEOUS ELECTRICAL EQUIPMENT

1. Alarm: Provide a programmable electronic alarm located on the downstream side of the bridge structure that sounds when the crane is in motion. The alarm shall have an ANSI rating of not less than 90 decibels (dB) at 10 feet, with a control circuit to maintain proper output levels above ambient noise levels, and shall operate on 120 VAC, 60 Hz. The alarm shall be controlled by operation of any traversing motion control switch, either in the cab or from the radio controls. The alarm shall also be operable by a manual switch located in the crane cab when the crane is not in motion.



2.25 SHOP ASSEMBLY TESTS

Perform shop inspections and tests in accordance with Section 01 91 14 Equipment Testing and Commissioning.

3.0 EXECUTION

3.1 PREPARATION FOR INSTALLATION

1. Install equipment as specified herein, as shown on the Drawings, and in accordance with “Approved” Shop Drawings. In case of conflict between the Contract Documents and the crane manufacturer’s Shop Drawings, Engineer shall issue clarification in writing.

2. Ensure that the assembly match-marks on delivered equipment are consistent with those shown of the crane manufacturer’s field assembly drawings.

3. Furnish suitable cranes, slings, and other equipment and tackle for handling the equipment, as well as incidental materials, welding equipment, torque wrenches and other tools, surveyor’s transits, levels, plumb wires, gauges, and other measurement devices, to facilitate erection, installation, inspection, and testing of the equipment.

4. Ensure that equipment used for handling is equipped with lifting lugs or has other suitable sling attachment points for safe and appropriate handling and placing of equipment.

5. Special tools shall be provided by Contractor and shall become the property of the District after completion of the Work. Repair or replace any tools used by Contractor that are damaged beyond further usefulness during performance of installation at no expense to District.

6. Furnish equipment, labor, and materials such as scaffolding, ladders, and blocking, necessary for installation, all in conformance with governing safety regulations.

7. Establish sequence of operations and methodology for installing the equipment in conformance with requirements set forth in the manufacturer’s installation instructions.

8. Become familiar with the problems involved in the installation and with the fact that certain erection and installation operations, particularly those that cannot be readily corrected and are fundamental to successful functioning of the equipment, will require levels of accuracy and iterative assembly and inspection procedures that exceed ordinary practices in construction.

9. Provide installation crew with experience in the installation of similar equipment, in accordance with Section 01 11 00 Summary of Work.



3.2 INSTALLATION

1. Installation shall conform to the requirements specified herein. Crane and appurtenant items shall be assembled for installation in strict accordance with the installation drawings, and shop match-marking drawings.

2. Preliminary Checks: a. Examine crane equipment for damage that may have occurred during

shipment. b. Examine crane equipment for rain or moisture damage to motors and

panels, inadequate painting, accumulation of dirt and rubbish, and oil leaks.

3. Perform crane assembly, erection, and testing under the supervision of the Contractor’s Superintendent.

4. All aspects of the electrical field installation work shall be performed under the direction of a licensed electrician. There shall be a minimum of one (1) licensed electrician onsite during all field wiring and electrical work. During installation, repeated checks of the tolerances shall be made so that the equipment is installed within the specified tolerances.

3.3 FIELD TESTING

Perform field inspections and tests in accordance with Section 01 91 14 Equipment Testing and Commissioning.

Contractor shall provide the services of Test Engineer(s) to direct field testing. Perform all tests under the direction of the Test Engineer(s).

3.4 ADJUSTMENTS AND REPAIRS

Adjust travel limiters, switches, controls, and other operating devices as required. After adjustments have been made, re-test functions to ensure correct functioning.

3.5 FIELD TRAINING

1. Contractor shall conduct a field training course for District’s operating staff, as described: a. Field training for District’s operating staff shall be carried out on site by

qualified individuals familiar with the installation, operation, and maintenance of the crane furnished under this Contract.

b. An individual from the crane manufacturer and the motor controller manufacturer shall conduct the training.

c. Training shall be required for 12 District employees during two (2) sessions of approximately eight (8) hours for each session.

2. Field Training Operations and Maintenance (O&M) Manuals shall be: a. Provided for each employee participating in the training. b. Created and assembled as described in Section 01 78 23 Operation and

Maintenance Data.



3. The District reserves the right to record such training for future use.

4. Training shall include: a. Classroom activities b. Hands-on type training with the actual equipment. c. Operation d. Troubleshooting the equipment to return it to service, e. All required maintenance activities, including

1) Preventative Maintenance 2) Corrective procedures.

3.6 SUBSTANTIAL COMPLETION

1. When Contractor considers the crane substantially complete, as defined in General Conditions, Contractor shall notify Engineer in writing and request that Engineer issue a notification of Substantial Completion.

2. The Engineer and Contractor shall make an inspection of each bridge crane to determine the status of completion within a reasonable time (two (2) weeks) after receipt of written notice from Contractor.

3. The Contractor shall be given notification in writing, by Engineer for the following: a. Fixing the date of Substantial Completion, if Engineer considers the Work

substantially complete. A punchlist of minor items to be completed or corrected before Substantial Completion notification shall be included, or;

b. If Engineer does not consider the Work substantially complete, a punchlist of those items to be completed or corrected in order for the Work to be considered substantially complete shall be included.

4. Contractor shall continue to submit requests for Substantial Completion inspection, as required.

5. Upon written notice from Contractor that the entire Work is complete, the Engineer shall make a final inspection with Contractor and shall notify Contractor in writing of any remaining or additional punchlist items. Contractor shall immediately take such measures as are necessary to complete or correct the punchlist items prior to 100% progress payment.

3.7 ACCEPTANCE

1. In addition to the requirements set forth in General Conditions. Final Acceptance of the Work shall not be given until Contractor has successfully completed all testing operations, corrected all material and equipment deficiencies, made all proper operational adjustments, and provided all required, Approved submittals.


EXHIBIT S TECHNICAL SPECIFICATIONS DIVISION 1 …

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