A07 TE 10.3 Bridge Maintenance Procedures (SOP) 20200807.pdf

TE 10.3 Bridge Maintenance Procedures (SOP)

TE 10.3 Bridge Maintenance Procedures (SOP) 1

BRIDGE MAINTENANCE STANDARD OPERATING PROCEDURES

SECTION 1 - CYCLIC BRIDGE MAINTENANCE REQUIREMENTS

Frequency

1. PM Upper Turntable - To include: Weekly

a. Clean and grease track.

b. Grease and clean fittings on rollers.

c. Check everything while swing span is turning.

d. Visual inspection of all equipment.

e. Inspect and lubricate railroad signal power rings.

f. Inspect enclosure heater for proper operation.

2. PM Control Tower - To include: Weekly

a. Keep gears greased and cleaned.

b. Grease and clean all fittings.

c. Check oil level in compressor and fill as required.

d. Inspect and perform preventive maintenance on emergency brake systems as required.

e. Clean air intakes on variable frequency drives as required.

f. Inspect all electric indicator lights for Proper operation, replace as required.

3. PM Railroad Deck - To include: Weekly

a. Grease and clean main shaft bearings.

b. Grease and clean all fittings on both ends.

c. Clean, oil and grease latches, cams, guides, etc.

d. Visually inspect all equipment.

e. Inspect hydraulic lines and cylinders for leakage, damage and assure proper operation.

4. PM Lower Turntable including: Weekly

a. Grease and clean all bearings.

b. Clean and oil chains.

c. Clean and oil pony wheels and tracks.

d. Inspect rack bolts.

e. Grease and clean center pivot assembly inside drum.

f. Clean drip pans as needed.

g. Inspect drum.

Frequency

h. Inspect pony wheel rods.

i. Inspect center pivot casting base bolts.

5. PM J1 and J2 Ends including: Weekly

TE 10.3 Bridge Maintenance Procedures (SOP) 2

a. Clean, oil, and grease sidewalk and roadway gates.

b. Grease and clean all fittings.

c. Clean and oil rollers and seats.

d. Clean and oil trunnion and crosshead pins.

e. Inspect linkage, hydraulic lines, hydraulic pumps, nuts, etc.

6. Remove roadway plates, clean and grease slides, cross-heads. Inspect hydraulic lines and cylinders for leakage, damage and proper operation, reinstall roadway plates. Traffic control required.

Monthly

7. Check hydraulic fluid levels and hydraulic pumps for leakage.

Daily

8. Perform daily operator maintenance. Daily

a. Check crosshead bolts for tightness.

b. Oil, grease and clean as required.

c. Inspect operational equipment for wear, cracks, loose bolts, etc.

9. Perform housekeeping. Daily

a. Remove paper and debris from railroad, road deck, pedestrian walks, and all other areas of bridge responsibility.

b. Clean machinery in control tower

c. Clean floors in control tower and bridge buildings. Empty trash.

d. Remove ice and snow from swing span equipment, railroad interlocks, and walkways to control tower, shop area, office area and south end of underpass.

e. Clean floors and work benches in shop area. Empty trash.

f. Sweep and clean all areas including but not limited to lower turntable area, stairwells, walkways, underpass area, and the Rodman Ave. and Ft Armstrong intersection.

10. All video, audio and gate operating equipment and systems will be maintained in accordance with Operation and Maintenance (O & M) manuals to ensure they are fully operational. Systems includes but are not limited to all cameras, recording, remote, transmitting and radio control equipment and all associated equipment, devices and systems and as described below.

Daily

a. DVR 4116DVD1000

b. Switches

TE 10.3 Bridge Maintenance Procedures (SOP) 3

c. Multi Viewer PMVCA

d. Code Distribution Unit CM 9760-CDU-T

e. Camera/Dome 5D435-PG-E1

f. Keyboard KBR 960

g. Fiber Transmitter (Dome) FS 85011 MST

Fiber Receiver (Rack) FR 85011MS TR

h. Data Manager CM 9760-DMR

i. Power Supply MCS16-20B

j. Camera Mounts (Dome) IWM-24BK

k. Rack RK 5000PS-3U

l. Monitor – 46” Samsung Model 460PX-S/N

BH46HCNP900481A

- 23” Samsung Model LNTX2353 HA-

S/N AH7JC3HP802044E

m. Phoenix Contact– 2.4.6H2– Video Transmission

1. Radio- Main- RAD-802111-YD-WM

2. Radio- Spare- RAD-80211-XD

Antenna Spare- RAD- ISM- 2400- Ant- Omni-9-0

n. Phoenix Contact- 900MHZ- Control Transmission

1. Radio-RAD-ISM-900SET-BD-BUS Antenna Cable-RAD-CAB-LMR400-60 Antenna- RAD-ISR-900-Aut-Omni-F6-3-N

2. Input Module-RAD- IN-8D

3. Relay-PLC-RSC-120 UC/21

4. Output Module-RAD-OUT-8D REL

5. Power Supply-Mini-PS-240 AC/24DC 11/3

o. UPS-MGE-Pulsar EX RT 3250

1. Battery -8500

p. Switch Box – Hoffman

q. Intercom-Aiphone-LE-SS-Speaker

SBX-2G-Box AD-10M-Master Unit

r. Fiber Cable- Optical Cable Corporation

#DX04-0500-WLS-900-OFNR

11. Wash windows in control tower, office and shop area (shall be done more frequently if visibility is affected)

Weekly

12. All lubricants used on bridge systems and components shall meet manufacturer’s specifications and be approved by the KO and COR prior to use.

TE 10.3 Bridge Maintenance Procedures (SOP) 4

SECTION 2 - SEMI-ANNUAL/ANNUAL BRIDGE MAINTENANCE

REQUIREMENTS

Frequency

1. Inspection/maintenance of swing span slip ring assembly shall include, but is not limited to(Inspect semi-annually; lube and clean annually):

Semi-Annual

a. Clean and lubricate upper turntable power rings inspect for defects and check heater function.

b. Verification of proper operation of the complete assembly.

c. Check the alignment of the enclosure with the main shaft.

d. Check alignment of the brushes on the rings.

e. Check for corrosion on ring surfaces and cleaning to remove if present.

f. Check for leakage at shaft seal and access panels.

g. Check for any unusual wear or deterioration.

h. Apply contact cleaner/protector to rings.

2. Inspect all nuts, bolts, rollers and track for upper turntable for defects.

Annual

(Shutdown)

3. Clean and inspect operation of all stop lights, roadway lights, and signs. (Operators shall visually check daily.)

Semi-

Annual(Shutdown and Jul)

4. Inspection/Maintenance of the Allen Bradley VFD units located in the Bridge Control Tower includes but is not limited to(Perform preventive maintenance annually):

Semi-Annual Shutdown and Jul)

a. Inspect Variable Frequency Drives, motor, terminal strips, switches, controllers, etc. for signs of overheating conditions, loose connections, and proper operation.

b. Replace/clean air filter in door. Check for cooling fan operation.

c. Vacuum cabinet interior.

d. Visual inspection of wiring and control boards to check for damage or overheating.

e. Check all wiring connections for tightness.

f. Provide all mobilization for badging and access to and from Control Tower.

5. Inspection/maintenance of Hydraulic Power Units Annual Shutdown

TE 10.3 Bridge Maintenance Procedures (SOP) 5

(HPU’s), Lifting and rail deck Cylinders includes but is not limited to:

a. Check for Oil leaks, oil appearance, and odor.

b. Check for clogged filters

c. Inspect HPU’s, hoses, and cylinders for oil leaks.

d. Check relief valve for proper operation.

e. Check operation of oil heaters.

f. Take oil sample for test. Sample oil cleanliness and lubricity; change oil as required per laboratory test results.

g. Check accumulator pressure.

h. Drain reservoir. Remove access cover, and check reservoir for foreign material. Clean reservoir. Visually inspect oil heaters.

i. Re-seal access cover. Filter and refill reservoir with new oil if test results require it.

j. Run HPU and recheck oil level.

k. Add oil as required.

l. Inspect hose and cylinders on both ends of rail deck for leaks and wear.

6. Inspection/maintenance of Bridge swing motor and gearbox includes but is not limited to:

Annual Shutdown

a. Inspect gear case for oil leaks.

b. Drain gear case to allow for drive coupling inspection. Remove end cover, inspect coupling, check gear case for debris. Realign gear motor and gear coupling as required. Reinstall plate.

c. Refill gear case to proper level with new oil if test results require oil change.

7. Inspect all gears couplings and drive shafts. Annual Shutdown

8. Inspection/maintenance of Bridge Rotation Brake

System includes but is not limited to:

Annual Shutdown

a. Remove shields over brake rotors to allow for inspection.

b. Inspect brake pads for uneven wear.

c. Inspect brake disc for unusual wear, discoloration, and other signs of ragging brakes.

d. Change brake pads as required.

TE 10.3 Bridge Maintenance Procedures (SOP) 6

e. Reinstall shields.

9. Inspection/maintenance of air compressor in tower includes but is not limited to:

Annual Shutdown

a. Disconnect power feed to compressor.

b. Check relief valves for freedom of movement by pulling on rings on valve stems.

c. Check compressor for any oil leaks.

d. Drain compressor oil. Change oil filter and air intake filters.

e. Refill compressor with recommended oil to proper level.

f. Run compressor and recheck oil level.

g. Inspect drive belts for wear and proper tension. Also check belt alignment.

10. Inspection/maintenance of pitman arms and complete power train mechanism. Repair or adjust as required on J1 and J2 ends.

Annual Shutdown

11. Inspection/maintenance of Lower Turntable: Annual Shutdown

a. Adjust main drive chains.

b. Adjust auxiliary drive chains.

c. Repair or replace primary draft shafts.

d. Inspect and tighten all component equipment as required.

12. Inspect all railroad interlocking components and initiate any needed repairs.

Weekly

13. Clean and inspect all video, audio and gate operating equipment and systems in accordance with Operation and Maintenance (O & M) manuals to ensure they are fully operational. Systems includes but are not limited to all cameras, recording, remote, transmitting and radio control equipment and all associated equipment, devices and systems.

Annual Shutdown

14. Inspection Turn Requirements Annual Shutdown

a. As early as weather permits, and prior to the start of navigation season, Contractor shall make an inspection turn. Notify COR to allow observation of inspection turn.

b. Turn bridge swing span 180 degrees one direction.

c. Raise and lower bridge lifting mechanism.

d. Turn bridge swing span 180 degrees in same

TE 10.3 Bridge Maintenance Procedures (SOP) 7 direction.

e. Raise and lower bridge lifting mechanism.

f. Repeat b thru e in opposite direction.

15. All lubricants used on bridge systems and components shall meet manufacture’s specifications and be approved by the Government POC prior to use.

SECTION 3 - BRIDGE CLEANING REQUIREMENTS

1. General:

a. This work consists of the removal of all accumulated foreign material from the entire bridge including:

1) Decks

2) Sidewalks

3) Curbs

4) Pier tops

5) Trusses

6) Lower flange

7) Beams

8) Girders

9) Cleaning of expansion joints

10) Wind links

11) Drains

Areas which have been cleaned shall be free of all accumulations of sand, gravel, dirt, bird nests, excreta, and other foreign materials. This work applies to the Government Bridge, and Rock Island Viaduct and associated bike path.

2. Equipment:

a. Cleaning equipment to properly flush, clean, and remove all foreign material from the bridge structure, may consist of:

1) Power brooms

2) Air compressors

3) Water tanks

4) Water pumps with associated delivery hardware

5) Hand tools

b. Other types of cleaning equipment may be used subject to the approval of the KO and COR. Air and/or water pressure shall be adjusted to ensure removal

TE 10.3 Bridge Maintenance Procedures (SOP) 8 of the accumulated material without damaging paint coverage of the structural steel.

c. Each self-propelled unit utilized in the cleaning option shall be equipped with an amber revolving light visible from the front and rear, mounted at least 42 inches high as measure to the lamp axis, and which flashes at least 60 times per minute but not more than 120 times per minute.

d. Other equipment such as hi-reach trucks, and under bridge access trucks or movable scaffolds may be necessary to gain access to areas designated for cleaning. It will be the Contractor's responsibility to determine and utilize whatever method and equipment best suits his operations to successfully and safely clean the structures.

3. Cleaning:

a. All accumulated foreign material shall be removed from the bridge deck, sidewalk, and curb tops

b. All deck drains shall be flushed with water under pressure, (NLT 100 psi)

c. Blockages in the deck drains shall be removed so that they will drain properly.

d. Drain systems may have to be taken apart to remove large blockages.

Should this be necessary, they shall be returned to their original configuration immediately after cleaning.

e. Foreign material in the scuppers at the drains shall be either removed externally or flushed down the drain system.

f. The area beneath all finger expansion devices shall be thoroughly flushed and cleaned with water under pressure. These areas include drain troughs beneath the expansion device and all structural steel for a distance of 50 feet in either direction of the expansion device.

g. All abutment bridge seats and pier tops shall have all foreign material removed either by compressed air, water under pressure, or hand sweeping.

h. The Contractor shall flush out with water under pressure, (NLT 100 psi), the interior of all truss members. Flushing of the interior of the truss members shall continue until such time as each truss member is draining out clear obviously uncontaminated water.

i. The exterior of all truss member, miscellaneous structural steel connecting truss members, and floor beam ends projecting outwardly from the row of

TE 10.3 Bridge Maintenance Procedures (SOP) 9 exterior stringers shall be thoroughly washed down with water under pressure, (NLT 100 psi).

j. Any water used shall be free from injurious amounts of oil, salts, acids, alkali, organic matter or other detrimental substances, and objectionable amounts of salt, mud, grass, or other foreign material.

k. Any roadway appurtenance damaged due the Contractor's activities shall be repaired or replaced at the Contractor's expense.

l. The Contractor shall exercise due caution and take all necessary precautions during cleaning operation so as not to soil, damage, or injure privately or publicly owned property.

4. Traffic Control:

a. Parking of private vehicles shall not be allowed on the structure at any time.

b. The Contractor shall furnish, erect, maintain, and remove all signs and traffic control devices and traffic control personnel made necessary for the work.