W912P522B0002 Amend. 0001 TPlans 2022.02 (2).pdf

Gearbox Heater System Kentucky Lock W912P522B0002, Amend. 0001 Ready to Advertise Livingston County, Kentucky

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

SECTION 26 05 00

ELECTRICAL SUPPLY AND CONTROLS TO GEARBOX HEATERS

PART 1 GENERAL

1.1 SCOPE

1.1.1 "FOR INFORMATION ONLY" Drawings

1.1.2 Design Drawings

1.2 REFERENCES

1.3 COMMERCIAL POWER SERVICE

1.3.1 Existing Power Service

1.3.2 Testing

1.3.3 Temporary Contractor Power and Water

1.4 GENERAL REQUIREMENTS

1.4.1 Standard Products

1.4.2 Equipment

1.4.3 Exposures

1.4.4 Corrosion-Resisting Materials

1.5 SUBMITTALS

1.6 LOCKOUT AND TAGOUT PROCEDURES

1.7 DELIVERY, HANDLING, AND STORAGE

1.7.1 Inspection

1.7.2 Shipment of Wire and Cable

1.7.3 Storage

1.8 IDENTIFICATION OF EQUIPMENT, CABLES, CONDUCTORS, AND CIRCUITS

1.8.1 General

1.8.2 Cables and Conductors Identification

1.9 WARRANTY

1.10 SAFETY

PART 2 PRODUCTS

2.1 CONDUIT AND CONDUIT FITTINGS

2.1.1 Rigid Steel Conduit

2.1.2 Flexible Metallic, Steel

2.1.3 Conduit Fittings, Conduit Outlets, and Outlet Boxes

2.2 SAFETY SWITCHES

2.3 HEATER CONTROL BOX

2.3.1 Contactor

2.3.2 Control Transformer

2.3.3 Fuses

2.3.4 Switches

2.3.4.1 Disconnect Switch

2.3.4.2 Selector Switch

2.4 GROUNDING MATERIALS

2.4.1 Bare Copper for Grounding Use

2.4.2 Grounding Conductors

2.5 JUNCTION AND PULL BOXES

2.6 INSULATED WIRE AND CABLE

SECTION 26 05 00 Page 1

2.6.1 General

2.6.2 Governing Standard

2.6.3 Rated Circuit Voltages

2.6.4 Conductors

2.6.4.1 Size

2.6.4.2 Stranding

2.6.5 Insulation

2.6.5.1 Material

2.6.5.2 Insulation Thickness

2.6.6 Jackets

2.6.6.1 Material

2.6.6.2 Jacket Thickness

2.6.7 Color Coding

2.6.8 Cabling

2.6.9 Dimensional Tolerance

PART 3 EXECUTION

3.1 EXAMINATION

3.2 INSTALLATION

3.2.1 Instructions

3.2.2 Requirements

3.2.2.1 General

3.2.2.2 Conduit Installation

3.2.2.3 Wiring

3.2.2.4 Grounding

3.2.2.4.1 Connections between Copper Cables

3.2.2.4.2 Connections to Equipment and Materials

3.2.3 Concrete Sawcut and Core Drilling

3.3 FIELD TESTS

3.4 TESTS AND FINAL ACCEPTANCE

3.4.1 Final Inspection and Tests

3.4.2 Test Reports

-- End of Section Table of Contents --

SECTION 26 05 00 Page 2

SECTION 26 05 00

ELECTRICAL SUPPLY AND CONTROLS TO GEARBOX HEATERS

PART 1 GENERAL

1.1 SCOPE

This section of the specifications consists of the means supplying power to the gearbox heaters. The gearbox heater system requires new heater controls, new fused disconnect switches, new cable, and the use of new conduit starting at the 480V shore power station and terminating at the immersion plug heaters located within the gate machinery recesses.

1.1.1 "FOR INFORMATION ONLY" Drawings

Existing Kentucky Lock drawings, included in the set of contract drawings listed below, are provided "FOR INFORMATION ONLY". The Government cannot guarantee that the information on the drawings is up-to-date. It is the Contractor's responsibility to verify all information and dimensions as needed with a site inspection.

Reference Drawing List:

See the cover sheet of the technical plans for the list for reference drawings.

1.1.2 Design Drawings

Design Drawing List:

E-101 - Plans & Details, Gearbox Heater System Layout E-102 - Plans & Sections, Gate Mach. Recesses & Heater Conduit Path E-601 - Wiring Diagram, Combination Heater Contactor

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 B8 (2011; R 2017) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 383 (2015) Qualifying Class 1E Electric Cables and, Field Splices for Nuclear Power Generating Stations 2004

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

ANSI/NEMA OS 1 (2013; R 2020) Sheet-Steel Outlet Boxes, SECTION 26 05 00 Page 3

Device Boxes, Covers, and Box Supports

NEMA KS 1 (2013) Enclosed and Miscellaneous Distribution Equipment Switches (600 V Maximum)

NEMA WC 70 (2009) Power Cable Rated 2000 V or Less for the Distribution of Electrical Energy--S95-658

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

UNDERWRITERS LABORATORIES (UL)

UL 6 (2007; Reprint Sep 2019) UL Standard for Safety Electrical Rigid Metal Conduit-Steel

UL 360 (2013; Reprint Oct 2020) UL Standard for Safety Liquid-Tight Flexible Metal Conduit

UL 514A (2013; Reprint Aug 2017) UL Standard for Safety Metallic Outlet Boxes

UL 514B (2012; Reprint May 2020) Conduit, Tubing and Cable Fittings

UL 4248-1 (2017) UL Standard for Safety Fuseholders

- Part 1: General Requirements

1.3 COMMERCIAL POWER SERVICE

1.3.1 Existing Power Service

The Contractor must minimize commercial power outage to all operating elements of the lock at all times. Do not leave operating circuits de-energized at the end of the work day. The Lockmaster and Contracting Officer shall be notified in writing 14 days prior to any required power outage which would exceed 30 minutes in length.

1.3.2 Testing

Upon completion of work, the electrical power and control systems to be installed under this contract shall be tested in accordance with paragraph "FINAL INSPECTION AND TESTS". The Contractor must furnish all power and instruments required for the testing.

1.3.3 Temporary Contractor Power and Water

The Government will make available to the Contractor without charge, all reasonably required amounts of water and electricity for small power tools

SECTION 26 05 00 Page 4 and equipment. The Contractor is responsible for furnishing all utilities and services required for other large equipment.

1.4 GENERAL REQUIREMENTS

All electrical equipment and materials must be new and listed by the Underwriters' Laboratories, Inc. as applicable, except as otherwise specified herein and/or delineated on the drawings. Equipment found to be defective or damaged during the course of installation or testing, shall be replaced or repaired in a manner meeting the approval of the Contracting Officer and at no additional expense to the Government. The contract drawings indicate the extent and general arrangement of the electrical system. The Contractor shall provide suitable storage space and properly store all equipment and materials that he/she is required to furnish. The conditions under which any equipment and materials are to be stored must be in accordance with standard practice, to ensure that all equipment and materials will be in perfect condition at the time of installation. The Contractor shall familiarize himself with regard to the location of all other equipment, materials, or conditions that may affect the electrical installation and shall install all parts of the electrical system so as not to interfere with their installations or to permit any part of the electrical system to be unnecessarily subjected to conditions detrimental to the dependability of the system. The final exact location and mounting of all parts of the electrical system shall be subject to the approval of the Contracting Officer and shall be field coordinated with the powerhouse Superintendent. The contractor shall be responsible for field verification of all dimensions associated with this contract.

1.4.1 Standard Products

Unless otherwise approved in writing by the Contracting Officer, the equipment and materials to be furnished under this contract shall be standard products of manufacturers regularly engaged in the production of such equipment or materials and shall be the manufacturer's latest design.

References to specific manufacturer's products within these specifications and/or contract drawings are for descriptive purposes only.

1.4.2 Equipment

Equipment of the same, similar, or allied service shall be of the same manufacture and type and, shall be interchangeable where practical.

1.4.3 Exposures

The electrical installation in general will be subject to severe moisture and corrosive conditions. All equipment, materials, and workmanship shall provide dependable service under the conditions to be encountered.

1.4.4 Corrosion-Resisting Materials

Stainless steel, copper, brass, bronze, aluminum, and nickel copper alloys are acceptable corrosion-resisting materials. However, contact between dissimilar metals must be avoided as much as practicable.

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

SECTION 26 05 00 Page 5 that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Equipment And Material Lists; G

Lockout And Tagout Procedures

Core Drilling Or Sawcut; G, ECD

SD-02 Shop Drawings

Electrical Wiring Diagrams; G

Control Diagrams; G

SD-03 Product Data

Wire and Cable; G

Disconnect Switch; G

Conduit And Conduit Fittings; G, ECD-E

Combination (Heater) Contactor; G, ECD-E

SD-06 Test Reports

Continuity Test; G

Insulation Resistance Test; G

600-Volt Wiring Test; G

SD-08 Manufacturer's Instructions

Manufacturer's Instructions

1.6 LOCKOUT AND TAGOUT PROCEDURES

The Contractor shall perform lockout and tagout procedures in accordance with EM 385-1-1, and shall coordinate all such procedures with the Contracting Officer before beginning any work involving disconnection and hookup of energized systems. All coordination, lockout and tagout devices, training, and inspections shall conform to the provisions of EM 385-1-1 and shall be submitted in written form to the Contracting Officer for approval.

1.7 DELIVERY, HANDLING, AND STORAGE

1.7.1 Inspection

All electrical equipment shall be checked upon receipt at the site for possible damage due to handling. At this time, a Megger reading shall be made and recorded along with successive periodic readings and inspections until the equipment is installed and put into operation. A minimum of four readings shall be made unless the non-operating or storage period is less than six months, in which case a minimum of three readings shall be obtained prior to energizing.

SECTION 26 05 00 Page 6

1.7.2 Shipment of Wire and Cable

All wire and cable shall be shipped on suitable reels or in coils in accordance with standard practice and shall be plainly marked to indicate the cable size, number and size of conductors, thickness and character of insulation, and other pertinent data including the name of the manufacturer. Wire and cable shall be purchased in such lengths as to ensure that wire and cable runs will be continuous without splices between points of termination.

1.7.3 Storage

All equipment shall be protected by being totally enclosed to prevent the entrance of dust, dirt, or precipitation under all weather conditions. In lieu of a clean, dry, and heated storage warehouse which is preferable, the enclosure may be transparent plastic, sisal Kraft, heavy reinforced building paper, or clean tarps. The Contractor shall provide a means of access to equipment for the periodic Megger readings and inspections. The enclosure shall be vented at the top with a small opening. Within the enclosure and at the base of the equipment, safe electric heat shall be provided to maintain an interior temperature of approximately 10 degrees F above the exterior ambient temperature. When the equipment is installed at the final operating site the above procedure shall also be followed. The specified protection shall start immediately upon delivery and shall be maintained until the equipment is put into operation or until construction has reached a stage where the dirt and moisture conditions are nonexistent. In the event cleaning and drying of electrical equipment is required due to accident or inadequate protection, the Contractor shall submit the procedures and methods he proposes for accomplishment for the approval of the Contracting Officer and he shall be responsible all associated expenses.

1.8 IDENTIFICATION OF EQUIPMENT, CABLES, CONDUCTORS, AND CIRCUITS

1.8.1 General

Equipment, cables, conductors, and circuits shall be identified by nameplates, tags, or labels as applicable and as specified in this paragraph. When the information to be inscribed or printed on a nameplate, tag, or label is not specified or shown on the drawings, the Contractor shall submit tabulations of such information to the Contracting Officer for approval and shall furnish and install nameplates, tags, or labels as approved. Provide the Equipment And Material Lists for approval.

1.8.2 Cables and Conductors Identification

All multi-conductor cables and each conductor of single-conductor cables as shown on the contract drawings shall be identified. Unless otherwise specified or shown on the drawings, identification shall be made by means of approved round brass tags tied to the cable or conductors at each junction box, conduit box, terminal point and at all other points where the cable enters or leaves a conduit. The tags shall be of an approved brass, 3/4-inch in diameter 1/16-inch thick and the specified inscriptions shall be accomplished by engraving letters 1/8" in height. A hole for attaching the tag shall be provided. Attachment shall be nylon snap-on ties approved by the Contracting Officer.

SECTION 26 05 00 Page 7

1.9 WARRANTY

All equipment furnished under this section of the specifications shall be guaranteed for a period of one year from the final date of acceptance of the project against defective materials, design, and workmanship. Upon receipt of notice from the Government of failure of any part of the guaranteed equipment during the period, the affected part or parts shall be replaced promptly with new parts and at the expense of the Contractor.

1.10 SAFETY

All work shall comply with the applicable requirements of EM 385-1-1.

PART 2 PRODUCTS

2.1 CONDUIT AND CONDUIT FITTINGS

Provide conduits, conduit fittings, outlets, and outlet boxes for approval.

2.1.1 Rigid Steel Conduit

Rigid steel conduit shall be galvanized and conform to the requirements of UL 6, except that it shall be zinc-coated inside and out by the hot dip galvanizing process, and in a manner that will also zinc-coat the threads on each end of standard lengths. All exposed conduit and conduit stub-ups shall be rigid steel.

2.1.2 Flexible Metallic, Steel

Flexible metal conduit shall conform to UL 360. The conduit shall be liquid tight.

2.1.3 Conduit Fittings, Conduit Outlets, and Outlet Boxes

Fittings, outlets, and outlet boxes shall conform to UL 514B, ANSI/NEMA OS 1, and UL 514A, respectively, and in addition, conduit outlets (cast type) shall be provided with cast covers and neoprene gaskets unless otherwise specified or indicated. All exposed outlet boxes and fittings installed outdoors shall be malleable iron. All conduit fittings shall be threaded.

Sealing bushings with neoprene ring seals must be provided at openings in conduits and where exposed cables enter conduits or junction boxes.

2.2 SAFETY SWITCHES

Ensure safety switches comply with NEMA KS 1, and are the heavy-duty fused type with enclosure type NEMA 4X, voltage rating of 480 V, current rating of 30 amps, 3 poles, 3 wire, and fusing as indicated on the drawings.

Ensure fused switch fuse holders comply with UL 4248-1. Enclosure material shall be of stainless material and corrosion resistant. Ensure switch construction is such that, when the switch handle in the "ON" position, the cover or door cannot be opened. Cover release device is coinproof and so constructed that an external tool is used to open the cover. Make provisions to lock the handle in the "OFF" position. Ensure the switch is not capable of being locked in the "ON" position.

2.3 HEATER CONTROL BOX

Provide heater control box for each gearbox recess. Heater control box shall be a combination (heater) contactor consisting of components as

SECTION 26 05 00 Page 8 indicated on drawing E-602 . Electrical components other than switches shall be fully encapsulated in a type NEMA 4X enclosure.

2.3.1 Contactor

NEMA 1, control voltage of 120 V.

2.3.2 Control Transformer

480-to-120 volt and 60 Hz with primary fuse protection.

2.3.3 Fuses

Fused switch, rated 460 volt, 3 phase, and 4 wire.

2.3.4 Switches

2.3.4.1 Disconnect Switch

Fused heavy duty-type switch, rated 460 volt, 30 amperes, 3 phase, and 4 wire. Utilize Class R fuses for fused switches. Ensure single operating handle indicates on/off position and is able to disconnect all three poles.

2.3.4.2 Selector Switch

Hand/Auto/Off selector switch.

2.4 GROUNDING MATERIALS

2.4.1 Bare Copper for Grounding Use

Grounding cables must be soft grade, Class B, concentrically stranded copper, unless otherwise noted, and shall conform to ASTM B8.

2.4.2 Grounding Conductors

Minimum size of grounding conductors shall be as noted on the contract drawings. All grounding conductors shall be insulated and must be color-coded green, except as otherwise noted.

2.5 JUNCTION AND PULL BOXES

Pull boxes must be provided and installed as determined necessary by the Contractor and in accordance with standard practices.

2.6 INSULATED WIRE AND CABLE

2.6.1 General

All wire and cable for power feeds to gearbox heaters must be multiple-conductor type XHHW-2 cable as indicated on the contract drawings, as specified, or as required, and shall conform to the specific requirements below.

a. The conductor size, number of conductors, and cabling for any particular application or service must be as indicated on the contract drawings.

SECTION 26 05 00 Page 9

2.6.2 Governing Standard

Materials, construction, fabrication, and tests, unless otherwise specified, must conform to the applicable requirements of NEMA WC 70. The referenced parts only of IEEE 383 form a part of this specification.

2.6.3 Rated Circuit Voltages

All wire and cable for circuits operating at 600 volts and below must have a rated voltage of 600 volts.

2.6.4 Conductors

Conductors must conform to all the applicable requirements of NEMA WC 70, as applicable, and must be annealed copper. Copper conductors must be tin or lead alloy coated, or bare, as required by the type of insulation used.

Conductors must be solid or stranded as required below, unless otherwise specified.

2.6.4.1 Size

Wire sizes must be as indicated on the drawings and shall be verified by the contractor. Minimum conductor size for power circuits shall be 10 AWG.

2.6.4.2 Stranding

Conductors No. 10 AWG and smaller must have Class B stranding. All other conductors shall have Class B or C stranding.

2.6.5 Insulation

2.6.5.1 Material

Insulation shall be a cross-linked-thermosetting-polyethylene type (XLPE) meeting the dimensional, electrical, and physical requirements of NEMA WC 70 or an ethylene-propylene-rubber type (EPR) meeting the dimensional, electrical, and physical requirements of NEMA WC 70.

2.6.5.2 Insulation Thickness

a. Multiple-Conductor Power Cable and Single-Conductor Power Cable. The insulation thickness for wire and cable rated 2,000 volts and below shall be as required by NEMA WC 70 as applicable. Some thicknesses of NEMA WC 70 will be permitted only for single-conductor cross-linked thermosetting polyethylene insulated cables without a jacket.

NEMA WC 70 ethylene-propylene rubber-insulated conductors shall have a jacket. The insulation thickness shall be based on the "Rated Circuit Voltages" of paragraph RATED CIRCUIT VOLTAGE.

b. Multiple-Conductor Control Cable. The insulation thickness of multiple-conductor cables used for control and related purposes shall be as required by NEMA WC 70 as applicable. The insulation thickness shall be based on the "Rated Circuit Voltages" of paragraph "RATED

CIRCUIT VOLTAGE".

2.6.6 Jackets

All single conductors and multiple-conductor cables must have jackets meeting the requirements specified herein unless otherwise specified.

SECTION 26 05 00 Page 10

Individual conductors of multiple-conductor cables must be required to have jackets only if the jackets are necessary for the conductor to meet the flame tests specified herein. Jackets of single conductor cables and individual conductors of multiple-conductor cables, must be in direct contact and adhere or be vulcanized to the conductor insulation.

Multiple-conductor cables shall be provided with a common overall jacket, which must be tightly and concentrically formed around the core.

2.6.6.1 Material

The jacket must be a synthetic thermosetting compound and conform to one of the following:

a. Heavy duty black neoprene in accordance with NEMA WC 70.

b. Heavy duty chlorosulfonated polyethylene in accordance with NEMA WC 70.

c. Heavy duty cross-linked chlorinated polyethylene in accordance with

NEMA WC 70.

2.6.6.2 Jacket Thickness

The minimum thickness of the jackets must be not less than 80 percent of the respective nominal thickness specified below.

a. Multiple-Conductor Cables. Thickness of the jackets of the individual conductors of multiple-conductor cables must be as required by NEMA WC 70, and shall be in addition to the conductor insulation thickness required by Column B of Table 3-1 of the applicable NEMA Publication for the insulation used. Thickness of the outer jackets or sheaths of the assembled multiple-conductor cables shall be as required by NEMA WC 70.

b. Single-Conductor Wires and Cables. Single-conductor wires and cables, where required, must have a jacket thickness as specified in NEMA WC 70.

2.6.7 Color Coding

Individual conductors of multiple-conductor cables shall be color coded in accordance with NEMA WC 70, except that colored braids will not be permitted. Control cable color-coding shall be in accordance with NEMA WC 70. The colors of the insulation on the phase conductors of different voltage systems shall be as follows:

120/208 volt, 3-phase: black, red, and blue (white for grounded neutral) 277/480 volt, 3-phase: brown, orange, yellow 120/240 volt, 1-phase: black and red

Conductor phase and voltage identification must be made by color-coded insulation for all conductors smaller than No.6 AWG. For conductors No.6 AWG and larger, identification must be made by color-coded insulation, or conductors with black insulation may be furnished and identified by the use of bands of colored electrical tape wrapped around the insulation 3 inches apart for the entire length within the indicated enclosure. Conductor identification must be provided within each enclosure where a tap, splice, or termination is made. Phase identification by a particular color must be maintained continuously for the length of a circuit, including junctions.

SECTION 26 05 00 Page 11

2.6.8 Cabling

Individual conductors of multiple-conductor cables must be assembled with flame and moisture resistant fillers, binders and a lay conforming to NEMA WC 70, except that flat twin cables will not be permitted. Fillers must 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 must be compatible with the cable insulation, jacket and other components of the cable. The rubber-filled or other approved type of binding tape must consist of a material which is compatible with the other components of the cable and shall be lapped at least 10 percent of its width.

2.6.9 Dimensional Tolerance

The outside diameter of single-conductor wires and cables and multiple conductor cables must not vary more than five percent and 10 percent, respectively, from the manufacturer's published catalog data.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with details of the work, verify conditions in the field, and advise the Contracting Officer of any discrepancy before performing any work.

3.2 INSTALLATION

3.2.1 Instructions

Install new conduit in accordance with design drawings E-101 and E-102.

Drawings contain on-site conditions and approximate path that shall be taken. Contractor shall coordinate proposed conduit path Contracting Officer Representative before the installation of any new work. Contractor shall provide a submittal of concrete placement plan, mixes and etc to government for approval.

a. Upstream Landwall: Provide materials and labor to wire and control miter gate gearbox heater located at the upper land gate machinery recess, G4. This work includes the following:

1. Install new conduit and new safety switch in accordance with Drawing E-101. Core drilling on lock face in chamber required until joint recess is reached. Connect new conduit to existing conduit located in joint recess.

2. Installation of trenched conduit must be made without sawcutting any existing utilities, existing structural components i.e. rebar, or cross already existing trenches at lock.

3. Install conduit a depth of 6 inches below grade. Backfill trenches with concrete material as indicated on drawings.

4. Existing conduit pentrating into gate machinery recess shall be capped for future use. Provide pull wire rope in the unused conduit.

b. Upstream Riverwall: Provide materials and labor to wire and control one miter gate gearbox heater located at the upper river miter

SECTION 26 05 00 Page 12 gate. This work includes the following:

1. Install new conduit and new safety switch in accordance with Drawing E-101. Core drilling required on outside face of lock required until gate machinery recess is reached. Minimize drilling length to maximum extent possible. Sawcut of the concrete for the installation of the electrical conduits is also acceptable.

2. Installation of trenched portion of conduit shall be made without sawcutting any existing utilities, existing structural components i.e.

rebar, or crossing/overlapping any trenching already existing at lock.

3. Install conduit a depth of 6 inches below grade. Backfill trenches with concrete material as indicated on drawings.

4. New (1 inch dia.) conduit pentrating into gate machinery recess shall be left with a 2-inch stub-up length and capped for future use.

Provide pull wire rope in the unused conduit.

c. Downstream Landwall: Provide materials and labor to wire and control miter gate gearbox heater located at the upper land gate machinery recess, G3. This work includes the following:

1. Install new conduit, cable, safety switch, and heater control box in accordance with Drawings E-101 and E-102.

2. Installation of trenched conduit shall be made without sawcutting existing utilities, existing structural components i.e. rebar, or cross already existing trenches at lock.

3. Install conduit a depth of 6 inches below grade. Backfill trenches with concrete material as indicated on drawings.

4.Install conduit inside machinery recess in accordance with drawings.

Wall mount combination heater contactor as shown. Existing vertical structure not shown on drawings may be used to strap overhead conduit in place and connect to plug heaters.

5. Test newly installed work in accordance with Section TESTS AND FINAL

ACCEPTANCE.

d. Downstream Riverwall: Provide materials and labor to wire and control miter gate gearbox heater located at the lower river gate machinery recess, G2. This work includes the following:

1. Install new conduit, cable, safety switch, and heater control box in accordance with Drawings E-101 and E-102.

2. Installation of trenched conduit shall be made without sawcutting existing utilities, existing structural components i.e. rebar, or cross already existing trenches at lock.

3. Install conduit a depth of 6 inches below grade. Backfill trenches with concrete material as indicated on drawings.

4.Install conduit inside machinery recess in accordance with drawings.

Wall mount combination heater contactor as shown. Existing vertical structure not shown on drawings may be used to strap overhead conduit in place and connect to plug heaters.

SECTION 26 05 00 Page 13

5. Test newly installed work in accordance with Section TESTS AND FINAL

ACCEPTANCE.

3.2.2 Requirements

3.2.2.1 General

All installations shall conform to the requirements of NFPA 70, unless more stringent requirements are indicated herein, or indicated on the contract drawings.

3.2.2.2 Conduit Installation

Conduit must be Rigid Galvanized Steel. Ends of conduit shall be cut square, reamed to remove rough edges and burrs, and all joints shall be brought to a shoulder. All conduit and fittings shall be carefully examined before being installed and all blistered, split, or otherwise defective conduit or fittings must be rejected and replaced with approved material. Long conduit runs must be installed with expansion fittings compatible with the conduit and provided per the conduit manufacturer's recommendations. Connections to junction and pull boxes, panels, and other fittings shall be water tight. All threads must be perfectly straight.

Conduits shall be supported with approved corrosion resistant hangers where necessary or required. Anchors used for fastening conduit clamps, conduit support hangers, and other items of electrical equipment to masonry must be lead. All cap screws used with anchors shall be corrosion-resistant of the size and length shown or required. Conduit runs must be pitched to provide suitable drainage and all low sections of conduit runs that may trap water shall be vented for drainage in an approved manner. Any runs of conduit extending through a construction joint or expansion joint must extend not less than the threaded length plus one inch past the face of the concrete.

Any defects in materials or workmanship must be remedied immediately. It should be noted that the wire and cable as specified may require larger conduit sizes than shown in standard wire tables to remain within the maximum allowable NEC conduit fill capacity. All conduit passing through walls, floors, and ceilings must be sealed where they pass through the floors or ceilings. Open conduit ends shall be capped, except when working on the run, to prevent entrance of dirt and moisture. Conduit must be installed in a workmanlike manner. All conduits shall be concealed or exposed as specified. Conduits must be supported where necessary or required. Conduits on wall and ceiling shall be supported on channels and pipe clamps. Corners must be turned with standard elbows or long radius bends. Conduit bends shall have radii not less than those of standard factory bends. Field bends may be used if each bend is of the proper radius and is carefully made with suitable tools so that the conduit is not flattened. Open conduit ends of empty conduits must be capped or plugged as required and 1/4 inch nylon pull rope must be provided in each spare conduit. Conduit leaving concrete shall be aligned at 90 degrees to the concrete surface unless otherwise required.

3.2.2.3 Wiring

Wiring shall consist of the installation of all wire and cable required at the locations specified or indicated on the drawings; the furnishing and installing of all cable and supports as indicated or required; the making of all connections and the proper placing, arranging, and identifying of all materials as specified or directed by the Contracting Officer. Wiring

SECTION 26 05 00 Page 14 shall be installed in conduit as shown on the contract drawings and as required to establish a complete and functional system. Provide Electrical Wiring Diagrams and Control Diagrams for approval. All wiring connections to terminal blocks and elsewhere shall be by means of "Sta-Kon" or equal connectors. Where three wires are placed on a terminal, ring type connectors shall be used.

3.2.2.4 Grounding

3.2.2.4.1 Connections between Copper Cables

Connections between copper cables shall be made by the "Cad weld" process or equal.

3.2.2.4.2 Connections to Equipment and Materials

Connections to equipment and materials must be made with solderless pressure connectors unless otherwise noted. Conductors must run continuous from device to device. Splices will not be allowed. Suitable approved copper to aluminum connectors shall be used when copper cable is being used to ground aluminum equipment. Where such connectors may not be available, suitable approved treatments shall be used. Where bare copper grounding cable is in contact with other metals such as aluminum or zinc-coated steel, it must be insulated by a minimum of three layers of plastic tape or by other approved means.

All groundable electrical equipment must be grounded. Locknuts and bushings must not be used as equipment grounds; separate grounding conductors must be provided. Steel conduits shall be provided with grounding bushings and grounded. Ground conductors for conduits must be based upon UL requirements for use with grounding bushings except that no conductor must be smaller than that noted on the contract drawings.

Non-PVC conduits carrying the main ground conductors must be bonded to the ground conductors at both ends of the conduits by brazing or by the use of solderless pressure connectors with conductors sized the same as the main ground conductors. Equipment must not be used as a grounding conductor.

Submit manufacturer's instructions including special provisions required to install equipment components and system packages. Special provisions include impedances, hazards and safety precautions.

3.2.3 Concrete Sawcut and Core Drilling

For recess No. 1 (Upstream Riverwall), core drilling or sawcut will be acceptable for the installation of the electrical conduits. Submit the plans of the core drilling or sawcut of the concrete for approval prior to the construction. Contractor shall not damage any existing equipment, conduits, pipe, etc. while working on this project.

3.3 FIELD TESTS

Following the complete installation of the new Gearbox Heater System, the Contractor must make such operating tests as required by the Contracting Officer to determine that all systems function in a satisfactory manner.

The Contractor shall make such adjustments or correct any conditions which the Contracting Officer deems necessary to provide the operating sequences specified.

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3.4 TESTS AND FINAL ACCEPTANCE

3.4.1 Final Inspection and Tests

Final inspection and tests of the Gearbox Heater Equipment and circuit functionality must be made in the presence of the Contracting Officer. The tests, except for cable insulation resistance tests, must be made under conditions simulating - as nearly as practical, those which will be obtained in operation and must show conclusively that the requirements of the specifications have been fulfilled. The insulation resistance of each cable shall be measured between conductors and between conductors and ground before terminal connections are made in order to determine that the megaohms resistance is comparable with factory insulation resistance test values. Insulation resistance values shall be not less than 10 megaohms.

All test data must be recorded and a complete test report including all test data shall be furnished in triplicate to the Contracting Officer and approved by him before final acceptance. The Contractor must furnish instruments, material, and labor necessary for the tests. The Contractor shall make all necessary changes and adjustments required to place the system in satisfactory operating condition and following any necessary changes and adjustments the Contractor must complete the tests without expense to the Government. Tests shall be made as follows:

a. Insulation Resistance Test.

b. Final Inspection and Tests Demonstrate that all gearbox immersion heaters operate satisfactorily in the presence of the Contracting Officer.

c. Perform continuity test to insure correct cable connection end-to-end (i.e correct phase conductor, grounded conductor, and grounding conductor wiring). Repair and verify any damages to existing or new electrical equipment resulting from mis-wiring. Receive approval for all repairs prior to commencement of the repair.

b=d. Provide a 600-Volt Wiring Test for approval.

3.4.2 Test Reports

Test reports, certified and in triplicate recording all data obtained during any given test, must be furnished to the Contracting Officer.

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SECTION 26 05 00 Page 16

3.2.3 Concrete Sawcut and Core Drilling