W912P5-17-B-0015_TSpecs_-_AMD_002.pdf

Site, Demolition and Utility Relocations Kentucky Lock Addition W912P5-17-B-0015 Grand Rivers, Livingston County, KY

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00 GENERAL REQUIREMENTS

01 22 00 PRICE AND PAYMENT PROCEDURES

01 32 01 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS

01 35 50 PROJECT SITE SECURITY AND AT/OPSEC PROCEDURES

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 00 QUALITY CONTROL

01 45 00.15 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE(RMS CM)

01 50 00 TEMPORARY CONSTRUCTION FACILITIES AND CONTROLS

01 57 19 TEMPORARY ENVIRONMENTAL CONTROLS

01 74 19 CONSTRUCTION AND DEMOLITION WASTE MANAGEMENT

01 78 00 CLOSEOUT SUBMITTALS

01 78 23 OPERATION AND MAINTENANCE DATA

01 95 00 FORMS AND ATTACHMENTS

DIVISION 02 - EXISTING CONDITIONS

02 41 00.01 DEMOLITION OPERATIONS BUILDING RENOVATION

02 41 00.02 DEMOLITION UTILITY RELOCATION

02 42 91 REMOVAL AND SALVAGE OF HISTORIC CONSTRUCTION MATERIALS

OPERATIONS BUILDING RENOVATION

02 82 14 ASBESTOS ABATEMENT WORK

DIVISION 03 - CONCRETE

03 30 53 MISCELLANEOUS CAST-IN-PLACE CONCRETE

DIVISION 04 - MASONRY

04 20 00 UNIT MASONRY

04 42 13 DIMENSION STONE CLADDING

DIVISION 05 - METALS

05 05 23 STRUCTURAL WELDING

05 12 00 STRUCTURAL STEEL

05 50 13 MISCELLANEOUS METAL FABRICATIONS

05 50 14 STRUCTURAL METAL FABRICATIONS

05 50 15 CIVIL WORKS FABRICATIONS

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07 60 00 FLASHING AND SHEET METAL

07 92 00 JOINT SEALANTS

DIVISION 08 - OPENINGS

08 11 16 ALUMINUM DOORS AND FRAMES

08 51 23 STEEL WINDOWS

08 71 00 DOOR HARDWARE

08 81 00 GLAZING

DIVISION 09 - FINISHES

PROJECT TABLE OF CONTENTS Page 1

09 90 00 PAINTS AND COATINGS

09 97 02 PAINTING: PEDESTRIAN BRIDGES

DIVISION 22 - PLUMBING

22 00 00 PLUMBING, GENERAL PURPOSE

DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING (HVAC)

23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS

23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS

23 83 00 ELECTRIC SPACE HEATING EQUIPMENT

DIVISION 26 - ELECTRICAL

26 00 00 BASIC ELECTRICAL MATERIALS AND METHODS

26 05 00 COMMON WORK RESULTS FOR ELECTRICAL

26 05 13 MEDIUM-VOLTAGE CABLE

26 05 19 INSULATED WIRE AND CABLE

26 20 00 INTERIOR DISTRIBUTION SYSTEM

DIVISION 31 - EARTHWORK

31 00 00 EARTHWORK

DIVISION 32 - EXTERIOR IMPROVEMENTS

32 34 35 PREFABRICATED UTILITY BRIDGES

32 92 19 SEEDING

DIVISION 33 - UTILITIES

33 11 00 WATER UTILITY DISTRIBUTION PIPING

33 30 00 SANITARY SEWERS

33 32 16 PACKAGED UTILITY WASTEWATER PUMPING STATIONS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 22 13 JIB CRANE

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 1 PAGES

KYL SDU Project

41 22 13 SD-02 Shop Drawings

1.6.3 G ECD-Jib Crane

1.6.3 G ECD-Electrical Controls

1.6.3 G ECD-Wiring Diagrams

SD-03 Product Data

1.6.3 Gjib Crane

2.1.4.3 GTrolley

2.1.4.2 GHoist

SD-06 Test Reports

3.2.4 GNo-load Test

3.2.5 GLoad Tests

3.2.2 GOperational Tests

SD-07 Certificates

1.6.2.1 GOverload Test Certificate

SD-08 Manufacturer’s Instructions

3.1 G ECDInstallation

SD-10 Operation and Maintenance Data

1.6.3 GJib crane

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION CONTRACTOR

CONTRACTOR:

SCHEDULE DATES

CONTRACTOR

ACTION

APPROVING AUTHORITY

A C T I V I T Y

N O

T R A N S M I T T A L

N O

S P E C

S E C T

DESCRIPTION

ITEM SUBMITTED

P A R A G R A P H

C L A S S I F I C A T I O N

G O V T

O R

A E

R E V W

R SUBMIT

APPROVAL

NEEDED

BY

MATERIAL

NEEDED

BY

A C T I O N

C O D E

DATE

OF

ACTION

DATE FWD

TO APPR

AUTH/

DATE RCD

FROM

CONTR

DATE FWD

TO OTHER

REVIEWER

DATE RCD

FROM OTH

REVIEWER

A C T I O N

C O D E

DATE

OF

ACTION

MAILED

TO

CONTR/

DATE RCD

FRM APPR

AUTH REMARKS

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13

JIB CRANE

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 DEFINITIONS

1.4 VERIFICATION OF DIMENSIONS

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

1.6.2 Pre-Delivery Inspections

1.6.2.1 Certificates

1.6.3 Drawings: Jib Crane

1.6.4 Welding Qualifications and Procedures

1.7 CRANE SAFETY

PART 2 PRODUCTS

2.1 MOTORIZED JIB CRANE

2.1.1 General

2.1.2 Boom Operation

2.1.3 Accessories

2.1.4 Motorized Hoist and Trolley

2.1.4.1 General

2.1.4.2 Motorized Hoist

2.1.4.3 Motorized Trolley

2.1.5 Crane Safety

2.2 STRUCTURAL, ELECTRICAL AND MECHANICAL REQUIREMENTS

2.3 CRANE PAINTING

2.4 IDENTIFICATION PLATES

2.4.1 Markings on Crane, Trolley, and Hook

PART 3 EXECUTION

3.1 INSTALLATION

3.2 FIELD QUALITY CONTROL

3.2.1 Post-Erection Inspection

3.2.2 Operational Tests

3.2.3 Test Data

3.2.4 No-Load Test

3.2.5 Load Tests

3.2.5.1 Hoist

3.2.5.2 Trolley

3.2.5.3 Rated Travel Tests

-- End of Section Table of Contents --

SECTION 41 22 13 Page 1

SECTION 41 22 13

JIB CRANE

PART 1 GENERAL

1.1 SCOPE

Contractor shall provide 1 jib crane for grinder pump installation and removal.

1.2 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 INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2011; Errata 1 2012; Errata 2 2013;

Errata 3 2015) Steel Construction Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

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

ASME INTERNATIONAL (ASME)

ASME B30.10 (2014) Hooks

ASME B30.16 (2012) Overhead Hoists (Underhung)

ASME B30.2 (2011) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASTM INTERNATIONAL (ASTM)

ASTM F3125/F3125M (2015a) Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2)

National Electrical Code

SECTION 41 22 13 Page 2

UNDERWRITERS LABORATORIES (UL)

UL 1340 (2004) UL Standard for Safety Hoists

1.3 DEFINITIONS

a. Boom: The horizontal beam on which the hoist trolley travels.

b. Capacity: The maximum live weight that the crane is designed to support.

c. End Stops: Bolted to each end of the boom to prevent the trolley from falling off of the beam.

d. Foundation: For free standing pillar base mounted jibs. Foundations are used to support the jib and prevent it from tipping over.

e. Height Under the Boom (H.U.B.): The distance from the finished floor to the underside of the crane boom.

f. Overall Height: The highest point of the jib crane (including any hardware).

g. Hoist: The actual lifting mechanism (powered by electric, air, or manual movement) that hangs from the trolley that rides on the boom of a jib crane.

h. Trolley: The mechanism that travels back and forth on the crane boom (powered by electric, air, or manual movement) which the hoist hangs from.

i. Span: The span for a pillar base mounted jib crane is the distance from the center of the mast to the end of the boom.

j. Hook Travel: The distance that the hook on the hoist travels.

1.4 VERIFICATION OF DIMENSIONS

The Contractor is responsible for the coordination and proper relation of his work to the building structure and to the work of all trades. Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

1.5 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. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Jib Crane; G, ECD-E

Provide shop drawings and product data for motorized jib crane, motorized hoist, and motorized trolley.

Electrical Controls; G, ECD-E

SECTION 41 22 13 Page 3

Wiring Diagrams; G, ECD-E

SD-03 Product Data jib Crane; G

Trolley; G

Hoist; G

SD-05 Design Data

SD-06 Test Reports

No-load Test; G

Load Tests; G

Operational Tests; G

SD-07 Certificates

Overload Test Certificate; G

SD-08 Manufacturer's Instructions

Installation; G, ECD

SD-10 Operation and Maintenance Data

Jib crane; G

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA, including weekly, monthly, semi-annual, and annual required maintenance items.

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

Jib Crane system, including sub-system components manufactured by vendors, must be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents.

1.6.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing and documentation of jib crane, hook assembly and trolley.

1.6.2.1 Certificates

Submit an Overload Test Certificate stating that the crane can be periodically load tested to 125 percent of rated load.

1.6.3 Drawings: Jib Crane

Submit shop drawings showing the general arrangement of all components in

SECTION 41 22 13 Page 4 plan, elevation, and end views; hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. I

Drawings must be reviewed, signed and sealed by a registered professional engineer.

Indicate the the trolley speeds, and the hoist lifting speeds; all speeds indicated are speeds with hoist loaded with rated crane capacity load.

All electrical controls and wiring diagrams shall also be provided on the shop drawings for approval.

1.6.4 Welding Qualifications and Procedures

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

AWS D14.1/D14.1M.

1.7 CRANE SAFETY

Comply with the mandatory and advisory safety requirements of ASME B30.10, and NFPA 70.

PART 2 PRODUCTS

2.1 MOTORIZED JIB CRANE

2.1.1 General

Crane shall consist of free standing mast requiring only foundation support and a motorized rotating boom. Primary boom shall have 360 degrees rotation.

a. Capacity: 2 ton. This is the minimum capacity since jib crane will be used to lift grinder pumps and other items. Mark the rated capacity in both kilogram and pound units printed in different colors on both sides of the crane. Capacity marks must be clearly visible to the operator at ground level.

b. Height under the boom: 20 ft

c. Span: 16 ft. This is a minimum span. The exact span shall be determined by the contractor based on the location of the jib crane from the lift station. Span should be adequate to remove grinder pumps and lift them up to the top of the lock wall at Elevation 382.00.

d. Design factor: Crane shall have a 25 percent factor of rated load for impact and 15 percent factor of rated load for hoist and trolley weight.

e. Service factor: Class C Normal/Industrial service.

f. Other items: Provide trolley stops.

SECTION 41 22 13 Page 5

Contractor shall verify the available electrical power at the job site prior to purchasing the jib crane, motorized hoist and motorized trolley.

Provide shop drawings, installation drawings, and product data of jib crane, hoist and trolley prior to purchasing equipment. Contractor shall provide all required accessories for the proper operation of the motorized jib crane, motorized hoist, and motorized trolley.

Operating temperature, electrical enclosures and all other parts of jib crane, hoist and trolley are suitable and rated for outdoor use. Jib crane shall be Series 351 as manufactured by Harrington, a Kito Group Company or Government approved equal.

2.1.2 Boom Operation

a. Provide motor operator to rotate crane boom. Operator to be bolted to back side of head assembly.

b. Type: Variable frequency, direct drive allowing single or multiple speed applications, with torque limiter and worm gear reducer in oil bath.

c. Motor: 1 HP (min.), 1800 RPM, 3 phase, Class B, 40 degrees C ambient continuous, C faced, 30 minutes rated. Motor shall be enclosed and fan cooled. 1 HP motor is the minimum. Actual motor will be sized by the Contractor to meet boom operation requirement and shall be submitted for approval.

d. Controls: Pre-wired controls in NEMA 12 enclosure with magnetic reversing starter, thermal overload protection, voltage transformer, and fuse block.

e. Supply power: single speed standard, 208/230 or 460-60Hz-3ph to meet the available power at the project

2.1.3 Accessories

a. Electrical bottom entry collector: Provide electrical collector installed in weight bearing channel of head assembly to conduct electrical power from inside mast through mast pivot pin to motor operator on head assembly and electrically operated hoist on boom.

Collector shall allow continuous 360 degrees crane rotation.

b. Tagline festoon system: Provide system of wire rope tagline or S-hooks, and brackets and eyebolts for attachment to boom. System shall support electrical cable supplying trolley hoist moving along boom.

2.1.4 Motorized Hoist and Trolley

2.1.4.1 General

Hoist and trolley shall be from the same company. The capacity is 2 tons.

2.1.4.2 Motorized Hoist

Hoist shall be in accordance with UL 1340 “Standard for Hoists" and ASME B30.16. The hoists’ enclosure ratings shall provide protection against water jets from any direction in accordance with IP55. Button pendant control station shall have IP65 rating. The hooks shall be equipped with spring loaded latch type throat closures. Transmission shall comprise of spur and helical gearing operating in an oil bath. The oil compartment shall be equipped with a pressure relief vent plug.

SECTION 41 22 13 Page 6

a. Capacity: 2 tons.

b. Motor shall be of the totally enclosed fan-cooled squirrel cage induction type. The motor’s insulation shall meet Class B requirements.

208V/230V/460V-60Hz-3ph. Control voltage is 110V.

c. Single speed motor: short time rating - 60 minutes; Intermittent rating: 60% ED, 360 starts / hr.

d. Brake: The electromagnetic brake is at least 150% braking capacity, and rated for at least 1,000,000 brake operations before adjustment. A secondary brake shall be installed in the transmission between the hoists’ electric motor and the load sheave to provides an additional safety feature.

e. Friction clutch shall be in the transmission between the hoists’ electric motor and the load sheave. The friction clutch shall prevent the motor from turning the load sheave when the load exceeds the friction clutch setting.

f. Limit switch: hoist shall be equipped with fixed, non-adjustable over-travel limit switches for the Up and Down directions of hoist operation. The limit switches, when activated, shall interrupt the control circuit to prevent additional lifting or lowering.

g. The button pendant control station shall have a rating of IP65. The pendant shall connect to the hoist via a quick disconnect plug/socket assembly and it shall be equipped with integral strain relief. E-stop shall be provided on all pendants.

h. Load chains: Nickel-plated, Grate 80. Provide steel chain container.

i. Lift: 16 ft.

j. Hook: steel. Hook will be equipped with latch type throat closure.

k. The electric chain hoists shall be equipped with a microprocessor based meter with on-board readout for monitoring the number of starts/stops and total hoist run time.

Contractor shall also provide all required accessories for the proper operation of motorized hoist. Hoist will be Harrington Electric Chain Hoists, Series ER2M or Government approved equal.

2.1.4.3 Motorized Trolley

a. Capacity: 2 tons

b. Power: 208-230/460V/60Hz/3ph. Power shall be compatible with the available power source at project site without the need of transformer.

c. Single speed motor: Short time rating - 30 minutes; intermittent rating - 40% ED, 240 starts / hr.

d. Enclosure rating: IP55

e. Button pendant: Provide a four-button pendant control station with a rating of IP65. The pendant shall connect to the trolley control box via a quick disconnect plug/socket assembly. It shall be equipped with

SECTION 41 22 13 Page 7 integral strain relief and an emergency stop button on the control station.

f. The motorized trolleys shall be equipped with a microprocessor based meter with on-board readout for monitoring the number of starts/stops and total hoist run time.

Contractor shall also provide all required accessories for the proper operation of motorized trolley. Trolley will be Harrington Electric Chain Hoists, Series MR2 or Government approved equal.

2.1.5 Crane Safety

Comply with the mandatory and advisory safety requirements of ASME B30.2 and NFPA 70.

2.2 STRUCTURAL, ELECTRICAL AND MECHANICAL REQUIREMENTS

a. Anchor bolts: Galvanized steel that meet the crane manufacturer's recommendation.

b. Bolts, nuts and washers: galvanized steel, ASTM F3125/F3125M

2.3 CRANE PAINTING

Paint exposed portions of the crane in manufacturer's standard. Desired color is brilliant yellow.

Coat faying surfaces of bolted connections per AISC 325, but do not apply finish paint.

Factory paint electrical and mechanical equipment in accordance with the manufacturer's best standard practice (for the specified environment), except that electrical equipment doors, which expose current-carrying electrical conductors when opened, must be orange.

2.4 IDENTIFICATION PLATES

Furnish and install identification plates. Provide non-corrosive metal identification plates with clearly legible permanent lettering giving the manufacturer's name, model number, serial number, capacity in both kilogram and pound units printed in different colors, and other essential information or identification.

2.4.1 Markings on Crane, Trolley, and Hook

Markings include: trolley motion direction arrows on both sides of trolley. Markings must be visible from push button station and from the loading point, corresponding to the push button labeling on the pendant pushbutton station. Mark the hook rated capacity in pounds or tons on both sides of the hoist load block.

PART 3 EXECUTION

3.1 INSTALLATION

Install crane and accessories in accordance with manufacturer's instructions and shop drawings. Contractor shall submit shop drawings that show installation details for approval.

SECTION 41 22 13 Page 8

a. Mast: Use base plate mounted, insert mounted or sleeve mounted.

b. Boom: Set boom on head assembly attach with bolts and other hardware. Level boom with shims or adjusting hexnuts.

c. End stops: In conjunction with hoist trolley installation, bolt end stops to boom ends.

d. Install tagline to boom with brackets and tension wire rope with eyebolts. Run festoon cable through S-hooks for connection to hoist.

3.2 FIELD QUALITY CONTROL

3.2.1 Post-Erection Inspection

3.2.2 Operational Tests

Check the clearance envelope of the entire crane prior to picking or traversing any load to ensure there are no obstructions. Test the systems in service to determine that each component of the system operates as specified, is properly installed and adjusted, and is free from defects in material, manufacture, installation, and workmanship. Rectify all deficiencies disclosed by testing and retest the system or component to prove the crane is operational. The Contractor must furnish test loads, operating personnel, instruments, and other apparatus necessary to conduct field tests on each crane.

3.2.3 Test Data

Record test data on appropriate test record forms suitable for retention for the life of the crane. Record operating and startup current measurements for electrical equipment (motors and coils) using appropriate instrumentation (i.e., clamp-on ammeters). Compare recorded values with design specifications or manufacturer's recommended values; abnormal differences (i.e., greater than 10 percent from manufacturer's or design values) must be justified or appropriate adjustments performed. In addition, note, investigate, and correct any high temperatures or abnormal operation of any equipment or machinery. Record hoist, trolley, speeds during each test cycle.

3.2.4 No-Load Test

Raise and lower the hook through the full range of normal travel at rated speed for three complete cycles. Raise and lower the hook, testing other speeds of the crane. Verify proper operation of hoist limit switches.

Operate trolley in each direction the full distance between end stops.

Operate through the entire speed range and verify proper brake operation.

3.2.5 Load Tests

Perform the following tests, as specified, with test loads of 100 percent (plus 0 minus 10) or 125 percent (plus 5 minus 0) of rated load.

3.2.5.1 Hoist

Disconnect or adjust the overload limit device to allow the hoist to lift the test load. Proof test the overload limit device after it is reconnected.

a. Static Load Test 125 percent only: Check entire structure, holding brake and hoisting components as follows: With the trolley in the

SECTION 41 22 13 Page 9 center of the span, raise the test load approximately one foot. Hold the load for 10 minutes. Rotate the load and hook 360 degrees to check bearing operation with no binding. Observe lowering that may occur which indicates a weakness in the structure or malfunction of hoisting components or brakes.

b. Raise and lower and test load through the full lift range. Operate continuously for a minimum of 5 minutes. As a minimum, operate in each speed for each test load. In addition, the dynamic test of test load sequence number 2 (125 percent of rated load) must be repeated for 10 cycles at rated speed, in order to demonstrate proper operation and repeatability of all functions without component overheating or malfunction. Completely stop the machinery at least once in each direction during each cycle to ensure proper brake operation. Do not stop hoist for more than 15 seconds prior to commencing the next cycle.

c. Hoist Load Brake: Raise test load approximately 5 feet. With the hoist controller in the neutral position, release (by hand) the holding brake. Document the method used to release the holding brake. The load brake must hold the test load. Again with the holding brake in the released position start the test load down (first point) and return the controller to the "off" position as the test load lowers. The load brake must stop and hold the test load.

3.2.5.2 Trolley

Operate the trolley the full distance in each direction with a test load of 125 percent of rated load on the hook (one cycle). Check proper functioning of all drive speed control points. Verify proper brake action.

3.2.5.3 Rated Travel Tests

Repeat travel tests for trolley with a test load of 100 percent of rated load. Repeat the test for 5 cycles at rated speed to demonstrate proper operation and repeatability of all functions without the overheating or malfunction of any components. Completely stop the machinery at least once in each direction during each cycle to ensure proper brake action. Do not stop machinery for more than 15 seconds prior to commencing the next cycle.

-- End of Section --

SECTION 41 22 13 Page 10

SECTION 26 05 13

MEDIUM-VOLTAGE CABLE

PART 1 GENERAL

1.1 GENERAL

1.1.1 Outer Diameter Restriction

The permanent replacement cables shall have an outer diameter capable of allowing the cables to be pulled through existing 4-inch nominal rigid steel conduit risers, each having an unverified inner diameter of 4.026 inches and running vertically for 18 ft maximum.

1.1.2 Scope

This section covers two separate cable systems: the permanent replacement cable, 3-conductor 15kV 2 AWG copper with shielding and insulation in compliance with NFPA 70 (National Electrical Code).

1.2 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.

ASTM INTERNATIONAL (ASTM)

ASTM B3 (2013) Standard Specification for Soft or Annealed Copper Wire

ASTM B8 (2011) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM B33 (2010; R 2014) Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes

ASTM B172 (2017) Standard Specification for Rope-Lay-Stranded Copper Conductors Having Bunch-Stranded Members, for Electrical Conductors

ASTM B174 (2017) Standard Specification for Bunch-Stranded Copper Conductors for Electrical Conductors

ASTM B496 (2016) Standard Specification for Compact Round Concentric-Lay-Stranded Copper Conductors

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 48 (2009) Standard for Test Procedures and Requirements for Alternating-Current Cable Terminations Used on Shielded Cables Having Laminated Insulation Rated 2.5 kV through 765 kV or Extruded Insulation Rated 2.5 kV through 500 kV

IEEE 386 (2016) Separable Insulated Connector Systems for Power Distribution Systems Rated 2.5 kV through 35 kV

IEEE 1202 (2006; R 2012; CORR 1 2012)

Flame-Propagation Testing of Wire and Cable

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA WC 74/ICEA S-93-639 (2012) 5-46 kV Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2013) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 44 (2014; Reprint Feb 2015) Thermoset-Insulated Wires and Cables

UL 1072 (2006; Reprint Jun 2013) Medium-Voltage Power Cables

UL 1569 (2014; Reprint Jul 2016) UL Standard for Safety Metal-Clad Cables

UL 1685 (2015) UL Standard for Safety Vertical-Tray Fire-Propagation and Smoke-Release Test for Electrical and Optical-Fiber Cables

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-01 Preconstruction Submittals

Submit within 90 days after Notice To Proceed:

Cable Installation Plan and Procedure; G

SD-03 Product Data

Submit within 60 days after Notice To Proceed:

Permanent Medium-Voltage Cable; G

Medium-Voltage Cable Terminations

SD-06 Test Reports

Submit five certified copies within 10 days after completion of tests:

Insulation Resistance Test

High Potential Test

Shield Resistance Test

SD-07 Certificates

Cable Terminator; G, HDC

Cable Installer Qualifications; G, HDC

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

The cables shall be furnished one length to a reel or coil. Each length, and the outside of each reel or coil, shall be plainly marked or tagged to indicate the cable length, voltage rating, conductor size, and manufacturer's lot number and reel number. Reels shall remain the property of the Contractor.

1.4.2 Marking

Tags or band markers must be securely fastened to the cables at each termination, junction or pull box, where cables enter or leave cable trays, and as required at other points of access. Tube-type markers shall be used at each terminating end of the conductor and shall be suitable for contact with the type of insulation material used. Tubing shall have permanent black marking on a light-colored background. The markers shall have been tested by an independent testing laboratory or by the manufacturer to indicate that the markers will not stain or discolor when subjected to an accelerated aging test while in contact with wire insulating materials and ultraviolet light exposure. Designations shall be as shown on the Contract drawings or as otherwise shown on approved shop drawings.

1.5 INSPECTION AND TESTS

1.5.1 General

Inspection and tests of wire and cable furnished under these specifications shall be made by and at the plant of the manufacturer. Testing in general shall comply with Section 9 of NEMA WC 74/ICEA S-93-639. Specific tests required for particular materials, components, and completed cables shall be as specified in the sections of the above standards applicable to those materials, components, and cable types. Tests shall also be performed in accordance with the additional requirements specified below.

1.5.2 Flame Tests

All multiple-conductor and single-conductor cable assemblies shall pass IEEE 1202 flame tests (formerly under IEEE 383) or UL 1685 flame tests.

Single-conductor cables and individual conductors of multiple-conductor cables shall pass the flame test of Section 10.6 of NEMA WC 74/ICEA S-93-639.

If such tests, however, have previously been made on identical cables, these tests need not be repeated. Instead, certified reports of the original qualifying tests shall be submitted.

1.5.3 Independent Tests

The Government may at any time make visual inspections, continuity or resistance checks, insulation resistance readings, power factor tests, or DC high-potential tests at field test values. A cable's failure to pass these tests and inspections, or failure to produce readings consistent with acceptable values for the application, will be grounds for rejection of the cable.

1.6 QUALITY ASSURANCE

1.6.1 Certificate of Competency for Cable Terminator

The cable terminator's Supervisor must have a certification from the National Cable Splicing Certification Board (NCSCB) in the field of terminating shielded medium voltage (5 kV to 35 kV) power cable using pre-manufactured kits (pre-molded, heat-shrink, cold shrink). Submit "Proof of Certification" for approval, for the Supervisor of the individuals that will be performing cable splicer and termination work, 30 days before terminations are to be made.

Certification of the qualification of the cable terminator Supervisor shall be submitted, for approval, 30 days before splices or terminations are to be made in medium voltage (5 kV to 35 kV) cables. The certification shall include the training, and experience of the individual on the specific type and classification of cable to be provided under this contract. The certification shall indicate that the individual has had three or more years recent experience terminating medium voltage cables.

The certification shall also list a minimum of three terminations that have been in operation for more than one year.

1.6.2 Cable Installer Qualifications

Provide at least one onsite person in a supervisory position with a documented level of competency and experience to supervise all cable pulling operations. Provide a resume showing the cable installers' experience in the last three years, including a list of references complete with points of contact, addresses and telephone numbers. Cable installer must demonstrate experience with a minimum of three medium voltage cable installations. The Contracting Officer reserves the right to require additional proof of competency or to reject the individual and call for an alternate qualified cable installer.

PART 2 PRODUCTS

2.1 PERMANENT MEDIUM-VOLTAGE CABLE

2.1.1 General

Cable shall be provided by the Contractor and shall conform to the requirements specified herein. Characteristics, including conductor size, stranding, number of conductors, rated circuit voltage, cabling, and other requirements for each type of service, shall be as indicated on the drawings, or as specified under the detailed requirements of these specifications for the particular construction or use, unless otherwise stated.

2.1.2 Wire and Cable Schedule

Permanent cable shall be furnished in accordance with the requirements of the Cable Isometric Diagram as indicated on the drawings. Estimated quantities listed in the Cable Isometric Diagram are approximate for bidding purposes and shall be verified by the Contractor.

2.1.3 Governing Standards

Materials, construction and tests, unless otherwise specified, shall conform to the applicable requirements of NEMA WC 74/ICEA S-93-639.

2.2 MATERIALS

2.2.1 Submittal Requirements

The Contractor shall submit catalog data to the Contracting Officer for review and/or approval as indicated in the submittal register. Data shall demonstrate compliance with the specifications requirements for all wire and cable types to be provided.

2.2.2 Rated Circuit Voltages

All wire and cable shall have minimum rated circuit voltages in accordance with NEMA WC 74/ICEA S-93-639.

2.2.3 Conductors

2.2.3.1 Material for Conductors

Conductors shall conform to all the applicable requirements of Section 2 of NEMA WC 74/ICEA S-93-639 and shall be annealed copper wire conforming to ASTM B3. Copper conductors may be bare, or tin- or lead-alloy-coated, if required by the type of insulation used. Tin-coated copper conductors shall conform to ASTM B33. Conductors shall be stranded as required by subparagraph entitled Stranding.

2.2.3.2 Size

Sizes shall be as indicated on the contract drawings.

2.2.3.3 Stranding

Conductor stranding classes cited herein shall be as defined in Appendix H of NEMA WC 74/ICEA S-93-639. Conductors No. 10 AWG and smaller shall be solid or have Class B stranding as defined in Table 1 of ASTM B8. All other conductors shall have class B stranding.

2.2.4 Insulation

2.2.4.1 Insulation Voltage Rating and Insulation Level

The rated voltage of the insulation shall be 5,000 volts for all circuits operating between 2,000 volts and 5,000 volts, with 133 percent insulation level, minimum 110 mils. The rated voltage of the insulation shall be 15,000 volts for all circuits operating above 5,000 volts, with 133 percent insulation level.

2.2.4.2 Insulation Material

Except as otherwise specified, insulation shall be an ethylene-propylene rubber (EPR) type meeting the requirements of Section 4.1 of NEMA WC 74/ICEA S-93-639 as applicable, and shall be shielded in accordance with NFPA 70 (NEC), Article 310.10, Paragraph (E).. Polyvinyl Chloride (PVC) insulation and thermoplastic type T insulation will not be accepted.

2.2.4.3 Insulation Thickness

The insulation thickness of the individual conductors of multiconductor cables shall be as required by NEMA WC 74/ICEA S-93-639 Section 4 Tables for EPR.

2.2.4.4 Insulation Shielding

Shielding shall be provided for all cables rated 5kV and higher, except only for internal direct connection of bus to surge protection devices within a circuit breaker enclosure or transformer enclosure. For this purpose only, cables listed as Jumper Cable with the appropriate voltage rating may be used. Cables listed as Welding Cable will not be accepted.

Shielding for all cables rated 5kV and higher shall conform to the requirements of Sections 5 and 6 of NEMA WC 74/ICEA S-93-639.

2.2.5 Jackets

All cables shall have jackets meeting the requirements of Section 7.1 of NEMA WC 74/ICEA S-93-639 as applicable, and as specified herein.

Individual conductors of multiple-conductor cables shall be required to have jackets only if they are necessary for the conductor to meet other specifications herein. Jackets of single-conductor cables and of individual conductors of multiple-conductor cables, except for shielded cables, shall be in direct contact and adhere or be vulcanized to the conductor insulation. Multiple-conductor cables and shielded single-conductor cables shall be provided with a common overall jacket, which shall be tightly and concentrically formed around the core. Repaired jacket defects found and corrected during manufacturing are permitted if the cable, including jacket, afterward fully meets these specifications and the requirements of the applicable standards.

2.2.5.1 Jacket Material

The jacket shall be one of the materials listed below, in accordance with the applicable paragraphs of Section 7 of NEMA WC 74/ICEA S-93-639.

Polyvinyl chloride compounds will not be permitted. Variations from the materials required below will be permitted only if approved for each specific use, upon submittal of sufficient data to prove that they exceed all specified requirements for the particular application.

a. Heavy-duty black neoprene (CR-HD).

b. Heavy-duty chlorosulfonated polyethylene (CSPE-HD).

c. Heavy-duty cross-linked (thermoset) chlorinated polyethylene

(CPE-XL-HD).

2.2.5.2 Jacket Thickness

The minimum thickness of the jackets of the individual conductors of multiple-conductor cables shall be as required by the tables in Section 7 of NEMA WC 74/ICEA S-93-639, and shall be in addition to the conductor insulation thickness for the insulation used. Thickness of the outer jackets or sheaths of the assembled multiple-conductor cables shall be as required by Section 7 of NEMA WC 74/ICEA S-93-639.

2.2.6 Cabling

Individual conductors of multiple-conductor cables shall be assembled with flame-and moisture-resistant fillers, binders, and a lay conforming to Section 8 of NEMA WC 74/ICEA S-93-639, except that flat twin cables will not be permitted. Fillers shall be used in the interstices of multiple-conductor round cables with a common covering where necessary to give the completed cable a substantially circular cross section. Fillers shall be non-hygroscopic material, compatible with the cable insulation, jacket, and other components of the cable. The rubber-filled or other approved type of binding tape shall consist of a material that is compatible with the other components of the cable and shall be lapped at least 10 percent of its width.

2.2.7 Dimensional Tolerance

The outside diameters of single-conductor cables and of multiple-conductor cables shall not vary more than 5 percent and 10 percent, respectively, from the manufacturer's published catalog data.

2.2.8 Ground Conductors

Ground conductors shall be bare, soft-drawn, Class A or B stranded copper cables sized in accordance with NFPA 70 or NEMA WC 74/ICEA S-93-639 Section 8 as applicable.

2.3 MEDIUM-VOLTAGE CABLE TERMINATIONS

Medium-voltage cable terminations shall be molded elastomer, prestretched elastomer, or heat-shrinkable elastomer, and shall be Class 1A meeting IEEE 48 requirements for outdoor or cable tunnel locations and Class 2 for indoor terminations within enclosures. Acceptable elastomers are track-resistant silicone rubber or track-resistant ethylene propylene compounds, such as ethylene propylene rubber or ethylene propylene diene monomer. Separable insulated connectors may be used for apparatus terminations, when such apparatus is provided with suitable bushings.

Terminations, where required, must be provided with mounting brackets suitable for the intended installation and with grounding provisions for the cable shielding, metallic sheath, or armor. Terminations must be provided in a kit, including: skirts, stress control terminator, ground clamp, connectors, lugs, and complete instructions for assembly and installation. Terminations must be the product of one manufacturer, suitable for the type, diameter, insulation class and level, and materials of the cable terminated. Do not use separate parts of copper or copper alloy in contact with aluminum alloy parts in the construction or installation of the terminator. Terminations shall utilize stress cones with long barrel, NEMA two-hole or four-hole compression-type terminals approved for connection to copper conductors.

2.3.1 Cold-Shrink Type

Terminator must be a one-piece design, utilizing the manufacturer's latest technology, where high-dielectric constant (capacitive) stress control is integrated within a skirted insulator made of silicone rubber. Termination must not require heat or flame for installation. Termination kit must contain all necessary materials (except for the lugs). Termination must be designed for installation in low or highly contaminated indoor and outdoor locations and must resist ultraviolet rays and oxidative decomposition.

2.3.2 Heat Shrinkable Type

Terminator must consist of a uniform cross section heat shrinkable polymeric construction stress relief tubing and environmentally sealed outer covering that is nontracking, resists heavy atmospheric contaminants, ultra violet rays and oxidative decomposition. Provide heat shrinkable sheds or skirts of the same material. Termination must be designed for installation in low or highly contaminated indoor or outdoor locations.

PART 3 EXECUTION

3.1 INSTALLATION INSTRUCTIONS

3.1.1 General

All cable shall be installed in accordance with NFPA 70 requirements. All necessary materials, tools and equipment required for proper handling and installation of wire and cable in conduits, cable trays, and elsewhere shall be furnished by the Contractor. Each cable shall be connected to the associated equipment at both ends, and new cable shall be continuous and without splices between the equipment termination points. Any cable damaged during installation shall be removed and replaced. Installation of cable shall include installation of all supporting devices and all terminations required to complete the circuits as required.

3.1.2 Phasing

All terminal connections for power cables and conductors shall be made in such manner that the phasing will be as marked on the equipment, or indicated on the approved shop drawings. The Contractor shall verify phasing on existing wiring before disconnecting and removing. The Contractor is also responsible for verifying that the phasing on new wiring is the same rotation as presently existing wiring. Normal phasing for existing equipment is A-B-C from left to right, from top to bottom and from front to back when facing the front of the equipment, but contractor shall verify. After cables have been terminated and the connection torqued, insulate all exposed parts to the cable's voltage rating.

3.1.3 Cable Pulling Requirements

Cable shall be pulled in a manner which will preclude damage to the conductor, insulation or jacket. Cable shall be pulled by the conductor and not by the insulation, jacket, or sheath. Pulling tension shall not exceed the manufacturer's recommended maximum. Strain gages shall be used when pulling cable if any kind of mechanical pulling device is required for installation. Where the puller is attached to the outer jacket of a cable pulling tension shall be limited to 100 lbs. Caution should be used to avoid exceeding the side wall rating of the cable. Any cable or conductor damaged during installation shall be removed and replaced with equivalent cable or conductor. Installation of cable shall include installation of all supporting devices and all terminations and identifications required to complete the circuits as shown on the drawings and as required.

3.1.4 Installation in Conduit

Cable shall not be pulled into conduit runs until the conduit has been checked for obstructions and determined to be clean and dry. Only lubricants approved by the cable manufacturer may be used to facilitate pulling of conductors.

3.1.5 Installation in Cable Trays

Cable pulling sheaves of adequate size shall be used where necessary to prevent damage to the cable. Cables shall be placed straight and parallel in the trays. There shall be minimum crossing of cables in trays. If two or more single conductors comprising a circuit to and from electrical equipment are routed in a cable tray, they shall be bundled together at intervals not to exceed six feet with approved cable ties. Identification markers shall be installed on each tied bundle at intervals not to exceed 18 feet. After all work in the area containing new cables is complete, the trays shall be thoroughly cleaned of all dirt and trash generated by the new cable installation. Cable moved in the cleaning process shall be repositioned and final cable positions in the trays checked and corrected if necessary. Each cable shall be secured to the tray with approved cable cleats, spaced at intervals as recommended by the cable tray/cable cleat manufacturer for an available fault current of 16.8kA symmetrical.

3.1.6 Bends

The minimum radius to which an insulated conductor or a multiconductor cable may be bent, without specific approval, whether permanently or temporarily during installation, shall be 12 times the overall diameter of the completed cable for tape-shielded cables and 10 times the overall diameter for other cables. In these instances where this radius is not possible, approval will be required for minimum radii as specified in NFPA 70. For multiconductor cable, follow manufacturer's recommendation for type of cable involved.

3.1.7 Cable Clamps

Clamps for protecting and supporting the weight of cables installed in vertical wireways shall be as required per NFPA 70 for adequate support.

The size of each clamp shall be in accordance with the manufacturer's recommendations for each diameter and weight of cable to be supported or protected.

3.1.8 Splices

Splices shall be by splice kits applied in strict compliance with the cable manufacturers' recommendations, as well as in compliance with code and any other requirements in these specifications.

3.1.9 Medium-Voltage Cable Terminations

The shield and shield insulating jacket of shielded cables shall be maintained to a point as close to the terminals as possible. The shield insulating jacket shall not be stripped from the shield except where necessary to make the ground connection. All cable shields shall be grounded at one end only unless otherwise indicated. Heat shrink, cold shrink or tape type stress cone terminating and splice kits shall be in accordance with the cable manufacturer's recommendations and as approved.

Installation of the stress cone terminations shall be as described in the kit instructions, except the taping of conductor terminals shall be extended over the terminal fitting and the terminal of the device to which the conductor is attached.

3.1.10 Cable Marking

All cables shall be marked as described in subparagraph Marking. All multiple conductor cables shall be clearly identified with the cable designation by either embossed 1-inch diameter brass tags or by embossed aluminum band markers. Tags or band markers shall be securely fastened to the cables at each termination, junction or pull box, where cables enter or leave cable trays, and as required at other points of access. Cables and individual conductors of multiconductor cables shall be identified with non-metallic tube type markers at each termination. Installed markers shall be uniform in position on the cable and legends shall be visible when conductors are terminated at the equipment. Designations on markers shall be as shown on the contract drawings or as otherwise shown on approved shop drawings.

3.1.11 Ground Conductors

A ground conductor shall be run for all circuits. If not an integral part of a multiple conductor cable, a separate ground conductor shall be provided. Ground conductors shall be installed as continuous pieces of copper cable whenever possible. Exposed ground cable runs shall be supported to follow conduit, equipment or concrete wall contours. Support clamps or clips shall be of corrosion resistant metal and existing equipment bolts or screws shall be used where possible for fastening.

Drilling of equipment housings or frames will be permitted only when approved. Concrete anchors shall be used for wall fastening.

3.2 CABLE INSTALLATION PLAN AND PROCEDURE

Obtain from the manufacturer an installation manual or set of instructions which addresses such aspects as cable construction, insulation type, cable diameter, bending radius, cable temperature limits for installation, lubricants, coefficient of friction, conduit cleaning, storage procedures, moisture seals, testing for and purging moisture, maximum allowable pulling tension, and maximum allowable sidewall bearing pressure. Prepare a checklist of significant requirements, perform pulling calculations and prepare a pulling plan, and submit along with the manufacturer's instructions in accordance with SUBMITTALS. Install cable strictly in accordance with the cable manufacturer's recommendations and the approved installation plan.

Calculations and pulling plan must include:

a. Site layout drawing with cable pulls identified in numeric order of expected pulling sequence and direction of cable pull.

b. List of cable installation equipment.

c. Lubricant manufacturer's application instructions.

d. Procedure for resealing cable ends to prevent moisture from entering cable.

e. Cable pulling tension calculations of all cable pulls.

f. Cable percentage conduit fill (as applicable).

g. Cable sidewall bearing pressure.

h. Cable minimum bend radius and minimum diameter of pulling wheels used.

i. Cable jam ratio.

j. Maximum allowable pulling tension on each different type and size of conductor.

k. Maximum allowable pulling tension on pulling device.

l. Net weights and load plans of loaded reel stands when reels are staged for installation.

3.3 FIELD ACCEPTANCE TESTING

3.3.1 Testing

Testing shall be per NETA ATS recommended procedures.

a. Submit Test Reports in accordance with referenced standards in this section.

b. After completion of the installation and prior to energizing the conductors, perform wire and cable continuity and insulation tests as herein specified.

c. Contractor must provide all necessary test equipment, labor, and personnel to perform the tests, as herein specified.

d. Field Acceptance Testing and submittals shall be performed as described herein.

e. Isolate completely all wire and cable from all extraneous electrical connections at cable terminations and joints. Substation and switchboard feeder breakers, disconnects in combination motor starters, circuit breakers in panel boards, and other disconnecting devices must be used to isolate the circuits under test.

f. Suitable records shall be kept of all tests, indicating the insulation-resistance tests, high voltage tests, continuity tests, phase rotation tests high potential tests, and conductor identification markings. A duplicate record of all tests shall be furnished to the Contracting Officer. Prior to testing, the wire and cable test record form shall be submitted for approval.