SECTION 11001 - EQUIPMENT GENERAL REQUIREMENTS PART 1 ... · EQUIPMENT GENERAL REQUIREMENTS 11001-5 2. Before acceptance, Manufacturer shall furnish certificates documenting approval

July 22, 2016 Frazer Shop & Yard Expansion Final

EQUIPMENT GENERAL REQUIREMENTS 11001-1

SECTION 11001 - EQUIPMENT GENERAL REQUIREMENTS

PART 1 - GENERAL

1.01 GENERAL PROVISIONS

A. Attention is directed to the CONTRACT and SPECIAL TERMS AND CONDITIONS and all Sections within DIVISION 01 - GENERAL REQUIREMENTS which are hereby made a part of this Section of the Specifications.

B. Definition of Terms Used in this Specification Section:

1. Manufacturer: The firm responsible for design, manufacture, delivery, installation and commissioning of the equipment. Referred to elsewhere in Advance Procurement Invitation for Bid (IFB) documents as the “Contractor” for contractual purposes.

2. Installer: The Manufacturer and any licensed subcontractors acting under its direction and supervision.

3. Construction Contractor or Contractor: The general contractor responsible for construction of the overall Frazer Maintenance Facility Expansion (also referred to herein as the Shop), having specific responsibilities related to the equipment as detailed herein.

4. Engineer: SEPTA or their designated Engineer.

1.02 SECTION INCLUDES:

A. Provide where shown on drawings equipment as specified, complete and ready for operation. Each item shall be specifically designed for the intended function. Provide necessary accessories, items of equipment, mechanical, electrical, and structural items, whether specified or not, for properly installed and functional equipment.

B. Equipment shall be suitable for installation in the space allocated on the drawings and operation with the available building utilities.

C. In all cases where a device or part of the equipment is referred to in the singular number, it is intended that such reference shall apply to as many such devices as are required to complete the installation.

D. Remove, relocate and repair any items necessary for the proper installation of the equipment at no extra cost to SEPTA.

E. Related Sections:

1. 14915 Shunter System



1.03 MEASUREMENT AND PAYMENT

A. Separate measurement or payment will not be made for work required under this Contract Specifications Section. All costs in connection with the work specified herein will be considered to be included with the related items of work in the Bid Schedule of the Bid Form or incidental to the Work.

1.04 REFERENCES

A. All equipment shall be manufactured and set up in accordance with all industrial and safety standards that apply to the work.

B. Industry Standards

1. AISC American Institute of Steel Construction

2. AREMA American Railway Engineering and Maintenance of Way Association

3. AAR Association of American Railroads

4. ASME American Society of Mechanical Engineers

5. ASTM ASTM International (formerly American Society of Testing and Materials)

6. NEMA National Electrical Manufacturers Association

7. AWS American Welding Society

8. UL Underwriters Laboratory

9. IEEE Institute of Electrical and Electronics Engineers

10. ABMA American Bearing Manufacturers Association

C. Safety and Governmental Standards:

1. OSHA Occupational Safety and Health Administration

2. ANSI American National Standards Institute

3. NEC National Electric Code

4. NFPA National Fire Protection Association

5. SAE Society of Automotive Engineers

D. All applicable Federal, state, and local codes and regulations:



1. If there is a conflict between codes and the Manufacturer’s standards, the most stringent requirements shall take precedence and the best quality as to materials and workmanship shall be supplied and applied.

1.05 QUALITY ASSURANCE

A. All articles, materials, fittings, equipment, and machinery incorporated in the work shall be new and unused, of recent manufacture, free from defects and imperfections, and as far as practicable, Manufacturer’s standard make of first grade industrial quality, from reputable manufacturers, suitable for the purpose intended and subject to approval by the Engineer.

B. All components used in the assembly of the system shall be standard, commercially available components and shall be manufactured by companies regularly engaged in the manufacture of the components. The design shall provide for the interchangeability of items of piping, equipment, sub-assemblies, motors, starter, relays and other devices.

C. All replacement parts shall be readily available in the United States. Lists of the sources for the parts shall be supplied for the maintenance and repair of the system.

D. Unless otherwise noted, the equipment shall be designed for installation and proper operation in an indoor, shop environment.

E. When installed, the layout of the new equipment shall be such that workers shall have sufficient room to access all parts of the equipment.

F. Fasteners shall comply with ANSI standards. This includes, but is not limited to, threads for nuts and bolts, heads for same, pipe, conduit, and electrical connectors. Mixing of metric and United States Customary Units (non-metric) standards on the same equipment is not permitted.

G. Products or composite materials containing asbestos, lead, mercury or cadmium shall not be used.

H. When two or more items of the same equipment are required, they shall be products of a single manufacturer.

I. All work shall be performed in a neat and workmanlike manner by workers skilled in their respective trades, and all material and equipment shall be installed as recommended by the manufacturer and in accordance with all applicable codes and standards.

J. Equipment shall be designed, fabricated, installed and adjusted to achieve smooth, quiet, convenient and efficient operation, durability, economy of maintenance and operation, and the required standards of safety.



K. All piping, valves, fittings, conduits, and wiring required for the equipment installation shall be in accordance with all applicable codes. Supplied connections shall properly interface with existing services.

L. All items requiring maintenance shall be accessible for maintenance or change-out without undue service interruption. Replaceable components shall be provided with appropriate mechanical isolation to facilitate change-out without extensive system shutdown.

M. Materials and equipment shall be manufactured in compliance to the ISO 9001- 2008 quality standards. This includes but it is not limited to nuts, bolts, threads and heads for the same, pipes, conduits and electrical connectors.

N. The language of the text for all documents shall be English.

O. All dimensions shall be displayed in US Customary Units.

P. All electrical equipment shall be UL listed and bear UL label.

Q. Substitutions:

1. Requests for approval of equipment items other than those specified shall be made in accordance with the Contract.

R. Permits and Tests:

1. Obtain all necessary permits from the State and other authorities having jurisdiction, make application and file all drawings required for such permits, and pay all permit fees. Arrange inspections and tests required by governing authorities and by SEPTA, and pay all costs connected therewith. Obtain and file with the Engineer written evidence that all of the above requirements have been met.

S. Applicable Codes:

1. Work shall conform to federal, state, and local governing rules and regulations and ordinances including OSHA and NFPA, and shall pass inspection by authorities having jurisdiction.

2. Furnish all materials and labor required to meet all requirements and to obtain approvals of inspections and tests required by jurisdictional authorities.

T. Certificates:

1. Manufacturer shall furnish an affidavit certifying that all materials and workmanship comply with all applicable code requirements.



2. Before acceptance, Manufacturer shall furnish certificates documenting approval of all authorities having jurisdiction.

3. Certificates of Compliance: A minimum of seven days prior to delivery of the equipment, Manufacturer shall submit certificates of compliance. Each certificate shall be signed by an authorized representative of the equipment Manufacturer stating that the equipment complies in all respects with all contract requirements, including applicable codes and regulations, as well as all approved design submittals.

U. Warranty: All equipment shall be warranted in accordance with Section B, Special Terms and Conditions and the following provisions:

1. The Manufacturer shall furnish written warranties required by the Contract Specifications for time stipulated in the related technical specifications. These warranties shall be in writing, on Manufacturer’s (or component suppliers’, as applicable) letterhead and shall be included in the operations and maintenance manual(s) as specified.

2. Major equipment components, specifically those manufactured by other than the primary equipment supplier, shall be covered by their own respective warranties, which shall not be less than the suppliers’ standard warranty. These warranties shall also be included in the operations and maintenance manual(s).

3. Nothing in these requirements, conditions or specifications including SEPTA’s right to a complete inspection shall constitute a disclaimer to or limit, negate, exclude or modify in any way any warranty created hereunder.

1.06 SUBMITTALS

A. Submit the following for approval:

1. Shop drawings

2. Product data

3. Samples, if requested

4. Installation instructions

5. Acceptance test procedure

6. Training program

7. Spare parts list



8. Operations & maintenance manuals

9. Certificates per quality assurance section

10. Warranties (Warranty signed by Installer and executed by Manufacturer for equipment, materials, and workmanship against defects agreeing to repair or replace equipment and materials and correct workmanship as specified.

B. Sequence of Approval:

1. Conditional Approval of Equipment: Before submitting Shop Drawings, Manufacturer shall submit to the Engineer for conditional approval drawings, specifications and lists of equipment to be incorporated in the Work. This list shall include catalog numbers, cuts, and other descriptive data as may be required to ensure compliance with requirements specified. No consideration will be given to partial lists. Conditional approval of equipment based on this submittal will be subject to submission of complete Shop Drawings indicating compliance with the Contract Documents prior to final approval.

2. Final Approval of Equipment: After receiving conditional approval of the equipment lists, submit Shop Drawings, product data and installation instructions for final approval.

C. Shop Drawings: Shop Drawings and diagrams shall be prepared using and showing scales and dimensions in the United States Customary Units (non-metric). Metric conversions may be provided in parenthesis. Shop Drawings may include exploded-view diagrams and shall include but not be limited to the following as applicable:

1. Drawings showing equipment layout, elevations, conduit runs, utility layout and hook-ups, and all required dimensions including but not limited to clearances and tolerances.

2. Fabrication drawings, including bill of materials.

3. Detail drawings.

4. Foundation with drainage requirements and structural support drawings including loads, embedded items, anchorage requirements and elevations.

5. Utility connection plan showing utility requirements. The information shown in this plan shall include but not be limited to the following, as applicable to the particular equipment:

a. Locations of existing utility services;



b. Location of required utility connections;

c. Required sizes of pipes and conduits;

d. Inverts and elevations;

e. Required water pressure, velocity cfs (cubic feet per second) and flow gpm (gallons per minute);

f. Required gas pressure and cfh (cubic feet per hour);

g. Required compressed air pressure and cfm (cubic feet per minute);

h. Required steam pressure and flow;

i. Required size of electric service;

j. Required size of wires;

k. Required voltage and amperage (full load);

l. Required insulation and/or insulators.

m. Types and quantities of lubricants and fluids required for proper operation of each item of equipment

6. Electrical control diagrams.

7. Electrical wiring diagrams. The information shown in these diagrams shall include but not be limited to the following:

a. Locations of existing utility services;

b. Location of required utility connections;

c. Required sizes of conduits;

d. Inverts and elevations;

e. Required size of electric service;

f. Required size of wires;

g. Required voltage and amperage (full load);

h. Required insulation and/or insulators;

i. Grounding connections.



8. Electrical equipment layouts, with all motors, limit switches, solenoid valves, disconnects, control panels, etc., located and labeled.

D. Product Data: Manufacturer’s literature including catalog cuts, pamphlets, descriptive literature, color charts (for selection by the Engineer), equipment specifications, performance and test data, and brochures that adequately describe the equipment or product for all purchased components of the system. Specific items included or specific items excluded in this installation shall be indicated on the product data sheets.

E. Installation Instructions and Acceptance Test Procedure: Manufacturer’s recommended installation instructions with manufacturer’s installation drawings and acceptance test program.

F. The Manufacturer shall submit a comprehensive list of all spare parts, supplies and consumables for the equipment to be supplied with the equipment. Spare parts list shall include tooling. Each entry shall include corresponding manufacturer’s part numbers, manufacturer, supplier, supplier’s part numbers, quantity, lead-time and current cost. The list shall clearly indicate entries on the list that fall into the following categories.

1. Parts, supplies and consumables necessary to perform all maintenance functions listed in the Operations and Maintenance Manuals for the first six months of operation. Upon approval of parts in this category, the Manufacturer shall supply these parts and supplies, at additional cost to SEPTA. The purchase of spare parts listed is not binding on SEPTA’s part.

2. Additional items recommended by manufacturer to be supplied due to their nature as a high-wear item or crucial to the operation of the equipment.

3. Items not readily available on the open market or for which it is anticipated ordering and delivery time will exceed 30 Days (long lead time items).

G. Submit pre-shipment inspection and testing procedures.

H. Submit final acceptance testing and checkout procedures.

I. Provide specifications and Material Safety Data Sheets (MSDS) of recommended lubricant, oil or chemical products to operate and/or maintain the equipment.

1.07 DELIVERABLES

In addition to the equipment or materials specified in the related technical specifications, Manufacturer shall provide the following:



A. Operation and Maintenance Manuals.

B. Training program.

C. Certificates.

D. As-Built Drawings.

E. Hardware and software.

F. Approved spare parts list.

G. Special Tools: Two of each special tool, and instruments if any, required for operation or maintenance, packed in two appropriate steel tool boxes.

H. Matching touch-up paint for each color used to permit retouching

I. Warranties

J. Commissioning Data

1.08 OPERATION AND MAINTENANCE MANUALS

A. Operation and Maintenance (O&M) Manuals shall address the following:

1. Operations – Detailing safety instructions, proper operation and basic troubleshooting of the supplied equipment. This data will be targeted for the daily equipment operator.

2. Maintenance – Detailing both corrective and scheduled preventive maintenance of the supplied equipment. This shall include in depth troubleshooting, system functional description, theory of operation and detailed illustrated parts catalog. The preventive maintenance information shall include recommended service and replacement intervals for all maintainable components up through system replacement.

B. O&M Manuals shall be submitted for each equipment system as follows:

1. Outline Draft: A minimum of three copies of sample formats and outline of contents in draft form 90 days prior to the earliest scheduled equipment delivery to be submitted to the Engineer for approval.

2. Draft: A PDF version of complete manual in final form for Engineer approval 30 days before equipment initial delivery date as appropriate for equipment.

3. Pre-Final O&M Manual: A minimum of two hardcopies of approved manual after the equipment is installed, ready for acceptance test and to perform training. In addition, an electronic version of the Manual on CD-



ROM or flash drive, one copy per employee to be trained plus two file copies.

4. Final Manual: Three hardcopies of final approved manual after the equipment is installed, the acceptance test has been approved, and training has been performed and completed.

a. The manuals shall be updated based on input from SEPTA and the Engineer during acceptance testing and training, for all sections of the manual.

b. The manuals shall show final as-built installed material, conditions, procedures, and drawings.

c. One of the copies shall be configured for the harsh shop environment by inserting all single pages in plastic laminate and foldout pages individually enclosed in clear plastic pockets.

d. Also include (3) electronic versions of all manual contents. Electronic version shall be non-editable but searchable Adobe Acrobat PDF, stored on CD-ROM or flash memory drive.

5. Final Acceptance will not be granted until receipt of the print and electronic copies of the approved manuals.

C. Hardcopy O&M Manuals shall be prepared from the following materials:

1. Loose leaf, on minimum 24-pound, punched paper.

2. Pages shall be 3-hole punched.

3. Entire length of margin with holes reinforced with plastic.

4. All pages, except for drawings, shall be 8.5 x 11 inches, portrait style. Drawing pages shall be 8.5 x 11 inches or 11 x 17 inches.

5. New sections and chapters shall begin on a right-hand facing page. At the end of each chapter or section if there is a blank left-hand page, print on the left-hand page, “This page intentionally left blank,” in whatever font style the body text of the document is.

6. Foldout diagrams and illustrations: Fan-fold 11 x 17 inches pages to 8.5 x 11 inches. For pages larger than 8.5 x 11 inches, display page identification on last fold of folded page so as to be readable without unfolding.

7. Reproducible by dry copy xerography method.

8. Oil-, moisture-, and wear-resistant plastic covers.

9. Protruding plastic coated tabbed dividers, cross-referenced by number or color to sections identified on the table of contents shall separate sections.



10. Manuals shall lie flat when opened. Pages shall not bind or join when turned for normal reading.

11. Manuals shall allow enough space for insertion of revised pages.

D. General Requirements for Manuals:

1. Front cover, spine and title page: Include the name and function of the equipment, manufacturer’s identification number, and Project Specifications number and title.

2. Front cover: Recognition illustration of the equipment described in the

O&M Manual.

3. Manufacturer’s operating manuals giving complete instruction relative to assembly, installation, operation, adjustment, lubrication, maintenance, and complete parts list shall be furnished by the Manufacturer for every item of machinery and equipment furnished by the Manufacturer. The information shall be presented in a clear manner such as:

a. For operating type procedures, the nomenclature for control positions, document test points and indicating devices having panel nomenclature as it appears on the equipment panel, placard, or structure (i.e., “Set Master Switch to ‘OFF’”).

b. Enumerate and describe every component and its related parts, including identifying numbers and commercial equivalents where applicable.

c. Include cut away and exploded view drawings for identification of all parts.

4. Manual (or Volume in the case of multi-volume Manuals) shall contain a Table of Contents and be organized into nine specific chapters (as applicable) as outlined below:

a. Chapter 1 – General Information and Specification

b. Chapter 2 – Theory of Operation

c. Chapter 3 – Troubleshooting

d. Chapter 4 – Primary Repair

e. Chapter 5 – Secondary Repair (Component Level)

f. Chapter 6 – Preventive Maintenance

g. Chapter 7 – Illustrated Parts Catalog

h. Chapter 8 – Miscellaneous



i. Chapter 9 – Wiring Diagrams

5. Manuals shall include copies of all approved Shop Drawings and catalog cuts submitted. They shall be provided in an Appendix Binder following the size and format requirements herein. 11” x 17” drawings shall be fan-folded per 1.07C above. Larger drawings shall be folded to page size, with title block information visible, and stored in three-ring clear plastic pockets.

6. Illustrations shall be clear, and printed matter, including dimensions and lettering on drawings, shall be easily legible. If reduced drawings are incorporated into manuals, original lines and letters shall be darkened and have their light weight increased as necessary to retain their legibility after reduction.

7. All material shall be in the English language. Sheets with English and another language on the same sheet shall be acceptable.

8. Chapter 7 (“Illustrated Parts Catalog”) of each Manual shall also contain a list of nearest local suppliers of all equipment parts, as well as contact information for the nearest factory-authorized service location.

9. Chapter 8 (“Miscellaneous”) shall also contain copies of start-up and acceptance test procedures and results/reports.

D. Operating Diagrams:

1. Piping diagrams, electrical wiring diagrams, fuel oil, lubricating oil, water capacity diagrams, and other diagrams necessary for operation of machinery and equipment shall be furnished and installed where designated by the Engineer.

2. No single diagram shall show more than one system, or parts thereof.

3. Diagrams shall be reproduced by photographic process to a size no to exceed 18 inches by 24 inches and shall be complete and legible in all respects. Systems shall be subdivided into portions, which are operable from location where diagrams are installed, and to provide intelligible information within specified size. They shall be made on white paper and vacuum-sealed in transparent plastic material impervious to moisture and oil, and resistant to abrasion. Other formats, which are equal in clarity, sharpness, durability, and permanence, will be considered.

1.09 AS-BUILT DRAWINGS

A. One complete hardcopy set of full size as-built shop drawings shall be furnished with the specified equipment. As-built drawings shall reflect all changes made during installation, testing, and checkout.



B. As-built drawings shall include all assembly drawings, exploded views of assemblies, operation drawings, electrical drawings, wiring diagrams and layouts, electrical schematics, control diagrams, and all other drawings necessary for the long-term operation and maintenance of the equipment.

C. As-built drawings shall also be supplied on a CD-ROM in non-editable, Adobe Acrobat (PDF) electronic file format.

D. If no changes to the equipment occurred during installation, testing, and checkout, provide a written certification to that effect in lieu of as-built drawings. This does not waive the requirement for Shop Drawings to be included with the O&M Manuals.

1.10 TRAINING PROGRAM

A. Identify all rail vehicles and other Owner-supplied items needed for training.

B. Provide timely notification to Construction Contractor to arrange for rail vehicles and other Owner-supplied items, but not less than 15 calendar days prior to the training date.

C. Manufacturer shall provide calibrated wheelsets, if required, for training and testing.

D. The Manufacturer shall be responsible for training as specified below:

1. Maintenance management classes shall take place prior to the use of the equipment by SEPTA.

2. Mechanics’ operation and maintenance training shall commence only after installation of the equipment is complete and equipment testing and checkout has been successfully completed to the satisfaction of the Engineer.

3. Training shall be conducted at the equipment or in a classroom at the Jobsite, as appropriate. Other locations may be utilized with prior approval of SEPTA.

4. Hours for training shall be between 7:00 AM and 3:00 PM unless specifically permitted otherwise in writing by SEPTA.

5. “Pre-Final” versions of the Operation and Maintenance Manuals shall be used in the training.

6. Revise O&M Manuals to incorporate corrections, additions and other feedback from the training.



E. The instructor(s) shall be fluent in both spoken and written English and shall have a thorough knowledge of the equipment and systems furnished. They shall be able to utilize proper methods of instruction, training aids, audiovisuals, etc., to ensure effective presentations. The instructor(s) shall have previous formal classroom instruction training.

F. The Manufacturer shall be responsible for providing all training aids, audiovisual equipment and visual aids for the conduct of the classes.

G. All training materials will become the property of SEPTA at the conclusion of training.

H. Submission and Approval of Training Plans:

1. Meet with SEPTA at least four weeks prior to the start of formal training. At that time, the Manufacturer shall submit lesson plans and an outline of the training program and demonstrate any training aids involved. Handouts shall be presented for approval and provided later in a ratio of one per student. Each location shall receive a complete set of prints and schematics.

2. Submit in writing plans for meeting the specification training requirements. SEPTA will approve and then coordinate and schedule all training involved.

I. Outline specific objectives for each of the courses:

1. The course shall include sessions in safety, machine operation and a comprehensive seminar on learning basic skills/knowledge of each operation. The course shall include both classroom and practical exercise sessions and shall provide the mechanic with the basic knowledge necessary to operate and maintain the equipment. The Manufacturer shall provide a detailed schedule outlining the length and content of each of these sessions in accordance with the guidelines established.

2. The training program shall include familiarization with equipment operation and performance and detailed instruction in operation, maintenance, calibration of system, and all test procedures. Maintenance training shall include scheduled maintenance, unscheduled maintenance (repair), adjustments, fine-tuning, troubleshooting, and testing.

3. Training program shall, as applicable, provide training for Engineering and Management, Operating and Maintenance Personnel.

4. Training program duration shall be appropriate for complexity of equipment, and subject to revision by Engineer during review of Contractor’s submitted Training Program. Typical minimum durations are



as follows, and would be superseded by requirements in a specific equipment section:

a. Off-The-Shelf Equipment: Operating Personnel: 8 hours; Maintenance Personnel: 8 hours

b. Systems: Engineering and Management: 8 hours; Operating Personnel: 40 hours; Maintenance Personnel: 40 hours.

1.11 HARDWARE AND SOFTWARE

A. Provide three copies of the final version of the control software, for back-up purposes, in electronic format on separate flash memory devices with a standard Universal Serial Bus (USB) socket (2.0/3.0 compatible).

B. Provide fully licensed versions of any and all software necessary to run, and process, the control software.

C. Provide any and all hardware necessary to run and process the control software.

1.12 COMMISSIONING DATA

A. As part of the final documentation, the Manufacturer shall provide a letter written on the Manufacturer’s letter head, and signed by an authorized representative of the equipment Manufacturer, providing the following commissioning data:

1. Equipment Description

2. Location (of the installation)

3. Original Equipment Manufacturer (OEM)

4. Model No.

5. Serial No.

6. Nameplate Data (provide where applicable)

a. Electric:

1) Volts

2) Amps

3) Phase

b. Air:

1) CFM



2) PSI

c. Water:

1) GPM

2) PSI

7. Dimensions:

a. Length

b. Width

c. Height

8. Weight

9. PLC Controlled (provide model, if applicable)

10. Date of Factory Test

11. In-Service Date

12. Warranty Expiration Date

13. Equipment Cost

1.13 GENERAL DESIGN AND FABRICATION REQUIREMENTS

A. Equipment shall be designed, fabricated, installed and adjusted to achieve the best results with respect to smooth, quiet, convenient and efficient operation, durability, economy of maintenance and operation, and the highest standards of safety.

B. All components used in the assembly of the system shall be standard, commercially available components and shall be manufactured by companies regularly engaged in the manufacture of the components. The design shall provide for the interchangeability of items of piping, equipment, sub-assemblies, motors, starter, relays and other devices.

C. It is not the intent of these Contract Specifications to detail the design and fabrication of the parts of the equipment, but it is expected that the type, material, design, workmanship, and fabrication of every part shall be fully adequate for the service required, durable, properly coordinated with all other parts, and in accordance with the best industrial standards and of the highest efficiency. The components of electric circuits shall be of proper size, design, and material to avoid injurious heating, arcing, and all other objectionable effects which may reduce the efficiency of operation and economy of maintenance. Minimum requirements are given herein for certain parts of equipment. Equivalent requirements shall apply to all equipment parts that are of special design, construction or material, and to which the specified



requirements are not directly applicable, and shall be approved by the Engineer. These minimum requirements as a whole shall also be considered as establishing proportionate general minimum standards for all parts of the equipment.

D. The Engineer may permit variations from the requirements of these Contract Specifications to permit the use of the Manufacturer’s standard equipment, provided such standard equipment is adequate for the intended use and meets the full intent of these Contract Specifications. All such variations proposed by the Manufacturer shall be called to the attention of the Engineer in writing and shall be made only if the Engineer approves such variations in advance and in writing.

E. Certain design limitations and tests are specified as a partial check on the adequacy of design, fabrication, and materials. These requirements do not cover all features necessary to ensure satisfactory and approved operation of the equipment. Conformity with these requirements shall, in no way, supersede the general requirements as to satisfactory and efficient operation of the equipment.

1.14 NOISE AND VIBRATION ISOLATION

A. Noise and vibration isolation pads shall be provided as Indicated and where required, shall meet all requirements Indicated, and shall be equipped with necessary bearing plates and bolts. Noise and vibration pads shall be specifically designed for the weights, speeds, and vibration characteristics of the equipment supported. The pads shall provide proper weight distribution to avoid distortion of the bedplates.

B. Bolts and other fastening in connection with these pads shall be effectively isolated.

1.15 SHOP PAINTING

A. Equipment shall be given one shop prime coat of approved rust-inhibitive paint containing at least 50 percent rust-inhibitive pigments and manufacturer’s standard finish coat system, unless otherwise indicated. Shop Drawings shall indicate brand and type of paint for both the prime coat and finish coat systems. Finish coating system shall be Pittsburgh Paints 409-2 (color selected by the Engineer) or equal for all major equipment items, unless otherwise indicated. All color selections shall be approved by the Engineer.

B. Surfaces shall be free of rust, scale dirt, grease and oil before painting. Matching touch-up paint shall be provided in the amount of one quart of each color used to permit retouching.



1.16 INSPECTION

A. The Engineer and SEPTA will periodically inspect work during the course of the construction.

B. Provide for inspections by all others having jurisdiction over the work.

C. At time of final inspection, furnish certificate or certificates of final approval by all others having jurisdiction as applicable.

PART 2 - PRODUCTS

2.01 EQUIPMENT

A. Equipment shall be factory-finished with Manufacturer’s standard primer and finish coats of paint, unless specified elsewhere.

B. Provide piping, fittings, valves, connections, etc., of a type and size in accordance with approved Shop Drawings and installation instructions that will properly interface with the piped services.

C. All piping, valves, fittings, conduits, and wiring required for the equipment installation shall be in accordance with requirements specified in Contract documents and approved Shop Drawings.

2.02 ELECTRICAL REQUIREMENTS

A. Power supply for equipment shall be a single 480 volts, 3-phase, 60 hertz feed unless otherwise Indicated.

B. Provide transformers for equipment as required to step down the specified supply voltage to provide lower voltage for controls and accessories and to provide voltage compatible with equipment as required.

C. Equipment grounding shall be accomplished by means of separate grounding conductor in each conduit sized according to code. Ground all equipment by means of a conduit ground according to NEC Article 250. The grounding conductor shall have green insulation.

D. Starters, controllers, disconnect switches and start-stop stations shall be provided for all equipment. Correct sizing of starters and disconnect switches shall be joint responsibility of the Construction Contractor and the equipment or apparatus Manufacturer.

1. Electrical enclosures shall be NEMA 12 for indoor units above the rail and NEMA 4 for outdoor and below the rail indoors units unless otherwise Indicated.



2. Starters shall be complete with two sets of auxiliary contacts; one set normally open; one set normally closed.

3. For motors 25 HP or greater provide autotransformer type reduced voltage starters unless otherwise Indicated.

E. Control devices necessary for proper operation shall be provided and shall be located to permit efficient operation of the equipment, and where possible shall be ground in a factory fabricated NEMA approved control panel complying with requirements Indicated.

F. Switches, lights, and control functions shall be identified with legend plates. The plates shall be constructed of polyvinyl chloride material of laminated multiple constructions, and engraved with appropriate legends. The legend plates, including size of letters, colors, and legend shall be submitted to the Engineer for approval. The legend plates shall be mounted on the equipment in an approved manner. No decals will be accepted.

G. Permanently label all equipment items including but not limited to switches, starters, controllers, and start-stop stations with engraved PVC labels with minimum 1 inch high lettering to identify corresponding equipment items.

H. Wiring shall be provided for complete installation of all equipment and accessories and shall be adequate for proper operation of equipment.

I. Wire and cable for light, power, and control circuits shall conform to those specified in the National Electrical Code. In no case shall maximum current carried exceed that specified by National Electrical Code for type of conductor used. Provide conduit where required; all wiring and conduit shall be in accordance with the requirements of National Electric Code.

J. Make connection to secondary side of disconnect switch and provide all wiring and conduit with supports from this point, including wiring to controller and starters.

K. Wire harnesses shall be used to the greatest extent possible.

L. Provide conduit where required; all wiring and conduit, not within standard manufactured assembled machinery, excluding fabricated items, shall be in accordance with the requirements indicated.

1. Minimum conduit size permissible shall be ¾ inch.

2. All wires shall be properly insulated and all conduit edges shall be protected to prevent wire chafing.

3. All wiring for the controls and motors shall be coordinated for use of type MTW, THWN, and THHN standard wire.



4. Conduit: Supply rigid galvanized steel conduit, or liquid tight flexible metal conduit. Liquid tight flexible metal conduit shall be used in lengths not exceeding 6 feet.

5. Identify wiring by a wire tag with a number corresponding to the wiring diagram.

6. Control Wiring Conductors: Not less than #14 AWG, strand copper, 600 volt insulated, water and oil resistant.

7. Power Wiring Conductors: Not less than #12 AWG or larger as required for power wiring.

8. All bus work and windings shall be copper.

2.03 GASKETS AND FASTENERS

A. Provide new gaskets wherever gasket mating equipment items or pipe connections have been dismantled.

B. Replace all assembly bolts, studs, nuts, and fasteners of any kind, which are bent, flattened, corroded, or have their threads, heads or slots damaged.

C. Furnish all bolts, studs, nuts, and other fasteners for make-up of all connections to equipment and replace any of these items damaged in storage, shipment or moving. Bolts shall comply with applicable SAE requirements including manufacturer’s identification and certification of testing.

D. All torque fasteners shall be torque-marked.

2.04 HOLES, OPENINGS, AND INSERTS

A. Provide holes and openings in floors and walls as required, coordinating work with Construction Contractor constructing the Facility.

B. Core drill holes in existing work using dustless method. Grout in holes in concrete walls, floor, and roof slabs after installation of equipment, and leave them in a completely neat and sealed condition.

C. Install concrete inserts and flashing as required.

D. Modifications with Structural Implications:

1. Do not perform any work that will alter existing structural elements unless it is shown on the Facility Drawings or proposed alterations have been approved in writing by the Architect.

2. Structural elements include, but are not limited to, the following: Steel beams and columns, structural masonry walls, reinforced concrete slabs.



E. Provide sealing and flashing for all penetrations through exterior walls.

2.05 CONCRETE FOUNDATIONS

A. Contractor will provide anchor bolts as required for equipment to be mounted. Manufacturer shall provide data for anchor bolts including material, diameter and length of embedment.

B. Provide grouting as necessary to stabilize equipment bases to concrete foundations.

C. Provide hard rubber shims and dampening pads as required for leveling of equipment and dampening of equipment vibration transmission.

2.06 MOTORS AND DRIVES

A. Motors:

1. Motors shall be high efficiency makes, each bearing the UL label and constructed to standard of NEMA, IEEE, ANSI, and ABMA.

2. Motors shall be suitable for operation on the electrical service Indicated.

3. Horsepower ratings and sizes shall be selected at 40° C ambient temperature for open motors, with service factor of 1.15 for open motors and unity for service factor for totally enclosed or drip-proof motors. Provide motors with epoxy encapsulated for severe usage in a corrosive atmosphere.

4. Motors rated one horsepower or greater shall have a full-load power factor of 85 percent or higher. Motors rated 25 HP and over shall be designed for reduced voltage starting.

5. Installation instructions shall have details regarding correct rotation and alignment of motor shafts. Motors shall include identification of the correct direction of rotation.

6. The motors shall be protected by overload devices to permit operation within their rating under all design load conditions. Provide each individual motor circuit with branch circuit over current protection in all three phases.

B. Drives:

1. Guards shall be provided for each coupling and belt drive in conformance with applicable codes.

2. Belt drives shall have adjustable motor drive pulleys.



3. Belt drives shall be adjusted and work belts replaced in sets. Speed adjustment shall be subject to approval of the Engineer.

4. Provide sliding motor bases where adjustable motor drive pulleys are provided.

C. Motors and drives shall be checked carefully for correct rotation and alignment before placing equipment into operation.

D. Couplings shall be disconnected and realigned before placing into service or testing.

PART 3 - EXECUTION

3.01 PREPARATION

A. Transmit submittals and deliverables as indicated.

B. Furnish products as Indicated.

C. Inspect pits, embeds and utility connections and notify Engineer if corrections are needed prior to equipment installation.

3.02 FABRICATION

A. Fabrication shall be in accordance with all requirements specified and approved Shop Drawings.

B. Fabricate equipment from newly manufactured materials, products, and components. Do not utilize used, refurbished, or remanufactured materials, products, or components. Surfaces shall not be warped (unless by design) and free of dents and distortions.

C. Pre-assemble units to greatest extent feasible for shipping. Grind exposed welds flush. Remove all sharp edges.

D. Field check for clearance and interferences before fabrication and relocate material and equipment furnished as required (if approved by the Engineer) to eliminate interferences.

3.03 PRE-SHIPMENT INSPECTION AND TESTING

A. Pre-shipment inspection and testing shall be performed when required by the relevant technical specification as Indicated and as follows:

1. Prior to shipping the equipment, the Manufacturer shall make the equipment ready for a comprehensive pre-shipment inspection and testing by the Engineer.



2. The equipment shall be laid-out in its final configuration to allow for all performance and functionality to be observed before shipment.

3. The pre-shipment inspection shall also allow for confirmation of compliance with all documentation submitted to the Engineer.

4. The Manufacturer shall prepare and submit for the Engineer’s approval a schedule and comprehensive procedure for functional testing and inspection. The submittal shall be submitted for review and approved not less than 4 weeks prior to the start of the pre-shipment inspection and testing and shall include step by step procedures, pass/fail criteria, all referenced documentation, and any other information necessary to perform one successful demonstration of the equipment’s operation and performance. At a minimum the pre-shipment inspection and testing shall demonstrate:

a. Equipment performs the work for which it is intended

b. Ability of the control logic to protect the mechanical and electrical equipment from common operator and other types of errors and problems shall be verified

c. All safety features

d. Basic functions of the equipment

5. The Manufacturer shall bear all expenses of all tests, including the furnishing of all necessary instruments, lubricants, hydraulic fluids, test weights, supplies, data recorders, and operating personnel.

6. Any issues or discrepancies identified during the pre-shipment inspection and testing shall be documented in a written report, prepared by the Manufacturer, detailing the issues or discrepancies identified and the Manufacturer’s proposed corrective actions. This report shall be submitted to the Engineer within two weeks after the completion of the pre-shipment inspection and testing and the Manufacturer must obtain approval from the Engineer before corrective actions may be implemented. All issues or discrepancies identified shall be resolved before the equipment is shipped to the SEPTA jobsite.

3.04 DELIVERY, STORAGE, AND HANDLING

A. It is fully the responsibility of the Manufacturer to deliver equipment to the Jobsite of the equipment installation, to provide any off-site storage of equipment required during the Contract duration until ready for delivery/installation (weekly charge included in Base Bid pricing), and for any protection and handling of the equipment.



B. Pre-assemble system to greatest extent possible to minimize field assembly. Disassemble only as necessary for shipping and handling limitations. Clearly mark units for re-assembly and coordinated installation. Re-assemble on Jobsite according to installation instructions.

C. Equipment and components shall be suitably packed or crated to prevent damage in transit or during handling. Items shall be carefully stored as required in a manner to avoid misalignment or distortion, and shall be adequately protected against damage by weather, construction exposure or other cause. Any items damaged during delivery, storage, or handling, shall be repaired to the Engineer’s satisfaction or replaced at the Manufacturer’s expense.

D. All materials shall be delivered to the Jobsite with their original manufacturer’s markings and identification intact. The Engineer will reject materials that are damaged, improperly identified, or not in conformance with reviewed Shop Drawings and catalog cuts.

E. The Manufacturer shall protect equipment during storage and prior to start-up, which shall include covering of openings, protection against rust and other damage. Equipment may not be stored outdoors.

F. Upon completion of work, leave the Jobsite and premises in good order. This includes removal of manufacturer-owned materials, and shipping and packaging materials used in support of delivery of the equipment.

3.05 INSTALLATION

A. It shall be the Manufacturer’s responsibility to assure that all information regarding the scheduling, delivery, and preparations necessary for setting up the equipment to be supplied under this Contract Specifications Section is coordinated with the Contractor or designated Installer, and reviewed by the Engineer prior to delivery.

B. Details listed in these Contract Specifications are given for a better understanding of the work required by the Installer, and do not place a limitation on the amount of work to be done nor do they relieve the Manufacturer or Installer of additional work that may be required for a complete installation.

C. Furnish common and skilled labor, tools, rigging equipment, scaffolding, shims, and other materials necessary to make complete installation of equipment Indicated.

D. All personnel provided by the Manufacturer or installer during the course of the Contract that require access to SEPTA’s property shall be Railroad Safety Trained (RST) through mandatory completion of the SEPTA Roadway Worker Protection Class, and wear required personal protective equipment and company photo ID at all times while on the property.



E. Receive, unload, check, and store equipment in suitable facilities. All equipment should be kept clean, dry, and free from damage and be marked and tagged with equipment item numbers.

F. Examine equipment for concealed damage and report any damage.

G. Be responsible for safety and protection from loss or damage of equipment received until work is complete.

H. Pay demurrage charges and claims for damage resulting from unloading operations.

I. Reassemble equipment items that were dismantled for shipment or moving. Assemble items that are delivered knocked down, or disassembled.

J. Coordinate the installation of equipment with the Contractor constructing the Facility.

K. Install equipment in accordance with approved installation instructions and approved Shop Drawings.

L. Provide grout, shim material and miscellaneous steel necessary for brackets, anchors, or supports required in installation of equipment.

M. Accomplish field machining that might be required to fit equipment together or to install equipment.

N. Lubricate apparatus before start-up.

O. Field check for clearance and interferences before fabrication or installation and relocate material and equipment furnished as required to eliminate interferences.

P. Perform mechanical and electrical work required to install the equipment in accordance with the requirements of the jurisdictional authorities and the current applicable codes and standards of practice employed by these trades.

3.06 SETTING AND ALIGNING EQUIPMENT

A. Equipment shall be set and aligned in accordance with Manufacturer’s instructions, approved Shop Drawings and applicable standards of trade practice.

B. Equipment shall be set true and level. Demonstrate adequate leveling of installed equipment.

C. Retighten bolted connections after installation.



3.07 CLEANING AND PROTECTION

A. Clean fabricated assemblies and equipment items thoroughly before and after operating and testing.

B. Protect equipment from damage, deterioration, paint or coating spills or spots, corrosion, or harm from any source.

3.08 FIELD PAINTING

A. Field painting equipment including touch-up painting, if any, is included under this Contract Specifications Section. Normally, equipment shall be factory-finished.

B. Where factory finishes are provided on equipment and no additional field painting is specified, all marred or damaged surfaces shall be touched up or refinished so as to leave a smooth, uniform finish at the time of final inspection.

3.09 EQUIPMENT TEST AND CHECKOUT

A. Submit an acceptance test procedure to the Engineer for approval a minimum of 60 Days prior to the start of the equipment test and checkout.

B. Before acceptance testing in the presence engineer, the manufacturer shall perform functional testing to satisfy himself and the general contractor that equipment is correctly connected, functioning and installed. A written record shall be kept of this functional testing and submitted to the engineer before the final acceptance test can be scheduled.

C. The final acceptance testing shall be performed in the presence of the Engineer and demonstrated to the Engineer’s satisfaction to be correctly connected, functioning and installed.

D. Testing and checkout procedures of the manufacturer shall be carried out completely.

E. The final acceptance tests shall not only be performed to demonstrate that the equipment has been properly installed and connected and operates properly but also to demonstrate that the equipment performs the work for which it is intended. It shall also demonstrate the operation of all pertinent safety devices including but not limited to the operations of limit switches and warning devices.

F. Tested equipment found to be defective or inoperable to any extent shall be reported to the Engineer immediately.

G. Any operating difficulty or defective item shall be repaired or replaced and put into proper operation by the Manufacturer immediately, at no additional expense to SEPTA.



H. Protect equipment and surrounding areas from damage resulting from testing operations. Clean-up spills or leakage from testing.

I. All materials for acceptance testing shall be provided by the Manufacturer with the exception of SEPTA’s rail vehicles, and/or major vehicle components.

J. Manufacturer shall bear all expenses of all tests, including the furnishing of all necessary instruments, lubricants, hydraulic fluids, supplies, data recorders, and operating personnel. Provide and bear all expenses for fuel, or fluids required to operate the equipment during the tests.

K. SEPTA will provide all pertinent railroad vehicle and/or components required for acceptance testing.

L. At the sole discretion of the Engineer, the Contractor shall be required to repeat any test, or portion of the test, at no additional cost to SEPTA. Reasons for repeating a test include, but are not limited to:

1. Software or hardware malfunction, alarm or shut-down during any part of the test.

2. Test results/data not accurately recorded. This includes failure of video equipment, if utilized to record the test.

M. The Engineer shall determine final acceptance of the installed equipment.

N. Conformed copies of the acceptance test procedure shall be available at the start of acceptance testing.

3.10 START-UP AND INSTRUCTIONS

A. Unless otherwise specified, all lubricants, cleaning compounds and similar operating materials shall be furnished by the Manufacturer during instruction of SEPTA’s personnel.

B. After all equipment and systems have been installed, connected and tested, proceed with the instruction of SEPTA’s personnel in the operation and maintenance of equipment. Provide sufficient personnel to adequately complement personnel made available by SEPTA.

C. During this period, provide qualified representatives for instruction of SEPTA’s personnel in operation and maintenance of the equipment.

END OF SECTION

July 22, 2016 Frazer Shop and Yard Expansion Final

Shunter System 14915-1

SECTION 14915 – SHUNTER SYSTEM

PART 1 - GENERAL

1.01 GENERAL PROVISIONS

A. Attention is directed to the CONTRACT and SPECIAL TERMS AND CONDITIONS and all Sections within DIVISION 01 - GENERAL REQUIREMENTS which are hereby made a part of this Section of the Specifications.

B. Definition of Terms Used in this Specification Section:

1. Manufacturer: The firm responsible for the manufacture, delivery and commissioning of the Shunter System. Referred to elsewhere in Advance Procurement Invitation for Bid (IFB) documents as the “Contractor” for contractual purposes.

2. Contractor: The general contractor responsible for construction of the Contract 2 Frazer Maintenance Facility Expansion (also referred to herein as the Shop), having specific responsibilities related to the shunter system as detailed herein.

3. Engineer: SEPTA’s designated representative.

1.02 SECTION INCLUDES:

A. Requirements for manufacturer, delivery and commissioning of the shunter

system, equipment item no. WT-01 including control systems.

1.03 REFERENCED SECTIONS:

A. Specification 11001 Equipment General Requirements

1.04 CITED STANDARDS:

A. AAR Association of Railroads B. AISC American Institute of Steel Construction

C. AREMA American Railway Engineering and Maintenance of Way

Association

D. AWS American Welding Society E. ASME American Society of Mechanical Engineers



F. ASTM American Society of Testing and Materials

G. NEC National Electric Code

H. NEMA National Electrical Manufacturers Association

I. OSHA Occupational Safety and Health Administration

1.05 QUALITY CONTROL:

A. Verify structures, track and other construction is adequate for the

shunter system.

B. Verify that the shunter system will function properly with every diesel & electric locomotive, electric multiple unit car and locomotive hauled coach in SEPTA’s heavy commuter rail fleet of vehicles.

C. Verify that all dimensions and utility supplies are adequate for the

shunter system.

D. Manufacture the system for a minimum 20-year life span, given that scheduled maintenance will be performed in accordance with the manufacturer’s instructions.

E. The equipment manufacturer shall employ a quality assurance

program that meets the requirements of ANSI and that satisfies all safety-related quality assurance requirements imposed by applicable government regulatory agencies.

F. All components used in the assembly of the system shall be

standard, commercially available components and shall be manufactured by companies regularly engaged in the manufacture of the components. The configuration of the shunter shall provide for the interchangeability of items of equipment, sub-assemblies, motors, starters, relays, batteries and other devices.

G. Delivery, startup, and testing of the shunter shall be carried out under

the direction of a qualified supervisor who is a trained technician provided by and employed by the Equipment Manufacturer, who is thoroughly experienced and trained in the pertinent crafts, and who shall be present at the site to direct the equipment delivery, setup, check out, start-up, and training for all related SEPTA personnel.

H. Qualification of Manufacturer:



1. Manufacturer shall be a reputable manufacturing firm, regularly engaged in the manufacturer of the type of equipment specified herein. Assembled components purchased by the Manufacturer for this Contract, such as motors, pumps, and electrical devices, shall be the standard products of qualified manufacturers. All similar items shall be the products of a single manufacturer.

1.06 SUBMITTALS:

A. The manufacturer shall provide for engineer review in accordance with

Specification Section 11001 system design drawings and other pertinent data, including but not limited to:

1. Equipment arrangement/mechanical drawings. 2. Detailed calculations determining the tractive effort (pulling/pushing

force) that will be required of the shunter when performing the operations specified herein. Calculations shall take into account the curves, grade, wet/ dry rail conditions and switches that the shunter and consist will be required to negotiate. Calculations shall be accompanied by documentation demonstrating that the shunter being provided has the capacity to at a minimum supply the calculated tractive effort required.

3. Braking calculations demonstrating the stopping distance in feet and inches for the shunter and consist when operating at maximum speed and utilizing only the shunter’s braking system.

4. Complete electrical wiring and control diagrams showing controls and

narrative operating procedure. 5. Narrative completely describing the sequence of operations. 6. System schematic diagram and general arrangement plan/elevations

of all system components.

7. Detailed information listing country of origin for components to be purchased by the Manufacturer and furnished as part of this Contract are to take place.

8. Detailed information on locations where fabrication and/or assembly

operations for the equipment to be furnished as part of this Contract are to take place.

B. Shop Drawings in accordance with Specification Section 11001:



1. Catalog information, and shop drawings for material and equipment including layout, supports, attachments, wiring and control diagrams.

2. Mechanical equipment schedule indicating capacities (motor

voltage and current), size and type.

3. Drive system control schematic.

4. Assembly drawings.

5. Electrical control diagrams.

6. Start-up and testing procedures.

7. Spare Parts List (submit for SEPTA information). C. Maintenance and Operating Manuals:

1. Maintenance and operating manuals for the equipment prepared and packaged in a manner suitable for use in a railroad operation environment. Manuals shall include, as a minimum, the following in accordance with Specification Section 11001:

a. Table of contents. b. Operations procedures, including a detailed description

of each operating component and its function in each sequential operating step.

c. Safety precautions. d. Preventive maintenance and expected corrective

maintenance frequencies and procedures, including printed or typewritten statements from the original equipment manufacturer covering methods of adjusting, lubricating, and otherwise maintaining each major item.

e. Catalog information on all equipment that makes up the system.

f. As-built shop drawings g. Parts ordering information. h. Recommended stock of spare parts. i. Emergency procedures. j. Schematic wire diagrams including a detail of the

control panels. k. Troubleshooting procedures written in trouble-cause-

solution approach.



l. Provide all revisions to O&M Manuals for five years after installation.

1.07 VERIFICATION OF DIMENSIONS:

A. The Contractor shall be responsible for coordination and proper relation of all work to the site and to the work of all trades.

B. Verify all dimensions of the site and locomotives/vehicles that relate to

fabrication of the shunter system and notify the Engineer of any discrepancy before fabrication and delivery of the equipment to the site.

1.08 DELIVERY, STORAGE AND HANDLING:

A. Equipment and components shall be suitably crated to prevent damage in

transit or during handling. Items shall be carefully stored at the site as required in a manner to avoid misalignment or distortion, and shall be adequately protected against damage by weather or other cause.

B. Special precautions shall be taken to prevent damage to electrical

components such as motors, controls, batteries and conductors.

C. All materials shall be delivered to the site with their original manufacturer’s markings and identification intact. The Engineer reserves the right to reject materials that are damaged, improperly identified or not in conformance with reviewed shop drawings and catalog cuts.

1.09 WARRANTY:

A. All equipment shall be warranted in accordance the requirements of

Specification Section 11001.

PART 2 - PRODUCTS

2.01 MANUFACTURERS:

A. The shunter system shall be provided by one of the following

manufacturers or approved equal:

1. Simmons Machine Tool Corporation 1700 North Broadway Albany, NY 12204 Tel. No. (518) 462-5431 www.smtgrp.com



2. Railquip, Inc. 3731 Northcrest Road, Suite 6 Atlanta, GA 30340 Tel. No. (800) 325-0296 www.railquip.com

3. Nordco/Shuttlewagon 4116 Dr. Greaves Road Grandview, MO 66430 Tel. No. (816) 767-0300 www.nordco.com

4. Whiting Corporation

26000 S. Whiting Way Monee, IL 60449 Tel No. (888) 944-8464 www.whitingcorp.com B. The basis of design is the shunter provided by Simmons Machine Tool Corporation.

2.02 GENERAL REQUIREMENTS:

A. The equipment shall be compatible with the shop layout as shown on the Contract Drawings. The arrangement may be modified only as required to suit the specific equipment being supplied. Layout dimensions as shown may be modified to improve operating efficiency subject to approval by SEPTA. Any modifications required to the building design as shown on the Contract Drawings shall be the responsibility of the Contractor and provided by the Contractor at no additional cost. All changes shall be approved by the Engineer.

B. The details shown on the Contract Drawings are based on typical

equipment. They do not necessarily meet the requirements of the actual selected equipment.

C. The system shall be complete and ready to operate, whether specific minor items required to make it operational are identified by this specification or not.

D. All components and equipment shall be new and free from defects. E. All replacement parts shall be readily available in the United States. Listing

of the sources for the parts shall be supplied for the maintenance and repair of the system.



F. The system shall be configured for proper operation in an outdoor, all-weather environment.

G. Noise Level: Comply with NEMA 1 12.49 and OSHA Article 1910.95 when

measured in accordance with IEEE 85. H. A corrosion-resistant identification plate clearly marked and stamped with the

manufacturer’s name and address, model number, serial number, date of manufacture, and all pertinent utility or operating data (or ratings) shall be attached in a prominent location to each major piece of equipment associated with the shunter system.

I. Equipment shall be configured, fabricated, assembled and adjusted to secure the

best industrially available results with respect to smooth, quiet, convenient and efficient operation, durability, economy of maintenance during the full 20 year operational life of the equipment and the highest standards of safety.

J. All piping, valves, fittings, conduits, and wiring required for the equipment shall be in accordance with the applicable codes. Supplied connections shall properly interface with the existing services.

K. All maintainable items shall be accessible for maintenance or changeout without

undue service interruption. Replaceable components shall be provided with appropriate mechanical isolation to facilitate changeout without extensive system shutdown.

2.03 SPECIFIC REQUIREMENTS:

A. The shunter shall operate entirely from built-in rechargeable batteries and be

provided with an on-board 480 V/ 3 PH/ 60 HZ charging system.

B. The shunter shall be capable of moving the following combination of vehicles in SEPTA’s heavy rail commuter fleet: 1. Three locomotive hauled coaches (420,000#) 2. Three electric multiple unit vehicles (Single vehicles or a married pair plus single vehicle, 450,000#) 3. One electric or diesel locomotive (220,000#)

C. The shunter shall only attach to the rolling stock by the coupler.

D. The shunter shall have couplers on each end and shall be compatible with standard AAR knuckle type couplers on SEPTA’s heavy rail commuter fleet and adapters for SEPTA’s electric multiple unit fleet.

E. The shunter shall operate on maintenance lead track 1, wheel truing track 9 and



repair tracks 8 & 10 to the east end bumping post of any of the named tracks. The maximum grade is 1.5%, the minimum track turning radius is 459’, maximum curve angle 17º, all turnouts are #8.

F. The shunter shall be able to move, at up to a maximum speed of 1.5 MPH,

when moving SEPTA rolling stock consists having a maximum gross weight of up to 450,000 pounds on level tangent track.

G. Overall nominal size of the shunter body, not including accessories, shall be

approximately 10’ long by 8’ wide by 5’ high above top of rail. H. Construction:

1. The frame shall be constructed of minimum ½ inch continuously welded steel plates

2. The longitudinal outside plates shall form the guides for the two axles

with flexible rubber suspension. 3. Spaces within the frame shall be filled with steel ballast for a total

machine weight of approximately 24,000 pounds.

4. Lifting eyes shall be provided to lift entire unit with batteries.

I. Drive system: 1. Four single flanged 4’-8½” gauge wheels. 2. Battery driven electric motors from 48 volt DC batteries 3. Variable speed up to 3 MPH when unloaded, 1.5 MPH maximum when moving the maximum rated loaded on level tangent track J. Brakes:

1. Electronic (regenerative) braking by electric drive motors. 2. Spring actuated emergency and parking brake on the drive motor.

K. Safety systems: 1. Optical flashing yellow light mounted approximately 12 feet above top

of rail operating whenever the shunter is moving.

2. Audible alarm shall operate up to 5 seconds prior to the shunter



moving.

3. Four (4) emergency disconnect mushroom push buttons on the shunter, 1 on each corner.

4. One emergency disconnect mushroom push button on each controller.

5. All push buttons shall be momentary.

6. When the tether is pulled from the side of the shunter the shunter shall stop.

L. Features:

1. When the battery power remaining reaches approximately the 30% level,

the shunter shall continue shall automatically notify personnel that the shunter needs re-charging.

2. There shall be no cab on the shunter from which to operate the unit.

3. Battery compartment shall be heated with a temperature cut-off

thermometer. 4. The operation of the shunter from the wheel truing pit will be controlled by a

local control console in the wheel truing machine pit. The range of radio control of this panel shall be limited to tracks 8, 9 &10 within the buildings and 300 feet west of the west face of the wheel truing bay.

5. An auxiliary control panel shall be provided on the side of the shunter, under

a locked cover, to allow all features to be tested.

6. The shunter shall be provided with a main battery disconnect switch, which will be used during maintenance.

7. The shunter batteries shall be located in a compartment that is able to contain battery fluid that may spill should a battery rupture.

8. The shunter shall be provided with an on-board air compressor with

desiccant type air dryer and quick disconnect capable of charging the 130-140 PSI air receivers, and operating the 110 psi pneumatic brake system on SEPTA Vehicles.

9. The shunter compressed air system shall be capable of charging the 110 psi pneumatic brake system on SEPTA vehicles fully within 15 minutes.



10. The shunter compressed air system shall be equipped with a safety relieve valve with a setting at no greater than 10% above the maximum operating pressure.

11. The shunter compressed air system shall be equipped with pressure

gages as required to adequately monitor the air pressure.

12. The shunter shall be provided with two (2) standard air connections on each end of the shunter that are compatible with SEPTA fleet vehicles and in compliance with SEPTA brake piping standards. Brake pipe on each end shall have brake pipe connector, a main reservoir pipe connection and a reservoir charging pipe, to feed the brake system/air compressor externally. All brake piping and main reservoir hoses shall be provided and mounted next to the coupler arrangements and must be equipped with a venting valve. The reservoir charging connector shall be near the side of the shunter to accommodate connecting a ground line. Straps shall be provided to prevent connectors from dragging on the ground when not in use.

13. Brake pipe air supplied from the shunter shall not be lost or leak

while the SEPTA vehicle is being moved. Allowable maximum air pressure loss shall be limited to one (1) psi/minute.

14. If the Emergency Stop pushbutton should be triggered on the

shunter, remote controller, or tethered controller all brake pipe air supply to the vehicle/s shall be interrupted immediately and brake pipe air shall be exhausted sufficient enough to cause an emergency brake on the vehicle/s being moved. If brake pipe air is exhausted from the vehicle/s being moved, it shall cause the shunter to perform like the Emergency Stop Button was pressed.

15. Provide shunter with two portable wireless remote controllers and two tethered controllers. The shunter shall have a tethered controller receptacle on each side.

16. Shunter shall have a robust chassis suitable for the application.

17. Shunter shall be provided with a horn activated from the tethered or

radio controller. 18. Shunter shall be provided with two white headlights and two red rail

lights on both ends of the shunter. Head lights and tail lights shall be activated on either end of the shunter automatically based upon the direction the shunter is traveling. Lights to be used submitted for approval by SEPTA.



19. The shunter shall be provided with the ability to disengage the drive system and set the shunter into a free/neutral position.

20. The shunter shall be capable of lifting/removing itself perpendicular from the

tracks (de-tracking system to be able to switch between adjacent tracks) and travel between adjacent tracks over paved roadways, concrete aprons, and grade crossings. The shunter shall be capable of aligning and engaging tangent and non-tangent tracks located in the paved roadways, concrete aprons, flush to the rail shop floors and grade crossings.

2.04 WHEEL TRUING SEQUENCE OF OPERATIONS:

A. The system shall be interlocked, mechanically with a single key or electronically

with the wheel truing machine so that it shall not operate when the wheel truing machine is in operation and the wheel truing machine cannot operate when the shunter system is in operation. The shunter manufacturer shall co-ordinate the configuration of equipment required for the interlock with the wheel truing machine manufacturer.

B. Depending on the position of the vehicles and the shunter, the shunter shall be moved to the vehicle/s with use of the either the tether or radio control to the coupling point.

C. After coupling to the vehicle/s, connect the vehicle/s air hoses to the shunter, the shunter compressor shall pump up the air pressure to release the vehicle/s brakes.

D. The key switch interlock shall be engaged to activate the radio controller at the wheel truing pit.

E. The shunter shall push or pull the vehicle/s up to and across the wheel truing machine pit.

F. The system shall individually spot the vehicle/s for the wheel truing operation from

the control console at the wheel truing machine. G. When the wheel truing operation is completed, the operator shall move the

vehicles clear of the wheel truing pit and deactivate the shunter control at the wheel truing pit.

H. The operator will move the vehicle/s with the shunter controlled by either the

tethered controller or the radio controller to the east end bumping post where it will be uncoupled from the consist.

I. The shunter can now be moved to a charging position and be plugged into the

charging outlet at the west end of track 9 in the wheel truing shop or on the east end of track 8 in the repair shop.



2.05 CONTROLS

A. The shunter shall be able to be controlled from three different control points:

1. By a fixed position radio controller provided in the wheel truing pit that is interlocked with the wheel truing machine controller/PLC. 2. By a controller tethered to the shunter.

a. Tethered controller shall be non-metallic, light weight, easy to

carry, requiring two handed operation and be of similar design to the radio controller. Tethered controller shall duplicate all functions of the radio controller with the exception of off rail travel.

b. The walk beside, 10 foot long tether, shall allow the shunter to be operated anywhere within the yard or shop.

c. A removable controller shall be tethered to the shunter and if the connection is broken for any reason the shunter shall automatically stop.

3. By a radio controller wirelessly connected to the shunter.

a. Remote controller shall be non-metallic, light weight, easy to

carry, and require two handed operation. Remote controller shall be provided with a on/off key switch with indicator light, low battery indicator lights indicating low battery power of the shunter and low battery power of the remote controller, a button to control the horn on the shunter, and an Emergency Stop Push Button in addition to all other controls required for operation.

b. Remote controller shall be designed with an electrical interlock that will shut down the shunter, apply the brakes and stop the vehicle/s in the event that the operator using the remote controller tilts or drops the remote control such as tripping or falling, or equivalent deadman function.

c. The receiver/antenna shall be built into the shunter. d. The range of the radio controller has be minimum 500 feet. e. The Contractor shall coordinate with other remote controller

frequencies used at the site to ensure that the shunter is on an independent frequency and will not interfere with or be interfered by other remote controllers on the site.

f. The remote controller radio frequency used shall be encoded between the shunter and the remote controller to prevent accidental interferences from other devices.



B. Only one controller shall be able to be turned on at a time, the other two controllers will be disabled.

C. The wheel truing pit controller shall be connected to and interlocked with the wheel truing machine.

D. Actual car movement shall be delayed up to 5 seconds by a variable timer.

E. The unit shall operate at a variable speed in forward or reverse as controlled by a

programmable logic controller (PLC).

2.06 ELECTRICAL REQUIREMENTS:

A. A single electrical service operating at 480 V/3 PH/60 HZ to be provided to each of two (2) charging stations, in the building.

B. Provide (2) minimum 30 feet long re-charging cables, sized for proper amperage,

complete with compatible plugs at each end and compatible wall receptacles. Provide (2) additional compatible plugs without cables.

C. A single electric service operating at 120V/1 PH/60 HZ to be provided at the wheel

truing pit for the wheel truing pit controller. D. Enclosures exposed to wet conditions: NEMA 4X stainless steel.

E. Ground all equipment by means of a conduit ground according to NEC Article 250. F. Provide each individual motor circuit with branch circuit overcurrent protection in all

phases using multiple circuit breakers. G. Equipment shall be totally wired including conduits and supports by the equipment

manufacturer up to and including the main disconnect switch. H. Use liquid tight flexible metal conduit connections to motor terminal boxes, dry type

transformers, and equipment subject to movement or vibration. I. Identify wiring by a wire tag with a number corresponding to the wiring diagram. J. Maximum current: Not to exceed that specified by NEC for the type of conductor. K. Provide unfused disconnect switches, motor starters and start-stop control stations

for all equipment.



L. Provide electrical switches in compliance with NEC, equipment design requirements, and the electrical power circuit design for each piece of equipment.

M. Wiring: 12 GA minimum; all bus work and windings shall be copper.

PART 3 - EXECUTION

3.01 PREPARATION:

A. Transmit submittals required by this Section.

B. Furnish products as indicated.

C. Ensure that substrates are in suitable condition to receive the Work.

3.02 FABRICATION:

A. Fabricate equipment in accordance with specifications and conformed shop

drawings.

3.03 PAINTING:

A. Paint all non-stainless steel and galvanized metal component parts of the shunter system, except electrical connections and machined surfaces. Prepare all surfaces to be painted as recommended by the paint manufacturer.

B. Exterior Primer: Compatible with finish; applied in two coats. C. Exterior Finish: Dupont IMRON 333, or approved equal; color selected by

the Engineer.

D. Perform touch-ups prior to acceptance of the equipment. Provide one gallon of matching touch-up paint.

3.04 INSTALLATION:

A. Install the equipment in accordance with the equipment manufacturer’s

recommendations and instructions of the on-site representative.

B. Provide lifting eyes or other mechanism to facilitate material handling for all equipment over 100 LBS.



C. Protect all joints, connections, and contacts between dissimilar metals from galvanic action.

3.05 START UP AND TESTING:

A. The Operation and Maintenance Manuals shall be submitted and approved

by the Engineer before the acceptance test shall be performed.

B. Following installation, the equipment manufacturer shall perform an acceptance test. The acceptance test shall be in accordance with the requirements of Specification Section 11001. At three and again at six months after acceptance of the car progression system, the vendor’s qualified representative shall perform a complete inspection and submit a written report detailing any abnormalities that may exist and instruct SEPTA personnel in the proper repair and adjustments required. This effort shall include a minimum of eight hours of instruction.

3.06 TRAINING:

A. Manufacturer shall submit for review a program to adequately train SEPTA

personnel to operate and maintain the equipment. The training test shall be in accordance with the requirements of Specification Section 11001. Following installation, the Manufacturer shall, at the convenience of SEPTA, conduct the approved program for training operating and maintenance personnel on a minimum of three separate occasions.

Topic Material

Orientation:

a. Equipment Introduction Hands-on b. SEPTA Manual Briefing O & M Manual

Maintenance:

a. Daily Preventive Inspection Checklist b. Weekly Preventive Inspection Checklist c. Monthly Preventive Inspection Checklist d. Semi-Annual Preventive Inspection Checklist

Trouble Shooting:

a. System Control Logic Trouble Shooting Guide b. Electrical Systems Trouble Shooting Guide

Operation:



a. Operating Requirements Hands-On b. Program Selection Hands-On

END OF SECTION