Specs_6_Oct_2016.pdf

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HSDRP, Raritan Bay and Sandy Hook Bay, Phase II W912DS-16-B-0014 Contract 2, Middletown Township, Port Monmouth, NJ

SECTION TABLE OF CONTENTS

DIVISION 11 - EQUIPMENT

SECTION 11 82 15

AUTOMATIC TRASH RAKE/RACK SYSTEMS

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Standard Products

1.2.2 Nameplates

1.2.3 Verification of Dimensions

1.2.4 Welding

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 Trash Rake/Rack System

1.5 DELIVERY AND STORAGE

PART 2 PRODUCTS

2.1 ELECTRIC

2.1.1 Power Requirement

2.1.2 Motors

2.1.3 Controls

2.1.3.1 Main Control Panels for Trash Rake

2.1.3.2 Local Control Panels for Trash Rake

2.1.4 Safety

2.2 MISCELLANEOUS

2.2.1 Lubrication

2.2.2 Wind Proofing

2.3 PROTECTIVE COATINGS

2.3.1 General

2.3.2 Field Painting

2.4 EQUIPMENT AND MATERIALS

2.4.1 General

2.4.2 Fasteners

2.4.3 Steel

2.4.4 Bar Screen

2.4.5 Bearings

2.4.6 Scrapers/Rakes

2.4.7 Chains and Connecting Hardware

2.4.8 Chain Guides

2.4.9 Drive Unit

2.4.10 Drive Shafts/Shafts

2.4.11 Speed Reducer

2.4.12 Spare Parts

2.4.12.1 Trash Rake/Rack System

PART 3 EXECUTION

3.1 INSTALLATION

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3.2 FIELD TESTING

3.2.1 Acceptance Test

3.2.2 Test Sequence

3.3 INSPECTION

3.4 MANUFACTURER'S SERVICES

3.5 FIELD TRAINING

3.6 WARRANTY

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SECTION 11 82 15

AUTOMATIC TRASH RAKE/RACK SYSTEMS

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 in the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 2004 (1989b; R 1995) Gear Materials and Heat Treatment Manual

AGMA 6001 (1997d) Design and Selection of Components for Enclosed Gear Drives

AGMA 6009 (2000a) Standard for Gearmotor Shaft Mounted and Screw Conveyor Drives

AGMA 6010 (1997f) Standard for Spur, Helical, Herringbone, and Bevel Enclosed Drives

ASTM INTERNATIONAL (ASTM)

ASTM A48/A48M (2003; R 2012) Standard Specification for Gray Iron Castings

ASTM A276 (2010) Standard Specification for Stainless Steel Bars and Shapes

ASTM F593 (2002; R 2008; E 2012) Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F594 (2009; E 2011) Standard Specification for Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2012; Errata 2011) Structural Welding Code - Steel

AWS D14.1/D14.1M (2005) Specification for Welding Industrial and Mill Cranes and Other Material Handling Equipment

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload

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Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA MG 1 (2011; Errata 2012) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014) National Electrical Code

1.2 SYSTEM DESCRIPTION

The trash rake/rack system installed for this job shall be an automatic, self-cleaning system for removing debris from the water before reaching the intake of the pumping unit. The trash rake/rack system employed shall not affect the designed operation of the pumping station.

1.2.1 Standard Products

The trash rake/rack systems selected shall incorporate standard materials and equipment from manufacturers that have at least a two-year's successful application of the systems prior to the bid opening. Any company licensed by a trash rake/rack manufacturer to manufacture trash rakes/racks bearing their name shall have the design and components approved by the licensor prior to submission to the Government for approval.

1.2.2 Nameplates

Each major component of equipment shall have the manufacturer's name, address, type or style, model or catalog number, and serial number on a corrosion resistant metal plate secured to the equipment.

1.2.3 Verification of Dimensions

The Contractor shall verify all dimensions in the field and shall advise the Contracting Officer's Representative (COR) of any discrepancy before performing any work.

1.2.4 Welding

Welding shall be in accordance with qualified procedures using AWS D14.1/D14.1M , as modified herein. Written welding procedures shall specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and such tolerances shall not exceed those specified in AWS D14.1/D14.1M . All welding shall be performed indoors. Welders and welding operators shall be qualified in accordance with AWS D1.1/D1.1M and

AWS D14.1/D14.1M .

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

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Wiring and Schematic Diagrams ; G, DO

Detailed drawings shall be submitted containing complete wiring and schematic diagrams and any other details required to demonstrate that the systems have been coordinated and will properly function as a unit. Drawings shall show proposed layout of the equipment and appurtenances, and equipment relationships to other parts of the work, including clearances for maintenance and operation. Drawings shall be required that show the trash rake/rack assemblies, their mounting to the pumping station, and necessary details that show sound installation.

SD-03 Product Data

Trash Rake/Rack System ; G, DO

Spare Parts Data

Spare parts data shall be submitted and shall include a complete list of recommended parts and supplies, with current unit prices and source of supply.

SD-06 Test Reports

Electrification System Tests ; G, DO

Results of electrification system tests shall be submitted.

Acceptance Testing ; G, DO

Test reports in booklet form shall be submitted showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria upon completion and testing of the installed system. The report shall include the information, as required, by Paragraph

FIELD TESTING.

SD-07 Certificates

Electric Motors ; G, DO

Wiring ; G, DO

Contact Conductors ; G, DO

Controls ; G, DO

Overcurrent Protection ; G, DO

Grounding ; G, DO

Certification shall be submitted attesting that the electric motors, wiring, contact conductors, controls, overcurrent protection, and grounding conform to NFPA 70 , NEMA ICS 2 , NEMA ICS 6 , NEMA MG 1, and and to Underwriters' Laboratories, Inc.

(UL) standards. The label or listing with re-examination by UL will be accepted as evidence that the materials conform to this requirement and to NFPA 70 .

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Trash Rake/Rack System and Controls ; G, DO

Sample Rake ; G, DO

Certification shall be submitted attesting that a sample system of the type specified has been factory tested for the test specified.

Thermal Monitoring of Motor Components ; G, DO

Certified results of thermal monitoring of motor components during tests shall be submitted.

SD-08 Manufacturer's Instructions

Trash Rake/Rack ; G, DO

Diagrams, instructions, and other sheets proposed for posting shall be submitted.

SD-10 Operation and Maintenance Data

Submit operation and maintenance data in accordance with Section

01 78 23 OPERATION AND MAINTENANCE DATA.

Operation Manuals ; G, DO

Six copies of operation manuals shall be furnished for the equipment furnished. Operation manuals shall detail the step-by-step procedures required for system operation. Operation manuals shall include the manufacturer's name, address, telephone number, point of contact, order number, model number, parts list, and brief description of all equipment and their operating features. Operation manuals shall include a copy of all the approved shop drawings in their final version and the acceptance test report for information and future reference. Operation manuals shall include an overall description of the system describing any unique features that may need specific attention.

Maintenance Manuals ; G, DO

Six copies of maintenance manuals shall be furnished for the equipment furnished. Maintenance manuals shall list routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Maintenance manuals shall include equipment layout diagrams, assembly drawings and wiring and control diagrams of the system, as installed. Maintenance manuals shall include a spare parts list of manufacturer's recommended spare parts that should be kept onsite and any long lead time items should be clearly identified. Maintenance manuals shall contain replacement part numbers for the entire assembly.

1.4 DESIGN CRITERIA

In addition to the references indicated herein, the design, fabrication, assembly, test equipment, and materials shall also be in accordance with the applicable provisions of the American Bearing Manufacturers Association (ABMA), American Institute of Steel Construction (AISC) and American National Standards Institute (ANSI).

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1.4.1 Trash Rake/Rack System

The trash rake/rack system shall be designed to cover the entire area (as shown) at the head of the intake channels of the pumping station, trap debris typically encountered in the water in the area, and automatically remove the trapped debris from the trash rack. The trash rake/rack shall be capable of operating continuously, and without affecting operation, through 5 feet of head differential. The trash rake/rack manufacturer(s) shall determine the exact inclination of the system for the application.

All construction shall be per AISC, Manuals of Steel Construction. The trash rake/rack system selected shall have the following features:

a. A rack fabricated from 316 type stainless steel, in accordance with ASTM A276 that covers the entire intake area at the head of the intake channels. The trash rake/rack manufacturer(s) shall determine the exact inclination of the system for the application.

b. An automatic, self-cleaning, rake/rack assembly that continuously removes the captured debris (typically encountered debris in the area) from the face of the rack and dumps the debris directly onto the deck or into a receptacle or has the debris stripped from the rake and dropped onto the station deck or in a receptacle. The rake may be a separate unit or a combined assembly with the rack. The rake shall be front cleaning, front return.

c. Electrically powered, automatically operated, and manual override capability.

d. Be easily maintained and have excellent corrosion resistance.

e. The trash rack shall be designed to adequately stop the known debris, not inhibit the designed operation of the pumping station, and withstand the loads and stresses that it will encounter during erection, fabrication, and intermittent or continuous operation of the trash rake.

f. The maximum clear opening between the rack bars shall be 1-5/8 inches.

g. The lifting capacity shall be 1,000 pounds minimum per rack unit.

h. The maximum linear speed of the rakes shall be approximately 10 feet per minute.

i. The rake assembly shall be designed so that the assembly will have the means to avoid overload or damage to the system from large/heavy debris.

j. The rake/rack assembly shall have scrapers.

k. The drive mechanism shall be designed to operate without binding, skipping, or disengaging of the drive components.

l. Each trash rake section will operate independently and will have its own drive unit and driven components.

m. The scrapers shall cause no damage to the bar rack finish or structure and shall be easily modified, if necessary, to suit changes

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n. The trash rake shall be capable of continuous cleaning, without an operator, from bottom to top for the entire width of the trash bar screen rack. The trash rake shall have multiple rakes or scrapers on the bar screen at one time. Units which have single raking arms that require cycle times will not be allowed. Scrapers shall be designed to clean the screen bars on three sides; fully penetrating the bar screen.

o. A stripper assembly shall be installed to assist in removing debris from the scrapers as recommended by the manufacturer.

p. Removal and Reinstallation: The rack shall be capable of being removed for access to the pump. Anchorage of the rack shall be Contractor designed to handle all loading without being detrimental to the structure and in accordance with ACI codes. The rack shall be designed for two lift points. The rack anchorage shall be readily accessible with adequate tolerance to facilitate easy reinstallation.

All fasteners shall be equipped with a locking device, such as, a lock nut or a lock washer.

1.5 DELIVERY AND STORAGE

Equipment delivered shall be placed in proper storage, protected from damage due to vehicular traffic, construction equipment, dirt and dust, other contaminants, and hazards.

PART 2 PRODUCTS

2.1 ELECTRIC

Electrical work and equipment shall be in accordance with Section 26 05 00 COMMON WORK RESULTS FOR ELECTRICAL and that specified herein.

2.1.1 Power Requirement

The power that is required available for the rake/rack system is 120 208 V/60 Hz/ 1 3 Ph. Horsepower shall be determined by the manufacturer.

2.1.2 Motors

All electric motors shall be totally enclosed, weatherproof, and suitable for outdoor service. Also, motors shall have protection from overload, low voltage, and heat damage. Motor shall conform to AGMA 6009-A00.

2.1.3 Controls

Each rake shall have a locally mounted NEMA 4X automatic on/off switch with manual override capability and with a fused disconnect switch.

The controls shall include safety measures such as indicators for operation, overload, and emergency stops, as specified below.

2.1.3.1 Main Control Panels for Trash Rake

a. Each panel shall be located in the control building in a NEMA 1, galvanized steel enclosure with a hinged door. The push-button stations, indicating lights, disconnect switch, and reset button shall

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b. Panel controls shall be rated 120 V for the trash rake system.

c. Provide a main disconnect switch for each system, lockable in the off position. The disconnect switch shall open all phases to the main control panel, local control panel, receptacle, and motor.

d. For each system, provide HAND-OFF-AUTO, three position, maintained selector switch, STOP momentary pushbutton, FORWARD momentary pushbutton, and REVERSE momentary pushbutton. The FORWARD and REVERSE pushbuttons shall be mechanically and electrically interlocked to prevent energizing FORWARD and REVERSE contactors simultaneously.

e. For each system, provide LED, push-to-test type indicating lights for MOTOR RUN (green), READY (green), HAND (green), OVERLOAD (red), E-STOP (red).

f. Provide an adjustable time-delay relay. The trash rake system shall be adjustable from 0 - 5 minutes.

g. Each motor shall be protected with an electronic overload-sensing device. The device shall monitor the motor current and protect the motor and drive equipment during an overload condition. Upon sensing an overload condition, the unit shall stop the drive motor, energize the OVERLOAD indicating light on the panel, and prevent the motor from restarting until the reset button is pushed.

h. Provide a space heater and an adjustable thermostat in each panel.

2.1.3.2 Local Control Panels for Trash Rake

a. Each local control panel shall be located at the trash rake in a NEMA 4X, stainless steel enclosure. The enclosure shall have a hinged, solid cover with a lockable door. A hinged inner door shall be installed in the panel that is only accessible when the outer door is open. The pushbutton stations, stop button, and receptacle shall be mounted on the inner door.

b. Panel controls shall be rated 120 V for the trash rake system.

c. Provide a motor disconnect switch for each system that is accessible from outside the panel and is lockable in the off position. The motor disconnect switch shall open all phases to the motor. Provide a nameplate on the panel door that reads, "MOTOR

DISCONNECT SWITCH DE-ENERGIZES MOTOR ONLY".

d. Provide FORWARD and REVERSE momentary pushbuttons. The FORWARD and REVERSE pushbuttons shall be mechanically and electrically interlocked to prevent energizing FORWARD and REVERSE contactors simultaneously.

e. Provide a maintained EMERGENCY STOP pushbutton. The stop button shall be a push-to-stop and pull-to-reset type with a red mushroom head. The emergency stop shall stop the motor in HAND or AUTO mode.

f. Provide a 120 V, duplex, GFCI receptacle.

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2.1.4 Safety

Safety controls shall be provided for the safe operation of the system.

2.2 MISCELLANEOUS

2.2.1 Lubrication

Proper lubrication shall be applied to all of the moving parts of the rake/rack assemblies installed. The lubricant shall be water resistant, have excellent corrosion resistance, and withstand the temperature extremes of the area.

2.2.2 Wind Proofing

The rake/rack assembly installations shall withstand and be capable of operating in wind velocities of up to 155 mph.

2.3 PROTECTIVE COATINGS

2.3.1 General

All equipment shall be painted per Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES, except stainless steel shall not be painted.

2.3.2 Field Painting

The Contractor shall touch-up coatings damaged during shipment or installation.

2.4 EQUIPMENT AND MATERIALS

2.4.1 General

All material and equipment used under this contract will be new and unused unless otherwise specified. All material that will operate under water shall be made of an ASTM A276 stainless steel, and be suitable for the application. All other material shall have a finish applied to it for corrosion resistance.

2.4.2 Fasteners

Fasteners shall be of a suitable stainless steel conforming to ASTM F593 and ASTM F594.

2.4.3 Steel

Structural steel for the trash rack/rake assembly (including frame and mounting) shall be a suitable stainless steel, in accordance with ASTM A276.

2.4.4 Bar Screen

The trash rack bar screen shall be of flat bar, Type 316, ASTM A276, stainless steel, minimum, and designed and built to function as necessary in the service intended. The bar screen shall be able to withstand a minimum of 1 foot head differential. The bar screen anchors and fasteners shall be of an appropriate ASTM A276 stainless steel. The maximum clear opening between the rack bars shall be 1-5/8 inches.

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2.4.5 Bearings

Bearings shall be sealed, greaseable ball bearing type and non-self aligning for the trash rake assembly and sealed, greaseable, tapered, roller bearing type. Bearings shall conform to ABMA standards and be designed and selected for the loads encountered.

2.4.6 Scrapers/Rakes

Applicable scrapers/rakes for the trash rake assemblies shall be constructed of a strong, corrosion-resistant material (such as UHMW) that can handle the loads that will be encountered. The scrapers/rakes shall not cause damage to the trash rack bar screen or structure. The brackets of the trash rake shall be a suitable ASTM A276 stainless steel.

2.4.7 Chains and Connecting Hardware

Chains for the trash rake, if applicable, and all associated hardware, shall be made of a suitable ASTM A276 stainless steel, being capable of handling the loads encountered.

2.4.8 Chain Guides

Chain guides, if applicable, shall be made of a suitable ASTM A276 stainless steel.

2.4.9 Drive Unit

The drive units for the trash rake, including sprockets, shall be made of a suitable ASTM A48/A48M cast iron or a suitable ASTM A276 stainless steel. If under water or used in a salt water application, use a suitable ASTM A276 stainless steel for all drive components.

2.4.10 Drive Shafts/Shafts

Shafts shall be of sufficient strength and size to transmit the power required. The trash rake shafts shall use a suitable ASTM A276 stainless steel.

2.4.11 Speed Reducer

Speed reducer shall be selected and rated as appropriate for the service intended. Speed and output shall be per manufacturer's design recommendations to meet these specifications and the service intended.

Speed reducer shall conform to AGMA 2004-B89, AGMA 6001-D97, AGMA 6010-F97.

2.4.12 Spare Parts

The minimum spare parts to be provided under this contract are as follows.

2.4.12.1 Trash Rake/Rack System

a. Drive Clevis Pins - 1 each.

b. Snap/Retaining Rings - 10 each.

c. Chain Clevis Pins - 4 each.

d. Scraper Bolts - 4 each.

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e. Scraper Nuts - 4 each.

f. Never Seez, 3-ounce Tube - 1 each.

g. Motor (or motor with gearbox) - 1 each.

PART 3 EXECUTION

3.1 INSTALLATION

Installation, start-up, and testing of equipment shall conform to the manufacturer's recommendations. Manufacturer's field representative shall meet with the Contractor and give the guidelines for installation of the equipment. Any metal work necessary to fit the trash rake system to the applicable structure shall be in accordance with Section 05 50 15 CIVIL

WORKS FABRICATIONS.

3.2 FIELD TESTING

3.2.1 Acceptance Test

The Contractor shall provide appropriate test material, instruments, and test weights and all personnel necessary to conduct the tests, including, but not limited to, the operators. Testing shall be performed in the presence of the Contracting Officer's Representative (COR). The Contractor shall notify the COR seven days prior to testing operations.

3.2.2 Test Sequence

The equipment shall be tested in the presence of the COR and a written report submitted showing tests performed and test results.

Operational tests shall be conducted to determine that the performance of equipment and controls is as specified. Factory tests shall be verified, as well as possible, with facilities available at the site of installation. The tests shall consist of placing the equipment in operation and observing its performance as it picks up, dumps, conveys, and deposits material which may, or is expected to be, in the area, or an acceptable substitute, approved by the COR. Make all necessary equipment adjustments and corrective work as indicated by tests.

3.3 INSPECTION

All equipment shall be rechecked after it has been in operation for approximately 30 days. An inspection shall be performed approximately 60 days prior to date of warranty expiration. Make adjustments as necessary to restore equipment within original tolerances. Submit a written report within 7 days of each of the inspections to the COR covering all inspection items and including applicable recommendations.

3.4 MANUFACTURER'S SERVICES

Services of a manufacturer's representative who is experienced in the installation, adjustment, erection, and operation of the equipment specified shall be provided, if it is found to be necessary. The representative shall supervise the installation, adjustment, and testing of the equipment.

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3.5 FIELD TRAINING

A field training course shall be provided for designated operating staff members. Adequate training shall be provided, and shall start after the system is functionally complete, but prior to final acceptance tests.

Field training shall cover operations and functions of the assemblies and all of the items contained in the operating and maintenance instructions.

The Contracting Officer and sponsor shall be given at least two weeks advance notice of such training.

3.6 WARRANTY

The trash rake/rack system manufacturer shall warranty all equipment furnished under this section against defective workmanship, materials, design, and performance for a period of five (5) years from the date the equipment is accepted. If the equipment or any part thereof does not conform to these warranties, and the Government or sponsor so notifies the manufacturer within a reasonable time after its discovery, the manufacturer shall thereupon promptly correct such nonconformity by repair or replacement. The down time for the equipment shall be coordinated with the Government or sponsor, and shall be kept to a minimum duration that is mutually agreed to by the manufacturer and the Government or sponsor. The manufacturer shall be liable during the warranty period for the direct cost of removal of the equipment from the installed location, transportation to the manufacturer's factory or service shop for repair and return, and reinstallation on site. The manufacturer shall be given the opportunity to perform the removal and reinstallation and to select the means of transportation. The expense of removing adjacent apparatus, installing spare equipment, costs of supplying temporary service, etc., is not included in this warranty provision.

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