14-Bid Specifications.pdf

ITEM 75675.1725XX - Furnishing and Installing Railroad Train Control System

Description:

The work will consist of complete installation into operational service and final testing of an automatic train control signal system installation in accordance with the plans or as ordered by the Engineer.

This specification must be adhered to in all respects unless relief there from in writing is obtained from the Railroad and with the concurrence of the Engineer.

In all cases, AREMA Specifications will be followed unless otherwise modified by this specification or in Special Provisions and Contract Plans. All installations shall be in accordance with Chance Rides

Railroad Specifications.

The contractor shall obtain and pay for all licenses and/or permits that may be necessary. The contractor shall arrange for all local inspections that may be necessary and pay all fees in connection with such inspections.

The contractor shall give the railroad a minimum of five days notice prior to the date work is to begin. The contractor shall, in the interim before work is begun, call for existing utility stakeouts; meet at the site with the appropriate State and Railroad representative, with the Engineer; to resolve all questions with regards to the layout of the equipment to be installed and installation procedures.

One (1) copy of corrected (As Built) circuit plans of the crossing shall be placed in a storage container provided by the contractor in each signal enclosure. A further one (1) copy of the corrected circuit plans

(As Built) of the crossing shall be provided the Engineer by the contractor; with five (5) sets (as built) railroad copies total and one computer file (memory stick or emailed) (total).

Testing Procedures

A. Final Testing – The Contractor shall perform every practical test to insure that the system is functioning properly and that faulty components are replaced before attempting to place the system in service.

All tests shall conform to the requirements of the FRA Part 236. These shall include tests of all battery systems, relays, grounds on battery busses, cable insulation resistance, proper lamp voltage, gate timing up and down, and lamp unit alignment. Proper forms for each shall be made available to the Owner or the Engineer for review, in accordance with FRA Part 234.273. These forms shall include the following, made available by the contractor to the Engineer prior to PE Certification and acceptance of the crossing:

Record Signal Housing

Copy

FRA

Requirement

Cable Resistance to Ground X 236.108

Relay Test Records X 236.104

Timing Relay Test Records X 236.109

Battery Bus Grounds X 236.107

Battery Cell Voltages (Individual) X 236.107

Detailed Circuit Plans X 236.1

B. No installation shall be considered complete until it has been approved and accepted in writing by the Engineer and the appropriate State and or Federal Highway representative and all other Railroad and Government agencies involved.

C. Contractor's Work Responsibility: In addition to the Contractor's responsibilities defined elsewhere in the contract documents, the Contractor shall also be responsible for all damages due to his negligence to existing equipment, cables, connections, etc. in the performance of his work defined under the various work requirements of this contract. The Contractor shall, at his own expense, replace or repair any existing cables that are broken or otherwise damaged by his forces, and shall be held responsible for the proper operation of the repaired circuits. The Contractor shall satisfy himself as to the operating conditions and integrity of the facilities that shall be affected by his work. This shall be accomplished prior to making any new electrical connections to existing facilities or the relocation of existing equipment. The Contractor shall notify the Engineer in the event that the operating condition or integrity of any affected facilities is not within performance standards.

Material Construction Details

Signal Enclosures:

Case: to be constructed of aluminum or carbon steel that is factory powder coated. Painting of carbon steel case to consist of one primer coat and two finished coats of aluminum paint prior to oxidation of the carbon steel. Any painting damaged in transit to be repaired in the field in a similar manner. Case to be lined with 13 mm (1/2") thick insulation board. Interior mounted 110V AC

Duplex outlet combination power on switch to control cabinet feed. Interior centrifugal type vent fan operating on 110V AC.

Instrument Case: Aluminum with two (2) doors. PTMW standard single door preferred or approved equal.

Instrument House: 1.83 m (6') x 1.83 m (6’). Aluminum with two (2) doors. PTMW BNSF standard house preferred, or approved equal.

Relays Siemens Type ST-1 Vital Relay-Plug In or approved equal

Exhaust fan with All signal houses and cases must be equipped thermostat

Battery Tray All signal houses and cases must be equipped

Floor Mat All signal houses and cases must be equipped

Power Out Light GEMS or approved equal

Thermax 2" Insulation or approved equal

Battery Charger National Railway Supply (ELC 12/20 or 12/40 depending upon load)

Lights 100 watt equivalent LED bulbs

Outlet GFD for use by maintainer

NOTE: FLOOR MAT, INSULATION, POWER OFF LIGHT, MAY USE HOUSE

SUPPLIED MATERIALS IN STANDARD HOUSES..

Wire Installaton: Follow AREMA Standard. All wire runs where practical shall be parallel, no sharp bends, supported and protected from sharp edges. AMP solderless pre-insulated terminals

(less copper sleeve) or equivalent shall be applied over cerefully stripped wire ends complying with manufacturer specifications, using manufacturer’s crimping tool with ratchet, insuring proper crimping.

Terminations shall follow AREMA standard. Double nuts for all cable and wire terminations.

Insulated nuts shall be on all high voltage (110VAC or higher) terminations including in Mast Bases of signals.

Lightening / Surge Protection: Heavy-duty arrestors with equalizers shall be installed on and between series paired track leads and ground (Surge protection with power protectors shall be installed across AC leads to protect rectifiers and other equipment. All arrestors shall fit standard AAR binding posts on 60 mm

(2 3/8") centers. Manufacturers as follows or approved equal:

Arrester – Heavy Duty 022615-1X Siemens

Arrester – Clearview 022485-28X Siemens

Equalizer – Heavy Duty 022700-1X Siemens

(Power Surge Protection – Joslyn 1259-21-A or Erico EPD120/240TDFL)

(The use of a circuit breaker panel with circuit breakers properly sized instead of line buss type fuses are required by this specification.)

Contractor shall use manufacturers recommended surge protection where it exceeds these specificaitons, such as GE’s MDSA panel as required.

Resistors: Siemens adjustable for track and light circuits or an approved equal. The contractor is responsible for installing the correct range adjustable resistors for lighting and track circuits so that adjustment is left for the railroad to use for future maintenance needs.

Locks and Keys: The contractor is to furnish locks for all junction box bases, pole boxes, manual control boxes, instrument cases, etc. They shall be Siemens Padlock 030399-13X or approved equal.

The contractor is to furnish 2 keys, Siemens key number 030399-7 or approved equal.

Foundations:

Gate Foundations: Dixie Precast DPS-2 or approved equal, 297 mm x 297 mm (11 11/16 inches x 11

11/16 inches) bolt spacing, height 1.68 m (5'-6” inches), all reinforcing to have a minimum of 25 mm (1") concrete coverage. Also a Siemens steel pyramid type model number 0035903-500X 1.52 meter (60") high, galvanized steel foundation can be used or approved equal.

All anchor bolts, washers and nuts to be galvanized and coated with antiseize compound. Gate and flasher foundation tops to be at the same elevation as the surface of the traveled way and no more than 102 mm (4 inches) above the surface of the ground. Instrument case foundation tops shall be

305 mm (12") above finished ground level and a minimum of 305 mm (12”) above top of rail. Base of all foundations to be set level and firmly tamped on firmly compacted ground. Backfill around all foundations to be firmly tamped to consistency of adjacent ground.

All stanchions and housings to be set plumb.

Ground conditions must be restored to surrounding conditions (asphalt, concrete or gravel) and is included in this item.

All signals / instrument housings shall have 3 inches minimum of walking stone, 5 feet radius around each unless shown as other on Contract Plans.

Driveway to instrument house to be constructed per contract plans, and consist of compacted

“crusher run” stone toped with 3” thick of walking stone shall be paid under its respective items.

Gate Mechanism:

WESTERN CULLEN 3593, or approved equal. Feed cable from terminal box base to gate mechanism to be installed with sufficient slack to allow for a 90 degree rotation of the gate mechanism. All units with gate arms longer than 6.1 m (20’) shall have two (2) counterweight arm assembiles. All units shall have gate motor heaters. All gate mechanisms shall have General Signals

Inc. SK1000 Gate Keeper Assemblies or approved equal. AC isolation transformers shall be used if heaters are 110 VAC. Disconnect relay shall be used if 12 VDC heaters are used in case of power failure.

Gate Arm:

The gate will be a High Wind Profile Aluminum/Fiberglass with all aluminum base section adaptable to WC Hayes Gate Gard P/N D-1049-1, RECO, National Elect. Gate, or Siemens Gate

Keeper Assembly. Gate arms shall have full (not a reduced size) tip section. Each gate arm shall display alternate red and white reflectorized stripes, facing in each direction along the roadway. The stripes shall be 406 mm (16”) wide, as measured parallel to the edge of the gate. The stripes shall be verticle in accordance with the current MUTCD. Striping shll be high intensity, 3M product, NYSDOT specificaiton 730-05.02 ASTM Type III Class B, Reflective Sheeting.

When gate assembly is complete with gate arm horizontal, gate shall be perpendicular to traveled lane and the distance from bottom of gate arm tip to surface of highway should be 1,219 mm (48”).

The tips hall not be less than 1,067 mm (42”) or more than 1,372 mm (54”) above the roadway or sidewalk.

(Gate lights shall be EZ-GATE LED Type (or Approved Equal) or have LED lamp inserts).

(On angled crossings, gate lights must be aimed toward oncoming traffic perpendicular to the roadway not the gate arm.)

Protective Coating: All ferrous metal components are to be hot dipped galvanized coated to prevent rusting in accordance with AREMA specifications. All threaded parts exposed to weather to be coated with antiseize compound to prevent rusting and maintain future adjustments after installation is complete.

Sealant:

To be waterproof, remain pliable, resist shrinking, cracking or drying and must be used to seal

(watertight) all ducts, conduits,and junction boxes. Silver-grey color sealant to be used to seal bolt holes and sides and bottom of juntion box bases.

Conduit:

Depth (highway and track) of conduit shall be 914 mm (36”) deep,measured from pavement surface or surface of ground to top of conduit and will extend 1.52 m (5’) beyond each side of crossings shoulders. Contractor will mark the field side locations of all conduits and wire locations on the project circuit plans. Conduit shown to be placed on the project plans shall be paid under its respective items.

Cable:

Track and Signal cable shall be Association of American Railroad’s Manual for Railroad Signaling

(latest revisions) (AAR) approved Direct Burial Type Okonite or approved equal. Standard sized cables are as follows:

(1) Flashing Light Signal Cable 5 Cond. #6 Cable min.

(2) Signal Gate Control Cable 5 Cond. #6 min. (Combo cable allowed).

(3) Crossing Gate Control Cable 5 Cond. #6 min. & 7 Cond #14 (Combo cable allowed).

(4) Interconnection cable 7 Cond. #14 min.

(5) Track Wire Cable 2 Cond. #6 Twisted (1 foot)

Cable Installation: Cable shall be placed in a trench no less than 914 mm (36”) below surface of the ground. The trench shall not be left open after the close of the workday. When excavating within the track structure, ballast will be covered to keep it clean. Cable shall be handled with care to avoid damage to the cable jacket and insulation. Cables are to be laid in the trench parallel and together and surrounded by approximately 152 m (6”) of suitable fine material (sand preferred) free of stones or other sharp objects. Cable shall be tested before and after installation to insure that conductors are free from open circuits, short circuits and grounds. All cable runs shall be terminated on test links (both ends) including mast bases.

Track Connection: Welded ERICO SBTBBU4A 3/16” Dia. X 1” Tab x 4” Long Bootleg or equal welded to the web of the rails. Slack should be kept to a minimum. Rubber hose used for riser wire.

All underground connection splice kits to be made with proper size nicropress sleeves fully encased with an epoxy splice kit.

If plug bonds are used, they shall be installed the same day the holes are drilled. The plug bond shall be installed 13 mm (1/2”) above the centerline on the gauge inside web (fishing) of the rail and 76 mm (3”) from the end of the joint (insulated). Siemens Track Connection Assemblies Model RCP-10

Rail Plug or No. 021127-4X with vertical drop under center of rail or approved equal.

Bonding Rail Joints: All joints within the limits of the signal circuits shall be bonded, unless otherwise specified by the Railroad. All joints within the highway circuit limits shall have a bond per joint unless otherwise specified. Bonds shall be (drilled web around joint bars on field side of rails) bonds 3/16” and manufactured by ERICO NVENT or approved equal. Bonding shall be in compliance with the Association of American Railroad’s Manual for Railroad Signaling (latest revision) (AAR) Rules and Regulations. Bond strand with track connectors may be used for this purpose.)

Track (Diode) Rectifier: Siemens Model TCR-6, GE RING 10, or approved equal.

Method of Measurement

Payment for furnish and install railroad signal system will be made on a lump sum basis.

Basis of Payment

The lump sum price bid for removal of existing signal system, furnishing and installing railroad grade crossing warning devices at an at grade crossing shall include all equipment, materials, labor, testing and engineering necessary to place the warning devices into accepted operational service as directed.

Partial payments will be made per the agreement section of the project manual.

Exclusions

The following are not included in this item, and will be paid under their respective item numbers unless otherwise specified in Contract Plans or Special Provisions:

Insulated Joints