Div_14 _Sec_14_24_00.pdf

CONSTRUCT VARIABLE HEIGHT TOWER C-86 FTFA 13-3005

EGLIN AFB 13BK

Section 14 24 00 Page 1

SECTION 14 24 00

CORD AND PINION LIFT SYSTEM

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

Safety, Color Coding and Identification Standards

ANSI B31.1 Power Piping Code

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M

(2010; Errata 2011) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME A17.1/CSA B44 Safety Code for Elevators and Escalators

Boiler and Pressure Vessel Code 2013 Edition; Section I: Piping Working Stresses, Wall Thicknesses, and Pressure Vessels; Section II: Ferrous Metals; Section VIII; Flanges and Heat Treatment; Section IX: Welding WPS’ and PQR’s

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC

(2012) International Building Code

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70

(2014) National Electrical Code

NFPA 79

Electrical Code for Industrial Machinery

NFPA 101

(2012) Life Safety Code

1.2 SUMMARY

Provide a Cord and Pinion Lift System, complete, as designed and manufactured by Bosch Rexroth Industrial Hydraulics, 2315 City Line Rd, Bethlehem, Pa. 18017, (610)694-8424, or approved equivalent by companies regularly engaged in the manufacture of custom lift systems, that complies with requirements specified herein.

Section 14 24 00 Page 2

1.2.1 Miscellaneous Requirements

A. HYDRAULIC DRIVE SYSTEMS

An electro-hydraulic pinion/rack and drive system will be provided to enable the vertical operation of the laboratory. Hydraulic Drive Systems shall be by Bosch Rexroth Hydraulics, or approved equivalent.

B. ELECTRONIC CONTROL SYSTEM

Maximum ascent and decent speeds will be infinitely variable from two (2) to eighteen (18) ft/min with up to twenty (20) programmable stopping locations along the one hundred feet (100) of maximum travel or lift, aligning the laboratory floor with the adjacent egress-stair landings. The electro hydraulic drive-control will be managed with a programmable-logic-controller and co-safety supervisory processor which will also provide four corner synchronization capabilities. During ascent/descent at maximum speeds, the controller must provide the actual laboratory leveling tolerances, to be within .125” from side to side and front to back.

Programmable stopping accuracies per the aforementioned stopping locations shall be within the same .125” tolerance. The system shall have three layers of safety supervisory controls, those being direct mechanical to the rack, continuous active hydraulic counter balance, and supervisory hydraulic locking all corporately-integrated to insure no unintended motion. All acceleration and decelerations to and from the programmed ascent and descent speeds shall be selectable at a main control console located within the laboratory.

In addition to all pertinent drive and control parameters being selectable, provide a fault diagnostic system that will aid in troubleshooting and repair in the eventuality of a system malfunction or failure. Due to the fact that there will be people in the laboratory during movement, the Lift System Manufacturer shall provide a Failure Mode Effect Analysis (FMEA) to identify and verify failure modes and their risk to operating personnel including subsequent Lift System design changes to mitigate the effects of the findings. The FMEA will reference ASME A17.1. The responsibilities for the electronic control system integrity and the operation of the drive system will rest solely with the Lift System supplier.

C. PIPING

Piping between the hydraulic reservoir and all drive motors will be as outlined in this Specification and referenced documents.

D. HYDRAULIC VALVING

All hydraulic valving will be manifold mounted on manifold blocks with material being steel per applicable ASME codes or proven hydraulic practice for operating pressures to 3000 PSI.

E. OIL/AIR COOLING SYSTEMS

Oil / air cooling systems will be provided to insure that the maximum oil temperature of the hydraulic fluid does not exceed 140 degrees Fahrenheit.

F. ELECTRICAL WIRING, SUPPLY AND INSTALLATION

Section 14 24 00 Page 3

Electrical wiring, supply and installation, will be the responsibility of the lift system supplier with the engineering and drawings to be approved by Eglin AFB Contracting Officer’s Representative.

G. DOCUMENTATION

Documentation will be provided to cover all of the design theory, application, and execution of the system design. This will include commented PLC source code and code used in the MLC controller.

H. CUSTOM HYDRAULIC, ELECTRONIC, SOFTWARE, and SYSTEM MAINTENANCE

TRAINING

Custom Hydraulic, Electronic, Software, and System maintenance training shall be conducted by the Lift System Supplier at the project site at the completion of the commissioning and turnover of the complete system. Training will be project and application specific. It is expected that all personnel to be trained are proficient in the basics of Drive and Control theories.

1.3 INSTALLATION AND COMMISSIONING AND REQUIRED ACCEPTANCE TESTING

Installation and, Commissioning and Required Acceptance Testing:

The Lift System Supplier will provide all required supervision required to proceed in a professional and most effective manner with the installation of the hydraulic, electrical and electronics. The General Contractor may, at its own discretion, elect to have the Lift System Supplier do any part of or all of the hydraulic equipment installation with particular concerns in the hydraulic piping installation.

The Lift System Supplier will provide the initial data to facilitate the development of a binding acceptance test that will serve as the task definition and ultimate goal for the Start up, commissioning and ultimate turnover of the completed system.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings;

G

SD-03 Product Data

Cord and Pinion Lift System;

SD-05 Design Data

Reaction Loads;

Failure Mode Effect Analysis; G

SD-06 Test Reports

Field Tests Reports

Section 14 24 00 Page 4

SD-07 Certificates

Welders' Qualifications; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G Maintenance and Diagnostic Tools; G Maintenance and Diagnostic Software Maintenance and Repair Action Plan; G Operation and Maintenance Training; G

1.5 QUALITY ASSURANCE

1.5.1 Lift System Specialist

Perform work specified in this section under the direct guidance of the Lift System Specialist who is regularly engaged in the installation and maintenance of the type and complexity of Lift System specified in the contract documents, and who served in a similar capacity for at least three systems that have performed in the manner intended for a period of not less than 24 months. Provide endorsement letter from the Lift System manufacturer certifying that the Lift System Specialist is acceptable to manufacturer. The Lift System Specialist will oversee the acceptance inspections and tests, and signs and certifies the successful results.

Provide the Lift System Specialist's written certification that the installation is in accordance with the contract requirements, after completion of the acceptance inspections and tests. Bring any discrepancy to the attention of the Contracting Officer in writing, no later than three working days after the discrepancy is discovered.

1.5.2 Welders' Qualifications

Comply with AWS D1.1/D1.1M, Section 4 Qualification. Provide certified copies of welders' qualifications. List welders' names with corresponding code marks to identify each welder's work. Submit a letter, no later than 14 days after the Notice to Proceed, providing the name and Statement of Qualifications, including ASME A17.1/CSA B44 Certificate and all required state and local licenses of the individual who will perform the duties specified herein for the Lift System Inspector. A letter of endorsement from the Lift System manufacturer certifying that the Lift System inspector is acceptable to manufacturer, no later than 14 days after the Notice to Proceed, providing the name and Statement of Qualifications of the individual who will perform the duties specified herein for the Lift System Specialist. Copies of certified welders' qualifications, demonstrating compliance with AWS D1.1/D1.1M

, Section 4; list welders' names with corresponding code marks.

1.5.3 Detail Drawings

Submit detail drawings, including dimensioned layouts in plan and elevation showing the arrangement of Lift System equipment, accessories, supporting systems, anchorage of equipment, clearances for maintenance and operation;

and details on frames, operation and signal stations, controllers, motors, guide rails and brackets, and points of interface with normal power, fire alarm system, HVAC or exhaust systems and interface with emergency power

Section 14 24 00 Page 5 systems. Provide drawings to show any revised building electrical system required to make the supplied Lift System function as specified. Prepare drawings with complete wiring diagrams showing electrical connections and other details required to demonstrate sequence of operations and functions of system devices. Include the appropriate sizing of electrical protective devices on the drawings, which are frequently different from National Electrical Code standard sizes.

1.6 WARRANTY

Provide routine warranty service in accord with manufacturer's warranty requirements, for a period of 12 months after the date of acceptance by Contracting Officer. During the warranty service period, include 24-hour emergency service, with 1 hour response time, without additional cost to the Government. Include adjustments, greasing, oiling, and cleaning. Provide routine inspection and tests of the Lift System in accordance with ASME A17.1/CSA B44 Section 8.11.3 and ASME A17.2

. Provide supplies and parts to keep the Lift System in operation. Perform service only by factory trained personnel. Maintain a maintenance log of all service orders performed during the warranty period and submit it to the Contracting Officer 21 days prior to the end of the warranty period.

1.7 MAINTENANCE AND REPAIR ACTION PLAN

Provide plan of action prepared by the Lift System Specialist for emergency and routine maintenance in accordance with paragraph titled WARRANTY.

Provide a list of phone numbers, personnel contacts, and all maintenance and diagnostic tools provided by paragraph "Maintenance and Diagnostic Tools", to the Contracting Officer.

1.7.1 Maintenance and Diagnostic Tools

Provide all special tools and software necessary to service and maintain the Lift System, delivered at time of final acceptance. Provide one of each tool needed. Include solid state or microprocessor diagnostic tools unavailable on the open market. Provide necessary diagnostic software in cases where the solid state or microprocessor diagnostic tools are available on the open market

PART 2 PRODUCTS

2.1 CORD AND PINION LIFT SYSTEM

2.1.1 Basic Requirements

Supplier will accept the contractual obligations for the design and function of this system which will be in accordance with NFPA 101 Life Safety Code, and the following requirements. These shall be considered minimal and are not intended to restrict or limit the use of the innovations that the Lift System supplier has currently available.

2.1.2 Intended Use

2.1.3 Functional Principle:

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2.2 Valving System

2.3 Filtration and Cooling System

2.4 Main Reservoir

Reservoir will be stainless steel, rectangular design with required accessories for maintaining proper monitoring of the hydraulic fluid.

2.5 Motor Control Center

2.6 Electronic System

The Electronic Control System will be supplied in accordance with the following:

2.6.1 Main Control Cabinet

2.7 Design

2.7.1 General Design Criteria

The design and manufacture of the specified equipment shall comply with recognized safety requirements as well as high standards of material and workmanship associated with heavy-duty, precision, industrial equipment. All components shall be constructed for long life under continuous service. The overall design of the equipment shall place emphasis on the accessibility, maintainability and reliability of components. Replacement and/or adjustment of components shall be possible without a major disassembly when at all possible.

2.7.2 Performance

Performance, reliability, long-service life, and low operating costs will be the prime considerations for determining the hydraulic system design.

2.7.3 Filters and Filter Elements

Filters shall be installed in the system to protect the components within the system.

All filters shall be of the absolute rated element type, designed for full flow through clean elements with a pressure drop not to exceed 12 PSI or better than common acceptable industry standards.

All filters shall be equipped with an electrical clogging indicator.

Presently, as designed, Filter changing will require a system shutdown. The filter configuration shall be such that contamination of the downstream line does not occur when changing a filter element.

All filters shall be of the same size and type, where feasible.

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2.7.4 Valves

Each main pump in the system shall be fitted with an adjustable pressure relief valve. All pressure gauges and other items of a like nature shall have shut-off valves incorporated in their lines.

Hydraulic Fluid sampling valves shall be located on the reservoir (s), each high pressure pump and the high pressure header.

2.7.5 Hydraulic Fluid

Specifications for the hydraulic fluid shall be provided by the Lift System supplier to the Contracting Officer’s Representative for review prior to the equipment selection.

2.7.5.1 Hydraulic Fluid Cleanliness

The Hydraulic system shall be capable of maintaining the following oil cleanliness:

Main Reservoir: ISO 4406/Cetop RP70H - 16/15 or NAS 1638 (1964) - 6 Pilot Reservoir and Manipulators: ISO 4406/Cetop RP70H - 13/10 or NAS 1638 (1964) – 4

2.7.6 Guards

All mechanical drives (gears, belts, splined shafts, couplings) shall be guarded per OSHA standards.

2.7.7 Covers

Protective covers shall be provided to eliminate the entry of foreign matter into the moving parts of any components.

2.7.8 Safety

The equipment and all necessary accessories shall comply with applicable OSHA and ANSI safety standards, NFPA 101 Life Safety Codes and with requirements contained in applicable national consensus safety standards. Avoidance of hazardous conditions and failure modes shall be the primary design priority for safety. Where hazards cannot be precluded by design, the equipment shall be provided with necessary safety devices and guards to protect personnel.

In addition to mechanical and electrical safeguards, the location and functioning of controls shall incorporate human engineering considerations to provide maximum protection against injury caused by operator error while using the Operator’s Devices. PLC and imbedded microprocessor failure analysis must be addressed at all levels of this equipment and its impact on the plant, equipment, and the manufactured surrounding operational environment.

2.7.9 Piping, Tubing and Hose

All piping, tubing and hose required to connect, control, filter and operate the hydraulic system described in this Specification shall be supplied by the Lift System supplier. All supports, pipe hangers, tubing supports, etc., shall be supplied by the Lift System supplier. The hydraulic plumbing shall be designed and located for maximum efficiency and neatness.

Section 14 24 00 Page 8

Pipe threaded fittings or connections are unacceptable without prior approval from the Contracting Officer’s Representative. The use of SAE type fittings, clamp type, integral flange mounted fittings, or mechanical connections are required.

All “in line” hydraulic components subject to wear or failure shall have joints which permit the parts to be easily removed and replaced. All such joints in high pressure lines shall be bolted flanges

The inside of all welded and stress relived pipe and fittings shall be cleaned and weld scale removed by an appropriate method and coated with hydraulic oil compatible rust preventative. The use of metal caps to maintain cleanliness after cleaning and prior to shipment is mandatory.

2.8 Laboratory

2.8.1 Building: approximate size 13’x31’x10’.

2.8.1 Weight: Not to exceed 65 US Tons.

2.8.2 Speed of Lift: 18 feet per minute.

PART 3 EXECUTION

3.1 INSTALLATION

The Lift System supplier shall verify all controlling dimensions and authenticate all piping manifolds, etc..

3.1.1 Electrical Equipment

3.1.1.1 Electrical Codes

Electrical equipment and its installation will comply with the NEMA standards.

3.1.2 Control System Voltage

The equipment shall operate from one basic power source utilizing 480VAC, three phase, 60 Hz power. The main power disconnecting device (fused disconnect or breaker) NEMA 12 enclosure, shall be supplied. All other power supplies shall be derived from this basic power disconnecting source.

Disconnecting device shall be lockable in OFF position for maintenance.

3.1.3 Control System

Control circuits shall be 24VDC with the only exceptions being the Oil/Air cooling motor starting circuits. (120 VAC)

3.1.4 Wire Termination

All interconnecting wires and cables between stationary terminal points and control cabinets shall be enclosed in oil tight sheet metal troughs with hinged or detachable covers or in conduit. All wire terminations shall be identified as shown on the wiring diagrams.

Section 14 24 00 Page 9

3.1.5 Conduit Connection

All control and power conduit connections shall use liquid tight flexible conduit.

3.1.6 Cabinet Door Interlocks

Any door(s) which permits access without use of tools to live parts (main power supply, magnetic contactors, control circuit, etc.) operating at 120 volts or more shall be so interlocked that door(s) cannot be opened unless all power is disconnected.

3.1.7 Cabinet Door Interlock Override

Provisions shall be provided for interlock override to provide a means for qualified persons to gain access without removing power. The interlocking shall be reactivated automatically when door(s) is/are closed.

3.1.8 Grounds

No electrical equipment shall use ground returns in lieu of power wiring.

3.1.9 Color Coding

Control wiring shall be color coded per NFPA 79 / NEC 2008.

3.1.10 Wire Terminals

All wire terminations, terminals, panel mounted components and line mounted components shall be identified in a durable permanent manner with the same names or codes used on wiring diagrams. Component identification shall be located on the chassis or other appropriate location such that replacement of the components does not cause loss of the identification means.

3.2 Construction Requirements

Regarding additional facility requirements, the Lift Supplier will not be responsible for the following:

Incoming power to Motor Control Center - primary and secondary wiring.

Interconnecting wiring and other site electrical work.

3.3 Workmanship

The equipment, including all parts and accessories, shall be constructed in a thoroughly workmanlike manner and to the best industry practices. No damage or defect shall be present that could make any part, accessory, or the equipment unsatisfactory for the operation or function intended

3.4 Interchangeability

All replaceable parts shall be manufactured to definite standards for tolerance, clearance and finish so that any such part may be field installed without modification. All parts shall be permanently and legibly marked with BOSCH REXROTH part number, where practical. The parts not marked shall be easily recognized on the parts list.

3.5 Painting

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All surfaces of the equipment requiring painting to resist rusting or corrosion shall be painted as follows per Eglin requirements:

5.1 Control Consoles and Electrical Cabinets

Both the master Control panel and remote control panel shall be primed one or more coats and then painted two coats of (to be Specified) paint.

3.5.2 Preparation

All surfaces requiring painting shall be properly prepared to ensure a durable, well bonded paint coating.

3.5.3 Previously Painted Components

Equipment which is supplied already painted will be repainted with the colors matching Eglin Base Standards if required.

3.5.4 Surfaces Not Painted

Surfaces of cables, hoses, instrumentation faces, etc. And non-corrosive materials, such as plastics, stainless steel, and aluminum shall not be painted unless specifically instructed by a document from the Contracting Officer’s Representative.

3.6 Documentation Offering

3.6.1 Required Data

The Lift System Supplier shall furnish the specified number of complete electronic copies of applicable drawings and data which are listed below in advance of delivery to meet established schedules. If any submitted data is changed prior to final shipment of the component or supply, revised drawings and/or documents shall be furnished. (Drawings shall be 24" x 36".) All manuals, drawings and other documentation developed under this specification shall remain the property of the Lift System Supplier.

3.6.2 Drawings

Three copies of preliminary lift system manufacturing drawings shall be submitted for approval 4 weeks after receipt of Purchase Order and prior to the construction of equipment. Approval by the Contracting Officer’s Representative shall be for concept, configuration, and maintainability only, and does not relieve The Lift System Supplier of any obligations as far as performance is concerned.

Power requirements for the specified system and all utilities required to allow the system to function, per requirements specified, shall be supplied with the preliminary drawings.

3.6.3 Maintenance Manuals

Manuals will include complete maintenance and operating instructions, including recommended preventive maintenance, suggested spare parts list and a complete list of all parts. The maintenance manuals will be separate and complete from other data and shall include the following:

a. Detailed instructions to service every component and assembly of the equipment.

Section 14 24 00 Page 11

b. Fault isolation information such as test point data to supplement wiring diagrams and schematics.

c. A description of the function operation necessary to provide back-up information for fault isolation.

d. A list of the special tools and test equipment needed for adequate maintenance of the equipment.

e. Theory of operation for each functional manifold in the system.

f. Complete schematic, logic, block and functional diagrams.

g. Circuit module descriptions and card drawings with part identification.

h. User's information, flow charts and timing diagrams.

i. Performance specifications and Bosch Rexroth procedures.

j. Electrical wiring schematics and diagrams.

k. Structural drawings, including foundation plan and footprint.

l. Hydraulic piping schematics drawings.

m. Manifold Assembly drawings.

3.6.4 ASME Test Data

ASME test data and certification for vessel(s) if applicable.

3.6.5 Maintenance Schedules

The recommended preventive maintenance schedule, including frequency, normal time to accomplish, detailed step-by-step procedure, parametric data to establish component replacement control according to the Lift System Supplier’s schedules.

3.6.6 Parts Listings

Parts listing all components by manufacturer’s part number, description, and model code.

3.6.7 Manufacturer’s Specifications

The original equipment alignment and clearances with tolerances, shall be provided so that the manufacturer's specifications can be met at a future date. This is to help determine whether or not replacement parts should be obtained from the factory.

3.6.8 Component Drawings

Exploded view or cross-sectional type drawings showing all mechanical components in their relative positions and identified by part number referenced to the applicable section of the parts book.

3.6.9 Test Program

The Lift System Supplier shall furnish a complete set of test programs and/or setup procedures for the equipment. The set shall include a program for the operators or maintenance personnel to use for exercising the equipment during start-up and programs to be used by maintenance to identify the location of malfunctions and the adjustment of the controls.

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3.6.10 Final Documentation

All drawings and documentation shall depict final "as built" configuration or design at time of turnover of project.

3.6.10.1 Software Documentation and Design

Software documentation will be provided per the following:

a. Programmable Logic Controllers:

All PLC software will be fully commented and cross referenced.

b. MLC-H Axis Controllers:

Complete Pseudo Code listings of all software.

The analysis of failure modes of the respective digital equipment must be provided in the software.

c. At the time determined by The Lift System Supplier to cease supporting the software provided in this system, ALL commented source code will be released at no additional charge to the government.

3.6.11 Recommended Spare Parts

Prior to the shipment of the System, the supplier shall provide a recommended spare parts list per the following:

The recommended spare parts shall be individually priced.

The list of recommended spare parts shall be limited to those which are believed to be most likely to fail and would not normally be found in a well equipped maintenance shop.

The list of recommended spare parts shall be limited to lowest replaceable unit, ex. electric motor - not wire required to rewind the armature of the motor.

The list of recommended spare parts shall include those parts which the lead time for replacement would make it economically wise to have in stock at the project location.

3.7 Design Reviews

Design reviews, both preliminary and critical, shall be conducted to evaluate design progress in respect to the equipment requirements. The Contracting Officer’s Representative shall be notified ten (10) working days in advance so that the required representatives may attend the review. Minutes will be kept by Supplier and distributed to attendees within five (5) working days.

The design review shall be conducted prior to release of installation or assembly drawings for fabrication. Any review discrepancy must be resolved prior to start of construction. Items that will be considered during design reviews are:

a. Detailed design drawings and schematics.

b. System and circuit (block and functional) diagram.

c. Functional Description (Section 4.0)

d. Test plans and proposed testing procedures.

e. Results of design development analysis.

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f. Plan and elevation of machine and isolated components with principal dimensions.

g. Drawings showing foundation or pits required and installation drawings showing anchor bolt locations, leveling requirements, location and sizes of all services required.

The government’s participation in review of Lift System designs during design review or otherwise does not relieve Supplier of any of their responsibility to fulfill all requirements of the Purchase Order.

3.7 Progress Reports

A progress report shall be submitted regularly as specified in the Purchase Order from time of a contract award until delivery of the system. This shall be a single report covering status reports of the individual sub-systems.

Emphasis should be placed on early identification of potential problems affecting schedule or design rather than routine reporting. Reporting shall consist of the use of the following techniques:

a. Major Milestone Chart.

b. Narrative Report where required with supporting Gantt charts.

3.8 Bid Presentation

The final package will include presentations, descriptive literature, drawings and specifications where required to make a complete evaluation and/or appraisal of the quotation with respect to government requirements.

The Lift System Supplier will indicate the contract performance time required. Scaled plan (top), front and limited elevations showing the approximate overall dimensions shall be provided.

A list of total utilities required, listing electrical, air and fuel quantities.

3.9

3.9.1 Waiver of Requirement

3.9.2 Lift System Supplier Requirement

The Lift System Supplier shall provide all the necessary hardware, labor, and documentation to perform the acceptance test outlined in the specification.

Prior to the shipment of electronics the system will undergo a preliminary acceptance test by government personnel at the Lift System Supplier’s facility to determine (where economically possible) adherence to the previously defined specifications.

3.10 Equipment Installation

All piping between the hydraulic drive and leveling compensation actuators must be prefabricated to the maximum extent possible in Supplier’s facility and in this case, piping shall not be installed until properly cleaned to prevent hydraulic system contamination. A visual inspection of each pipe shall be made before it is installed to ensure absence of rust, corrosion, slag, contamination on interior surfaces, or other conditions thought to be harmful to the integrity of the installation.

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3.10.1 Electrical Power

Electric power is available for lighting, welding, flushing and testing at the project site.

3.10.2 Installation Completion

Lift System Supplier shall be responsible for the Supervision of the complete installation of the hydraulic system, interconnecting piping and wiring to utilities. This includes connection from electrical MCC to the hydraulic system and all control electrical wiring. On commencement of the commissioning and acceptance tests the hydraulic and control system must be complete and fully capable to operate as outlined in this specification.

3.10.3 Piping Runs

All hydraulic piping runs shall take precedence over other piping runs and electrical conduit runs.

All piping runs shall be as straight as possible. With consideration given to stresses due to vibration and expansion due to environmental and hydraulic fluid temperature changes.

The maximum distance for High pressure pipe clamps used in this application will be 48 inches maximum. Pilot and low pressure lines will be 6 to 8 feet.

Pipe clamps must be fastened directly to the steel structure by Supplier.

Standoffs will not be used unless approved, in writing, by the Contracting Officer’s representative.

3.10.4 Conduit Runs

All electrical conduit runs to Hydraulic Drive systems and to the various interlocking devices located on the pump and reservoir shall be mounted directly on the Drive System within the weatherproof enclosure.

3.10.5 Electrical Installation

All electrical installation shall be done in accordance with the National Electrical Code (NEC 2008).

3.10.6 Construction/Installation Schedules

Acceptable construction installation schedules shall be negotiated at the time of purchase and preliminary dates shall appear in the final contract.

3.10.7 Painting

All parts of the hydraulic system shall either be painted or have a finish which will protect it from corrosion and be compatible with recommended hydraulic oil.

All Piping Supply shall be painted as follows:

a. High Pressure Supply: Orange

b. Suction and Return Lines: Dark Green

c. Pilot System: Yellow

3.10.8 System Flushing (If required)

Before the start of the commissioning, the Lift System Supplier shall clean the entire system. This cleaning operation shall consist of internal

Section 14 24 00 Page 15 flushing of the completed hydraulic system of all contaminates. If hydraulic fluid is not used for the major part of this cleaning operation, it will be used in the final flushing operation. In this flushing operation, the hydraulic fluid shall be circulated and filtered at design maximum pipe velocities until the oil samples from all sampling valves meet the cleanliness specified in Section 5.8. Flushing company shall dispose of all flushing fluid and that fluid which is considered contaminated. New filter elements will be installed in all filters after the flushing operations have been completed.

3.10.9 Proof Pressure Tests

A proof pressure test shall be conducted on all hydraulic fluid systems to verify the system is leak proof. The proof test values are to be at maximum operating pressure in the piping systems.

Proof pressure test shall be maintained for ten (10) minutes. There shall not be any deformation or damage after the proof pressure is completed.

The hydraulic system piping shall not leak when subjected to proof pressure test.

3.10.10 Installation Site Conditions

Extremely cold Installation site conditions will affect the efficiency of the installation. This will require the Lift System Supplier to carefully control and monitor material handling, and storage, installation activity to preclude any type of equipment damage. Additional costs will not be borne by the government.

3.11 Inspections

Prior to the start of the acceptance tests, the completed hydraulic system installation shall be inspected by a team composed of EOR (Engineer of Record), Lift System Supplier and government personnel. This joint EOR, Supplier, government team will inspect the entire hydraulic system to ensure compliance with specifications. It will also investigate and resolve any possible areas of conflict concerning the setup and installation of the system. Any deviation from the specifications must be submitted in the form of a written request from the Lift System Supplier to the Contracting Officer. At the conclusion of these joint inspections, the Contracting Officer shall give written approval of the installation to Supplier and permission to proceed with the commissioning and acceptance tests.

3.11.1 Lift System Manufacturer’s Representative

The manufacturer will designate a single individual who shall be responsible for the functions associated with design, fabrication, installation, checkouts, etc. The individual shall act as a focal point to ensure continuity of these functions and smooth transition into commissioning and acceptance testing.

3.11.2 Test Equipment

The Lift System Manufacturer must furnish all items (material, instrumentation, etc.) required to checkout the equipment required in this specification unless prior notification is given to and acceptance received from the Contracting Officer. The burden of proving the system performance to the government is on the Lift System Supplier.

3.11.3 Notification of Test Preparedness

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Before the government is called to witness acceptance tests, the Lift System Supplier shall certify in writing to that all of the specified equipment has been checked and found to satisfy all requirements of the specification.

The Contracting Officer shall receive notice two weeks prior to start of final acceptance tests so that arrangements can be made for government personnel to schedule for and witness the tests.

The purpose of the inspection is to ensure compliance with the specification by the Lift System Supplier and not to help or oversee erection or corrective measures being taken.

The Lift System Supplier shall deliver to the Contracting Officer’s Representative, not less than 30 days prior to final inspection, an acceptance test document based on a previously agreed upon format. This document shall completely define all tests, materials required, test procedures and test equipment to be used. Government approval of this document is required prior to scheduling final acceptance testing.

3.12 Acceptance Test

3.12.1 Acceptance Criteria

The Lift System equipment shall meet or exceed all performance and design parameters and requirements as delineated in this procurement specification, and referenced documents.

3.12.2 Acceptance Test Methods

The Lift System Supplier shall submit, as part of their proposal, a written description of acceptance test methods which will be employed in determining compliance with this specification. The acceptance test procedure shall be approved by the Contracting Officer prior to beginning of acceptance testing.

3.12.3 Acceptance

Final acceptance will be given by the Contracting Officer after all requirements of this specification have been met. Acceptance will be based on compliance with the specification and satisfactory testing in conformance to this specification as proven by acceptance test results approved by the Contracting Officer. Lift System Supplier-conducted acceptance testing shall be witnessed by the Lift System Manufacturer’s Representative.

3.12.4 Rejection

Should a situation of non-acceptance arise, The Lift System Supplier shall make the necessary corrections or modifications to make the component or the entire system meet this specification as quoted, with no additional cost to the government.

If the Lift System Supplier fails to meet any of the specification requirements as defined in this specification, the system will not be accepted by the government unless the specific requirement is waived or deviated from, in writing by the Contracting Officer.

3.12.5 Correction of Defective Equipment

The Lift System Supplier will take whatever action necessary for the Lift System to meet the requirements of this specification. Additional expense shall not be borne by the government.

3.12.6 Acceptance Test Procedure

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This shall be provided in writing by the Lift System Supplier and agreed upon by the Contracting Officer.

3.12.7 Test Result Report

A report giving the results of the acceptance test program and any correcting action taken shall be transmitted to the Contracting Officer within 5 days following the completion of the witnessed acceptance tests.

3.12.8 Final Acceptance

Final acceptance by the Contracting Officer will be provided in writing and it will be based upon the Lift System Supplier completed test report of government-witnessed acceptance testing.

3.13 Training

The Lift System Supplier shall prepare a custom training program for approval by the Contracting Officer. The training program shall consist of all requirements deemed necessary to properly operate and maintain the Lift System. This shall include training in all functions of operation, maintenance, repair, calibration, and certification as they apply to each specific item or system.

3.13.1 Training Material

The Lift System Supplier shall provide all required training manuals, maintenance manuals and vendor data describing their respective equipment and all required related data.

3.13.2 Demonstrations

This will include demonstrations by the Lift System Supplier in functional areas of operation, maintenance, repair, calibrations and certification on the actual equipment where possible.

3.13.3 Training Schedules

Training will be conducted after completion of installation and acceptance of the Lift System.

3.14 Warranties

Supplier shall submit a written warranty for the Lift System, complete.

Warranty shall be for design, installation and hardware of the complete Lift System as manufactured, assembled and installed by Supplier.

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