B.08 SOW Trash Rake System.pdf

Clemson Pump Station, New Trash Rake

TRASH RAKE SYSTEM

SCOPE OF WORK

1. General

1.1. Description of Work

1.1.1. Site Access

Provide new concrete driveway connecting the existing roadway of Lake Drive to the trash dump area (see CS102). No survey was performed for the site. Any survey work needed for performance of the work to be done by the contractor.

1.1.2. Trash Rake

1.1.2.1. Provide a Trash Rake, its monorail, support structure, foundations, controls, and associated accessories as described. The Trash Rake System shall service the existing Hunnicutt Creek Bar Screens and shall be constructed independent of the existing Hunnicutt Creek Footbridge and Bar Screens. See

CS102.

1.1.2.2. Provide removable personnel guardrail at the edges of the existing and new concrete pad to the extent required by Code.

1.1.2.3. Provide wheel stops on the existing concrete pad to prevent vehicles/dumpster from damaging new guardrail.

1.1.2.4. The trash rake, controls, and accessories shall come from a single manufacturer.

1.1.2.5. Equipment requiring minimum maintenance is a prime factor when selecting equipment.

1.1.3. Electrical

The Design-Build Contractor shall design, furnish, and install all secondary electrical work required to serve the Trash Rake System. The secondary electrical power system shall include, but is not limited to, safety switches, copper conductors, conduit, circuit breakers, conduit fittings, and other electrical equipment or components for a complete and functional Trash Rack System. The existing Main Distribution Panel (Square D I- Line Panelboard rated for 225 Amp and 480 Volt) located in the pump station shall provide power to the Trash Rack System.

1.1.4. Lightning Protection System

The Design-Build Contractor shall design, furnish, and install a lightning protection system (LPS). The LPS shall include, but is not limited to air terminals, down conductors, main conductors, ground rods, and other equipment or components for a complete and functional LPS. The lightning protection system shall comply with NFPA 70, NFPA 780, and UL 96. The Design-Build Contractor shall provide certification from a commercial third-party inspection company whose sole work is lightning protection, stating that the lightning protection system complies with NFPA 780. Third party inspection company cannot be the system installer or the system designer. Provide a UL Lightning Protection Inspection Master Label Certificate indicating compliance to NFPA 780.

1.2. Quality Assurance

1.2.1. Only qualified manufacturers that have been regularly engaged in the design and manufacture of Trash Rakes, controls, and accessories similar to those specified herein with multiple systems operating in the United States will be considered.

1.2.2. The Trash Rake System shall be electrically tested at the Factory before shipping.

1.2.3. The Contractor shall warrant that the equipment provided is free from defects in the material and workmanship for a period of one year from the date the equipment is placed in operation.

1.2.4. Provide electrical materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Provide products which have been in satisfactory commercial or industrial use for 2 years prior to bid opening. Ensure the 2-year period includes applications of equipment and materials under similar circumstances and of similar size.

Ensure the product has been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items must be products of a single manufacturer.

1.2.5. Trash Rake system shall be submitted electronically for Government review and acceptance prior to manufacturing.

2. Products

2.1 GeneralTrash Rake System: Provide detail drawings to include site plans, equipment plans, and installation plans. Provide operational data, materials of construction, and diagrams. Provide range and setting of indicators, instruments, timers and other related devices, motor product data, and control components product data. Historical drawing has been provided for reference only at the end of this scope of work.

2.1.2 Provide detailed electrical drawings to include site plans, lightning protection plan, and as-built one-line diagrams. Site plans shall show all electrical equipment and devices, conduit type, conduit sizes, and conductor sizes. One-line diagram shall show all electrical equipment and devices, conduit type, conduit sizes, conductor sizes, and device trip ratings. Ensure each item of equipment has a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place;

the nameplate of the distributing agent is not acceptable. NEMA ratings shall be as required by the NFPA 70 National Electric Code (NEC).

2.2 Concrete Driveway

2.2.1 Provide new concrete slab driveway as shown on the attached CS102.

2.3 Bollards, guardrail and wheel stops. Bollards shall be concrete filled steel pipe designed to meet applicable Codes. Guardrails shall be constructed from aluminum and shall be removable. Wheel stops shall be a commercially available product that is anchored to the existing concrete slab and meets applicable Codes.

2.4 Trash Rake

2.4.1 Monorail Trash Rake for collection, removal and handling of coarse solids from Bar Screens. The rake shall be a single piece of equipment capable of manually (under pushbutton control) raking bar screens and transporting debris to the designated dumpsite, awaiting 30 cubic yard roll-off dumpster, or dump truck. Multiple pieces of equipment such as trash rakes combined with conveyors and handling equipment shall not be allowed.

2.4.2 Each bar screen shall be front cleaned by the rake head assembly with teeth designed to fully penetrate the bar screens while descending and shall operate on an overhead monorail. Designs employing multiple rakes and designs employing chains, sprockets, bearings, shafts or other moving parts fixed to bar screens are explicitly excluded. Designs employing open monorail construction (I-Beams) and designs employing pivoting teeth by changing cable lengths or by static weight shall not be allowed.

2.4.3 There are three existing Hunnicutt Creek Bar Screens, each approximately 10’-0” wide and 14’-0” tall.

2.4.4 The Trash Rake System shall include the following equipment:

a. Rake/Gripper (Trash Rake)

b. Support Structure

c. Monorail

d. Main Panel

e. Remote Controller

f. Cable Festooning System

g. Anchor Bolts

2.4.5 Requirements:

2.4.5.1 Trash Rake shall be suitable for manual operation in raw water. The Trash Rake shall be a single piece of equipment designed to remove debris from the Bar Screens, such as, weeds, grasses, trash, plastic bags, branches, logs, tires and other debris. The Trash Rake shall transport debris and discharge it into the appropriate discharge area. Coordinate dimensional design/fabrication with existing site.

2.4.5.2 The Trash Rake System shall primarily consist of an overhead monorail type track, a traversing trolley and a rake/gripper unit. The trolley shall travel along an overhead track until the desired Bar Screen has been reached. The rake/gripper shall then be lowered to engage and penetrate the Bar Screen for debris removal to just above invert elevation. The rake/gripper shall then be closed, raised and debris transported to the appropriate dumping site.

2.4.5.3 Fabricate overhead track from folded plate or two channel sections continuously welded to an intermediate top plate to protect the traversing motor/wheels from inclement weather. Open type monorails shall not be allowed.

This provides the track for the traversing drive and support wheels fitted to the top of the trolley. The track shall be supported at various points by steel support columns located at strategic structural points.

2.4.5.4 The trolley unit shall contain the traversing gear motor, hoisting shaft and hydraulic power pack. The trolley shall be traversed by a gear motor mounted on top of the trolley and shall include rubber-rimmed wheels, fitted directly to the gearbox output shaft designed to run inside the track. The hoisting gear shall consist of two spirally grooved rope drums mounted on a common shaft within the trolley to raise and lower the rake/gripper. The hoist shaft shall be driven by a geared motor unit.

The hydraulic power pack shall provide for the operation of the hydraulic cylinders which open/close the rake/gripper. Designs which utilize mechanical closing rakes shall not be allowed. Fluid power shall be transferred to cylinders through high strength hoses which are to be wound on a spring tensioned drum operating in sequence with hoisting drums. The hoses shall be located downstream of the hoisting cables for protection. The hydraulic fluid shall be biodegradable for environmental concerns. Electrical power to the trolley unit shall be supplied by a trailing cable which contains both power and control leads supported on cable wagons inside the track or other festooning method acceptable to the rake/gripper.

2.4.5.5 The rake/gripper shall be supported by the hoisting shaft via wire ropes and shall consist of a series of special teeth designed to engage with the Bar Screen and shall be opened/closed by hydraulic cylinders. The rake/gripper head shall be prevented from excessive lateral swaying when traversing motion stops by specially designed swing restrictors.

2.4.5.6 The Trash Rake System shall be capable of handling an allowable (unfactored) debris load of 2000 pounds. This load is a Live Load.

2.4.6 Design Requirements:

2.4.6.1 Trash Rake: The existing bar screens and their supports shall be the only obstructions in the creek channel. The Trash Rake/Gripper shall operate manually (via RF Remote) at each Bar Screen. The rake/gripper and cables shall only obstruct the creek channel during cleaning. Design of the Trash Rake System shall ensure that the Bar Screens can be removed from their supports, without requiring removal of any part of the Trash Rake System. Provide diagrams showing clearances of monorail to 30 cubic yard roll off dumpster during drop off and 14 cubic yard dump truck.

2.4.6.2 Final Geotechnical Evaluation Report: Provide a Final Geotechnical Evaluation Report as indicated in the “Report of Preliminary Site Characterization – Trash Rake System Clemson Lower Dam, Clemson, SC” dated November 2020 by the Soils Section, Geotechnical & HTRW Branch, U.S. Army Engineer District, Savannah.

2.4.6.3 The Trash Rake System and its support structure (including foundations) shall be of sufficient size and strength to withstand the forces from the trolley, fully loaded rake/gripper, impact, required support span and environmental loads (wind, ice, seismic, etc) in accordance with AISC practices and ASCE 7-16. The Importance Factor for the Rake and associated structure is 1.0. The maximum allowable drift of the support structure is H/240. Maximum deflection of the monorail track is L/800.

The trash rake shall be operable during wet weather with a sustained wind speed of 30 mph. Provide a S curve in monorail to allow the dumpster/dump truck to be placed approximately where shown on Civil Site Plan. Coordinate final location with user.

2.4.6.4 The height of the system shall be designed to allow for emptying of the monorail contents into a 30 cubic yard roll-off dumpster or into a 14 cubic yard dump truck. The supports for the monorail at the concrete pad shall be separated with adequate clearance between them to allow a 30 cubic yard roll-off dumpster or a 14 cubic yard dump truck to be place under the monorail. The support columns shall be protected with bollards.

2.4.6.5 Provide personnel guardrail designed in accordance with UFC 3-301-01 and IBC 2018.

2.4.6.6 Provide wheel stops coordinated to protect the new guardrail from damage.

2.4.6.7 Equipment Guards: The equipment shall operate on an overhead monorail and shall include access enclosures and guards.

2.4.6.8 Maintenance Access: Design of the Trash Rake System shall ensure that routine maintenance of the trolley components can be accomplished easily and safely.

The rake/gripper shall be maintained by lowering to the designated dumpsite for direct access.

2.4.6.9 Local Electrical Control Panel and Control Pendant Station: Local electrical control panel shall be designed by the manufacturer and shall be provided with NEMA 4X enclosure. Remote pendant station (RF remote) shall be in NEMA 3R enclosure.

2.4.6.10 Electrical Calculations: Provide short circuit, voltage drop, and demand load calculations. Provide short circuit, voltage drop, and demand load calculations in accordance with UFC 3-501-01.

2.4.7 Materials of ConstructionTrash Rake System:

a. Rake/Gripper Stainless Steel, Grade 316

b. Hoist Cables Stainless Steel, Grade 316

c. Trolley/Hoist Parts Mild Carbon Steel

d. Trolley Enclosure Stainless Steel, Grade 304

e. Track Mild Carbon Steel – Hot Dip Galvanized

f. Support StructureMild Carbon Steel – Hot Dip Galvanized

g. Track/Column Fasteners Zinc Plated Steel

h. Anchor BoltsStainless Steel, Grade 316

2.4.7.2 Accessories

Provide the first filling of lubricants. Ensure all lubricants are filled to manufacturer’s specification prior to Government acceptance of equipment.

2.4.7.3 Protection

Hot dip galvanized in accordance with ASTM A123/A123M as indicated above.

OEM items, such as, motors, gearboxes, etc. shall be supplied in the manufacturers’ standard finish, suitable for marine application.

2.4.8 Equipment

2.4.8.1 Welding

Welding on items designated for galvanized shall be per recommended standards for galvanized structural fabrication.

2.4.9 Rake/Gripper

2.4.9.1 The rake/gripper shall be manufactured from heavy plate and shapes with teeth spaced to match the openings in the bar screens. The rake/gripper shall operate by being traversed over the required bar screen during a cleaning cycle. The rake/gripper shall be in the open position when being lowered.

2.4.9.2 The rear (downstream) teeth shall normally engage with the bar screen at the normal water elevation. Teeth shall automatically engage and self-center between the bars during the descent.

2.4.9.3 The rake/gripper rear teeth shall be capable of passing through the bar screen without interference from the bar screen horizontal supports. The rake/gripper shall continue to be lowered until it reaches the invert elevation (or an immobile object).

2.4.9.4 The rake/gripper shall be closed under hydraulic power by manual control, when the invert has been reached (or at any time). The hydraulic cylinders shall be suitable for submerged service.

2.4.9.5 When closing, the upstream teeth of the rake/gripper shall be rotated towards the rear teeth and close in conjunction with the rear teeth to remove and lift objects or debris build up wider than the bar screen opening and within the lifting capacity of hoist.

2.4.10 Trolley

2.4.10.1 The trolley shall contain necessary traversing and hoisting equipment.

This shall include the traverse motor-reducer, traversing drive and follower wheels, hydraulic power unit and hoist drums, hoist cables, hydraulic hose with spring tensioned hose reel, slack cable tension roller and limit switches, hoist raising and lowering limit switches, and over-travel limit switches.

2.4.10.2 The trolley shall be enclosed on four sides by a stainless-steel enclosure.

The two sides parallel to the track shall include doors to allow access for maintenance of the internal components.

2.4.10.3 The traverse motor reducer shall be adequately sized to allow for continuous operation including loads from the trolley and rake/gripper fully loaded with a minimum service factor of 1.15.

2.4.10.4 The hoist motor reducer shall be adequately sized to allow for continuous operation including loads from the rake/gripper fully loaded with a minimum service factor of 1.15. The hoist drive unit shall be mounted directly onto the hoist drum shaft. The hoist drums shall be sized to properly wind the wire ropes during raising or lowering operations. The hoist drums shall be machined heavy tubing and shall include welded ends with hubs keyed to the hoist shaft. Each trolley unit shall include two hoist drums. The opposite end of the hoist shaft shall include a chain drive and nylon pinion to properly operate the hydraulic hose reel in unison with the hoist drums. The hydraulic hose reel shall be spring tensioned to prevent the hoses from allowing slack. The hoist shaft shall also include two slack rope rollers which shall maintain a constant tension on the hoist cables and stop the lowering operation of the hoist upon sensing a "slack" hoisting wire rope.

2.4.10.5 The hydraulic power pack shall provide fluid to open and close the hydraulic cylinders mounted on the rake/gripper. The unit shall be capable of continuous operation and shall be sized to develop a minimum 1300 psi operating pressure. The unit shall include necessary components for adequate operation including but not limited to the motor, pump, coupling, oil return filter, oil reservoir, hydraulic hoses and fittings, etc.

2.4.10.6 The unit shall trip "OFF" and signal "Hydraulic Failure" if the required fluid level is not maintained. The hydraulic unit shall be filled with biodegradable fluid with additives at the required viscosity based on service conditions.

2.4.11 Track (Monorail)

2.4.11.1 The track (monorail) shall be manufactured from folded plate or two carbon steel channels with an intermediate plate welded between the facing flanges to protect the traverse drive motor/wheels and other trolley components from inclement weather. Designs utilizing an open "I" beam or wide flange monorail shall not be allowed. The track shall be of sufficient size and strength to withstand the forces from the trolley, fully loaded rake/gripper, impact, required support span and environmental loads in accordance with AISC practices and ASCE 7-16. The track shall include caps at each end to prevent over travel and access plates to allow for access/removal of the trolley and rake/gripper.

2.4.12 Support Structure

The track support structure shall be manufactured from carbon steel tubing and plate. The structure shall be adequately sized to support the track. The columns and beams shall be rectangular shaped with base plate for fixing to the footings. The base plate shall be grouted in place by the contractor and shall be anchored via properly sized anchor bolts and foundations, as determined by the manufacturer. Ends of HSS members shall be sealed.

2.4.13 Cables and Festooning

Electrical power shall be supplied to the trolley unit via electrical cables supported by a festooning system running within the track.

2.4.14 Electrical Controls General

Electrical Controls, other than the Human Machine Interface (HMI) should be located inside the Pump Station Building, to the maximum extent possible. The manual controls shall include the necessary components to allow for proper operation of the equipment, basically consist of the following, and shall be internally pre-wired:

a. Enclosure: NEMA 4X – Wall Mounted Type

b. Enclosure Front Mounted Components

2.4.14.2 Human Machine Interface (HMI) – NEMA 4

a. The HMI shall provide inputs and displays.

b. Running, Faults including Trolley – Hoist – Hydraulic – System, E-Stop, Manual

Control, Reset, and Stop.

2.4.14.3 Internal Control Components

Control Power Transformer with mounted fuse block.

2.4.14.4 Motor Starters and Overload Protection

a. Trolley Motor

b. Hydraulic Pump Motor

c. Rake/Gripper Motor

2.4.14.5 Separate/Loose Components

Manual Pendent – Radio Frequency wireless remote for local manual controls –

NEMA 3R.

2.4.14.6 Safety Features

a. Solid State Motor Overload Relays with Automatic/Manual Resets. These relays have field selectable trip class 10, 15, 20 or 30 and provide jam and ground fault protection.

b. Limit switch to prevent trolley over travel.

c. Limit switch to detect a slack rope condition, which indicates an obstruction in the rake/gripper's path.

d. Trolley Mounted Visual and Audible Alarms activated by equipment operation, to warn personnel nearby, of moving equipment.

2.4.14.7 Manual Control

a. Manual operations shall be performed by depressing the appropriate momentary contact pushbutton on the wireless remote. A line of sight with the receiver must be maintained.

b. The operator moves the trolley and rake/gripper out along the track until it is properly positioned above the selected area or bar screen to be serviced. The operator then visually verifies the rake/gripper teeth are open and then proceeds to lower the rake/gripper. As the rake/gripper descends, the rear teeth shall engage with the screen bars near the top of the Bar Screen. As the rake/gripper continues to descend, the accumulations of debris shall be projected into the "jaws" of the rake/gripper until the invert evaluation is reached where lowering shall automatically cease. The operator may now close the rake/gripper and raise it, along with accumulated screenings, to a level above the top of the footbridge safety railing where raising shall automatically cease when the rake/gripper is properly engaged within the trolley.

c. With the rake/gripper at fullest height, the operator may now traverse the trolley to the pre-determined dumpsite. When the operator verifies that the rake/gripper is properly positioned over the dump area, they my now open the rake/gripper to dump the contents. The operator may now traverse the rake/gripper to the next cleaning position.

d. When the positions have been cleaned, the rake/gripper may be returned to the pre-determined "park" position until the next cleaning cycle is required.

2.4.14.8 Safety Functions

a. If a large quantity of debris or other obstruction prevents the rake/gripper from descending to the invert elevation, a "Slack Rope" limit switch shall cease the lowering motion. The rake/gripper may then be closed, raised and the debris taken to the dump area.

b. If a large quantity of debris or other obstruction is too heavy for the rake/gripper to remove, the motor overload shall "trip-out" and render the system inoperable until manually reset.

c. Limit switch(es) shall be fitted to the end(s) of the track to prevent inadvertent over travel.

2.4.15 Equipment Guards

The trolley shall be enclosed on four sides by a guard enclosure. The trolley enclosure shall include access doors which shall only be opened with the machine disabled to allow maintenance. The trolley and rake/gripper shall operate on an overhead monorail and cannot be guarded during operating from below therefore extreme caution shall be utilized during operation.

2.4.16 Finishes

Stainless Steel components shall be provided with an ASTM A240/A240M or ASTM A276 finish. Galvanized components shall be provided with an ASTM A123/A123M or ASTM A153/A153M finish, whichever is applicable.

2.4.17 Spare Parts

Provide the following:

a. Hydraulic Oil (Biodegradable for Environmental Concerns) 20 Liters

b. Oil Filter 1 Each

c. Swivel Couplings 2 Each

d. Side Wheel 4 Each

e. Hydraulic Hoses Rake/Gripper 1 Set

f. Hydraulic Hoses to Reel 1 Set

2.5 Electrical Equipment and Components

2.5.1 Wiring and Cables

All conductors shall be cooper. Provide wires and cables in accordance applicable requirements of NFPA 70 and UL for type of insulation, jacket, and conductor specified or indicated. Do not use wires and cables manufactured more than 12 months prior to date of delivery to site. Conductors No. 8 AWG and larger diameter shall be stranded.

Conductors No. 10 AWG and smaller diameter shall be solid. Minimum size conductors shall be No. 12 AWG. Provide power wires rated for 600-volts, Type THWN/THHN conforming to UL 83, except that grounding wire may be type TW conforming to UL 83;

remote-control and signal circuits: Type TW or TF, conforming to UL 83

2.5.2 Conduit and fittings

Rigid metallic conduit shall comply with UL 6. Use threaded fittings for rigid steel conduit. Split couplings are unacceptable. Use solid gaskets. Ensure conduit fittings with blank covers have gaskets, except in clean, dry areas or at the lowest point of a conduit run where drainage is required. Provide covers with captive screws that are accessible after the work has been completed. Plastic-Coated Rigid Steel and IMC Conduit shall be NEMA RN 1, Type 40, ETL PVC-001, ANSI C80.1, UL 6. Sealing Locknut - A “PVC Coated Sealing Locknut” shall be used on all exposed male threads transitioning into female NPT threads which do not have sealing sleeves, including transitions from PVC Couplings/Female Adapters to PVC coated GRC elbows in direct burial applications, “PVC Coated Sealing Locknuts” are not to be used in place of a conduit hub. Fittings for Plastic-Coated Rigid Steel Conduit shall conform to UL 514B. Fittings shall be Form 8 with a V-Seal tongue-in-groove gasket and supplied with plastic encapsulated stainless steel cover screws. Form 8 fittings shall be UL Type 4X listed and IEC IP69 certified.

Fittings shall be from the same manufacturer as the conduit in order to maintain system continuity and warranty. Rigid nonmetallic conduit shall comply with NEMA TC 2, NEMA TC 3, and UL 651 with a wall thickness not less than Schedule 40.

2.5.3 Safety Switches

Ensure safety switches comply with NEMA KS 1, and are the heavy-duty type. Ensure fused switch fuse holders comply with UL 4248-1. Ensure switch construction is such that, when the switch handle in the "ON" position, the cover or door cannot be opened.

Cover release device shall be constructed that an external tool is used to open the cover.

Make provisions to lock the handle in the "OFF" position. Ensure the switch is not capable of being locked in the "ON" position. Provide switches of the quick-make, quick-break type and terminal lugs for use with copper conductors. Ensure safety color coding for identification of safety switches conforms to ANSI Z535.1

2.5.4 Circuit Breakers

Provide circuit breakers that conform to UL 489 and NEMA AB 3. Provide bolt-on type, molded-case, manually operated, trip-free circuit breakers, with inverse-time thermal-overload protection and instantaneous magnetic short-circuit protection. Completely enclose circuit breakers in a molded case, with a factory-sealed, calibrated sensing element to prevent tampering. Plug-in type, tandem, and half-size circuit breakers are not permitted. Provide sufficient interrupting capacity of the panel branch circuit breakers to successfully interrupt the maximum short-circuit current imposed on the circuit at the breaker terminals. Provide circuit breaker interrupting capacities as determined by the short circuit calculations and that conform to NEMA AB 3.

2.5.5 Junction Boxes and Pull Boxes

Ensure outlet boxes for use with conduit systems are in accordance with NEMA FB 1, UL 514A, UL 514B, UL 514C and are not less than 1-1/2 inches deep. Furnish all pull and junction boxes with screw-fastened covers.

2.5.6 Air Terminal

Provide solid air terminals with a blunt tip. Tubular air terminals are not permitted.

Support air terminals more than 24 inches in length by suitable brace, supported at not less than one-half the height of the terminal.

2.5.7 Ground Rods

Provide ground rods made of copper-clad steel conforming to conform to UL 467.

Provide ground rods that are not less than ¾” in diameter and 10’ in length.

2.5.8 Connections and Terminations

Provide connectors for splicing conductors that conform to UL 96, class as applicable.

Conductor connections can be made by clamps or welds (including exothermic). Provide style and size connectors required for the installation.

2.5.9 Main and Bonding Conductors

Main and bonding conductors shall comply with NFPA 780 and UL 96 Class I, Class II, or Class II modified materials as applicable.

3. Execution

3.1. Installation

3.1.1 Install monorail support structure including foundations.

3.1.2 Install concrete slab, guardrail and vehicle stops.

3.1.3 Install equipment in accordance with manufacturer’s installation instructions.

3.1.4 Obtain the services of factory-trained personnel to supervise installation, adjustment, field testing and initial operation of components.

3.1.5 Electrical installations, including weatherproof and hazardous locations shall conform to requirements of NFPA 70 and IEEE C2 and to requirements specified herein.

3.2. Wiring Methods

Provide insulated conductors installed in conduit except where specifically indicated or specified otherwise or required by NFPA 70 to be installed otherwise. Grounding conductor:

separate from electrical system neutral conductor. Provide insulated green equipment grounding conductor for circuit(s) installed in conduit and raceways. Minimum conduit size shall be 1/2 inch in diameter for low voltage power circuits. Firestop conduit which penetrates fire-rated walls, fire-rated partitions, or fire-rated floors.

3.3. Conduit and Duct

For underground installation use PVC, Type EPC-40. Depths to top of the conduit must be not less than 24 inches below finished grade. Provide not less than 0.3 inches clearance from the conduit to each side of the trench. Grade bottom of trench smooth; where rock, soft spots, or sharp-edged materials are encountered, excavate the bottom for an additional 3 inches, fill and tamp level with original bottom with sand or earth free from particles, that would be retained on a 1/4 inch sieve. The first 6 inch layer of backfill cover must be sand compacted as previously specified. The rest of the excavation must be backfilled and compacted in 3 to 6 inch layers. Provide color, type and depth of warning tape. Plastic-Coated Rigid Steel installers shall be certified by the manufacturer and be able to present a valid, unexpired installer certification card prior to installation beginning. Repair damage to PVC coatings with manufacturer supplied touchup compound or PVC Coating Repair Kit for PVC Coated Raceway Systems.

3.4. Grounding and Bonding

Provide in accordance with NFPA 70 and NFPA 780. Ground exposed, non-current-carrying metallic parts of electrical equipment, metallic raceway systems, grounding conductor in metallic and nonmetallic raceways and neutral conductor of wiring systems.

3.5. Operator Training

3.5.1. Provide one 8-hour training session for the members of the operating staff as designated by the Contracting Officer. The training session shall occur after all work is functionally complete and all operational tests have been approved. The proposed on-site training schedule shall be submitted concurrently with the operation and maintenance manuals and at least 2 weeks prior to conducting the training session. The training session shall include preventive maintenance requirements, overhaul and troubleshooting instructions, and normal operating practices. The training session shall be recorded, and 3 copies of the recording shall be provided on DVD.

3.5.2. Provide 3 copies each of the operation and maintenance manuals, at least 2 weeks prior to operator training.

3.6. Testing

3.6.1. Electrical Visual Inspection

Perform visual inspection as listed below:

a. Visual Inspection: Inspect exposed cable sections for physical damage.

b. Verify that cable is supplied and connected in accordance with contract plans and specifications.

c. Verify tightness of accessible bolted electrical connections.

d. Inspect compression-applied connectors for correct cable match and indentation.

e. Visually inspect jacket and insulation condition.

f. Inspect for proper phase identification and arrangement.

3.6.2. Electrical Field Quality Control

a. Electrical Tests: Test wiring rated 600 volt and less to verify that no short circuits or accidental grounds exist. Perform insulation resistance tests on wiring No. 6 AWG and larger diameter using instrument which applies voltage of approximately 1000 volts dc for one minute. Perform continuity tests to insure correct cable connection.

b. Test the lightning protection and grounding system to ensure continuity is not in excess of 1 ohm and that resistance to ground is not in excess of 25 ohms. Provide documentation for the measured values at each test point. Test the ground rod for resistance to ground before making connections to the rod. Tie the grounding system together and test for resistance to ground. Make resistance measurements in dry weather, not earlier than 48 hours after rainfall. Include in the written report: locations of test points, measured values for continuity and ground resistances, and soil conditions at the time that measurements were made. Submit results of each test to the Contracting Officer.

3.6.3. General

a. The following operational tests shall be performed in the sequence specified. Tests shall be conducted with the raking machine supplier’s Field Representative present.

b. Test 1: Test the traversing length of the trolley by manual operation to verify that the trolley shall reach the farthest bar screen at the side opposite the trolley parking position. The trolley shall then be traversed to the respective parking position where traversing further in that direction shall be prevented.

c. Test 2: Park the trolley at the respective dumpsite and lower the trolley to the ground elevation to verify that the lowering operating shall cease upon the trolley resting on the ground and providing a slack rope situation. The rake/gripper shall then be raised to its fullest height to verify the hoist shall stop upward motion upon rising to the proper height.

d. Test 3: Test the opening and closing capabilities of the rake/gripper and verify it shall fully open and close as required.