SECTION 01010 SUMMARY OF WORK PART 1 - GENERAL 1.01 ...septa.org/business/bid/100k/detail/2017-2-16-00250-aczc-ad3.pdf · SECTION 01010 SUMMARY OF WORK PART 1 - GENERAL 1.01 DESCRIPTION

Wayne Junction SFC 01010-1 60% Design Submittal Rehabilitation Project November 29, 2016

SECTION 01010

SUMMARY OF WORK

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

A. This specification covers the rehabilitation of the Wayne Junction Static Frequency Converter (SFC) Station. The work will be executed through multiple prime contracts representing significant elements of work for each Contractor.

B. The Work shall be performed concurrently and in close coordination with the respective Prime Contractors listed in these construction documents, and possibly other trades working at the site. The Contractors for this project include:

1. Contractor for General Construction Work (to be known as “General Contractor” - GC).

2. Contractor for Mechanical Construction Work (to be known as “Mechanical Contractor” - MC).

3. Contractor for Electrical Construction Work (to be known as “Electrical Contractor” - EC).

4. The EC Contractor shall be designated the Coordinating Contractor.

C. A separate Contract will be awarded for the design, supply, installation supervision, testing, and commissioning of the separate SFC equipment system contract (to be known as “Static Frequency Converter Contractor” - SFCC).

D. Brief Description of SEPTA’s Traction Electrification System

1. SEPTA operates a comprehensive transportation system in the Philadelphia metropolitan area and suburbs. The Regional Rail network of commuter lines is an important part of SEPTA’s service. The Regional Rail operates on tracks and systems formerly owned by the Pennsylvania Railroad (PRR) and the Reading Railroad (RRR).

2. The former Reading Railroad system is electrified at 36/24/12 kV, 25 Hz, single-phase, by an autotransformer system. Traction power is supplied from SEPTA’s three existing static frequency converters (SFCs) located in Wayne Junction, PA. This project program includes the addition of a fourth SFC at Wayne Junction SFC Station and the sequential replacement of the three existing Wayne Junction SFCs with three new SFCs.

3. The Wayne Junction converter output transformer has three bushings on its secondary side: 12 kV trolley, 24 kV feeder, and a solidly-grounded rail connection tapped at 1/3 of the secondary winding. Voltage measured from trolley-to-feeder is 36 kV, trolley-to-rail is 12 kV, and feeder-to-rail is 24 kV.

E. The Work generally consists of, but is not limited to, the following:

1. The design, supply, construction, testing, and commissioning into full service of four new SFC systems, with an input of 13.2 kV, 60 Hz, 3-phase and an output of 36/24/12 kV, 25 Hz, single phase. The continuous full-load power capacity of the new SFCs shall be not less than 15 MVA. The total station capacity shall be 60 MVA with all four SFCs in operation.


Table 1 - New SFC Requirements

Parameter Value Total capacity of station 60 MVA Number of converters 4 Rating (each unit) - continuous 15 MVA Rating (each unit) - overload 18 MVA for 1 hour

24 MVA for 6 minutes 30 MVA for 30 seconds 4000 A for 2 seconds at 12 kV followed by 15 MVA for 1 hour before next overload cycle

2. Each new and replaced SFC shall be fully interoperable and compatible with the existing SFCs so that it can perform its function either alone or with any combination of the existing SFCs on line.

3. The new SFC equipment will be supplied as part of a separate Contract and shall have an expected lifetime of no less than forty years. The equipment supplied with the SFC system includes the following:

a) SFC power block equipment

b) SFC input and output transformers

c) SFC harmonic and power factor correction filters

d) SFC precharging circuit breakers and auxiliary transformers

e) SFC control system

f) SFC cooling system, including pumps, piping, and heat exchangers

g) SFC power distribution system and UPS equipment

h) SFC protection system equipment

i) Sequence of events recorder

j) Transient disturbance recorder

k) Remote terminal units (RTUs)

l) SFC interconnecting cabling, conduits, and accessories

4. The construction of a new building for the fourth SFC, attached to the existing SFC #3 building.

5. Modifications to the existing SFC Control Room for SFC control and protection equipment for the new SFC system.

6. A new isolation switch and protective relays to be supplied and installed in the existing Wayne Junction 25 Hz Traction Power Substation.

7. The existing 25 Hz Traction Power Substation 12 kV and 24 kV protection schemes shall be recalibrated in order to incorporate SFC #4.


8. The replacement of the existing Pyrotronic suppression/fire alarm control panels with a new updated addressable fire alarm system and a Halon suppression activation panel in the Wayne Junction 230 kV substation and SFC building.

9. Renovations to the existing SFC building, including architectural, structural, mechanical, electrical, and plumbing work.

10. Electrical duct bank installation between the 230 kV Control Building, the SFC Building, and the existing 25 Hz Wayne Junction Traction Power Substation to support the new SFC #4. All existing power and control duct banks supporting SFC #1, #2 and #3 will remain.

11. All existing filter equipment in the 60 Hz and 25 Hz Filter Yards will be removed, but the existing foundations and associated equipment with the open-air bus system will remain. A new open-air bus system will be constructed to support the new SFC #4 on the 60 Hz and 25 Hz sides of the SFC Building.

1.02 RELATED WORK

A. Agreement

B. Section 01011 – Summary of Project

C. Section 01025 – Measurement and Payment

D. Section 01041 – Project Coordination

E. Section 01060 – Regulatory Requirements and Safety

F. Section 01400 – Quality Requirements

1.03 QUALITY CONTROL AND QUALITY ASSURANCE

A. Each prime Contractor will assume responsibility for executing a quality control and quality assurance program. This program’s basic form will be specified in their Quality Control Plan as submitted under Section 01400 and will include the tests & inspections called for in the technical sections of the specifications. Each prime Contractor shall be responsible for requiring all subcontractors and suppliers to adhere to their Quality Assurance Program and participate in quality assurance activities.

B. Where governed by “Buy America” requirements, SEPTA will require documentation to confirm the country of origin of all applicable products and materials. Each prime Contractor is responsible for communicating Buy America requirements to their subcontractors and suppliers. The lack of sufficient documentation will be grounds for rejecting a product or material.

C. Quality activities will be documented by the Contractor. SEPTA may audit the Contractor’s quality assurance and quality control activities. Each prime Contractor will make their and their subcontractor’s, applicable documentation available to SEPTA.

D. Each prime Contractor, and their subcontractors, is required to cooperate fully with testing and inspection activities carried out by SEPTA and its agents. The Contractor will provide the SEPTA PM with adequate (as determined by the SEPTA PM) notification for all activities which require testing and/or inspection. For all inspections and testing required by code, work will not proceed until this testing and inspection has been completed.

E. Once a product or material has been accepted through the Submittal process, no substitution of this material or product will be allowed without resubmitting it following


the provisions of Section 01300. SEPTA reserves the right to require removal of any non-reviewed material and product.

1.04 CONTRACTOR RESPONSIBILITIES

A. Furnish all materials, tools, equipment, supervision, administration and transportation, and perform all labor and services necessary to furnish, deliver, construct, install, connect and/or to interconnect and test as required to complete all work described in the Specifications and indicated in the Contract Drawings.

B. Each Contractor shall be aware of, and be familiar with, the responsibilities and work of the other Contractors especially with regard to the sections of Division 1, which pertain to all contracts. In addition to the responsibilities shared by the/each prime Contractor, the coordinating Contractor shall have additional responsibilities as specified in the Contract documents.

C. Each Contractor is responsible for securing and paying for all necessary permits and approvals required to complete the work. No work may commence on site without securing and paying for the necessary approvals including but not limited to:

1. Permits

2. Governmental Fees

3. Licenses

4. Local Applications

5. Local Taxes

D. SEPTA Notification

1. Give written notices necessary for, and incidental to, the due and lawful prosecution of the Work.

2. Provide written notification at least 14 days in advance to SEPTA for all construction work which requires observation and/or testing.

3. Notify the SEPTA Project Manager (PM) at least 14 days in advance of the date the individual construction stages (and/or elements) will be fully complete and ready for inspection.

4. Notify the SEPTA PM at least 14 days in advance of the date the entire work will be substantially complete and ready for inspection.

5. Notify the SEPTA PM at least 14 days in advance of the date the entire work will be complete and ready for final acceptance inspection.

E. Utility Notification

1. Known existing utilities will be indicated on the Contract Drawings but the Contractor may not interpret this information as either complete or accurate. Regardless of those shown on the drawings, the Contractor must identify and verify the location of all existing utilities prior to working by following applicable regulations and procedures, such as contacting the PA One Call system and asking SEPTA personnel to identify utilities at the site.

2. The Contractor shall determine ownership of all utilities and notify utility owners prior to intended start work date. Deliver a copy of this notice to the SEPTA PM within 48 hours of the submittal of the notification.


F. Protection and Repair of the Work and Adjacent Property

1. Prior to the commencement of Work, the Contractor and the SEPTA PM shall examine the site and document the condition of all areas not intended to be changed by the project. Depending on the scope of work, this may include features such as sidewalks, driveways, roadways and adjacent facilities.

2. The Contractor must repair any damage to property caused, directly or indirectly, by the actions of the Contractor, at no cost to SEPTA, to the satisfaction of the SEPTA PM (and property owner if the damage is to property not owned by SEPTA).

3. Until Final Acceptance of the Work by SEPTA, the Contractor(s) shall be responsible for maintaining the executed work in its finished condition as determined by the SEPTA PM. All work shall be restored to its finished condition prior to final acceptance at no expense to SEPTA.

G. Support of Existing Structures & Right of Way

1. Existing structures, adjacent to the project work area, must be supported adequately utilizing underpinning, shoring and other temporary stabilization measures. A plan to execute this temporary support and stabilization must be approved by the SEPTA PM prior to any excavation commencing. At the discretion of the SEPTA PM, the Contractor will be required to have this plan prepared and sealed by a licensed engineer.

2. Under no circumstances excavate in the vicinity of track, embankment and right-of way without the prior approval of the SEPTA PM, or SEPTA representative.

H. Contractor’s Field Staff

1. Superintendent: The Superintendent shall have demonstrated competency in the Work of the project. This work includes:

a) Demolition and installation of heavy equipment foundations.

b) Installation of medium-voltage duct banks and cables.

c) Installation of large power transformers, reactors, filters, and circuit breakers.

d) Installation of power conversion equipment.

e) Installation and calibration of protective relaying and control equipment.

f) Construction of an industrial masonry building.

g) Work around an energized traction power system.

2. Safety Officer: The Contractor shall assign a designated on-site Safety Officer. The Superintendent may perform the duties of the Safety Officer in addition to their own. The presence of the Safety Officer at the site is mandatory while work is being performed.

3. Quality Manager: The Contractor shall assign a Quality Manager for the duration of the work. The Superintendent may perform the duties of the Quality Manager in addition to their own. For a definition of the responsibilities of this position see Section 01400.


4. Project Coordinator: The Project Coordinator shall coordinate the prosecution of the Work with prime Contractors, public utilities, governmental bodies, City of Philadelphia, utilities having jurisdiction, SEPTA Operations, and other Contractors having access; The Project Coordinator will be responsible to either eliminate or minimize, as much as possible, delays in the Work and conflicts with those utilities, governmental bodies and Contractors. This coordination may include preparation of diagrams and delivery schedules, and control of site utilization, from beginning of construction activity through project closeout and warranty periods.

5. Staff Qualifications

a) The work of this Contract requires specified experience in a description of the specialized work called for in this Contract. The positions referenced above are considered key personnel and the review of their resumes and experience is a responsibility requirement under paragraph 4d 6) of the Instructions to Bidders. The successful bidder shall furnish SEPTA with the resumes for the people who will hold the above positions within five (5) days of receipt of SEPTA’s written request.

b) If, in the course of the work, these individuals are proposed to be replaced by the Contractor and/or SEPTA deems that their work is no longer satisfactory, the terms of the Paragraph VIII K of the Agreement will be invoked.

I. SEPTA Construction Sustainability Policies

1. SEPTA has adopted a series of sustainability policies which it expects its Contractors to follow. These include but are not limited to the following:

2. Building Site Waste Management - Within 10 days of Notice-to-Proceed, and before any site work begins, the Contractor shall submit a building site waste management plan. The plan shall specify which site debris shall be recycled, reused or otherwise diverted. The goal of this plan shall be to reuse or salvage 75% of the land clearing debris including rock, trees, stumps and associated vegetation and 100% of excavated soils. Any materials which are disposed of off-site must meet all applicable regulations and be specifically approved by the SEPTA Project Manager. For material which is disposed of off-site, the Contractor will be responsible for chain of custody documentation.

3. Material and Waste Management – Within 10 days of Notice to Proceed, and before any site work begins, the Contractor shall submit a construction material and waste management plan. The plan shall specify which construction and demolition materials shall be recycled, reused or otherwise diverted. The goal of this plan shall be to divert 50% of nonhazardous materials and waste (measured by weight or volume) from landfills unless the local municipality has designated a greater amount.

4. Sustainability documentation – All sustainability strategies which are fulfilled by the Contractor’s actions must be documented to the satisfaction of the SEPTA Project Manager.

1.05 SEPTA RESPONSIBILITIES

A. SEPTA shall furnish, free of charge to the Contractor, five complete sets of the Contract Documents including full size Contract Drawings, Specifications and Addenda, and/or


conformed Contract Documents. Additional copies are available from the SEPTA PM at cost of reproduction.

B. SEPTA Force Account will include:

1. Electric Traction (ET) personnel to block circuits for the protection of Contractor personnel when equipment or personnel must work close to energized circuits. ET personnel shall also de-energize and ground traction and signal power circuits incidental to the work, as required for safe working conditions.

2. Flagman when Contractor’s personnel are working close to the tracks.

3. Flagmen to take track(s) out of service when needed or when construction Work fouls the tracks.

4. Communications and Signal (C&S) employees providing interface support, de-energization of active circuits, and support on the SEPTA end for the installation and termination of copper and fiber optic signal and communication lines. SEPTA will not terminate any new cables or wires into new equipment. SEPTA will only perform final connections into existing equipment.

5. Operations personnel to inspect any Contractor high-rail vehicles that will operate on SEPTA track.

6. ET and C&S personnel to identify and tag cables uncovered or pointed-out by a Contractor.

7. Review of crane installation procedures by SEPTA Engineering, if needed.

8. Witness the testing/commissioning of the SFC systems.

C. SEPTA Equipment will include:

1. One existing 15 kV circuit breaker to supply the new SFC #4 converter power.

2. Two existing 480 V circuit breakers to supply the new SFC #4 auxiliary power.

1.06 CONTRACTOR’S USE OF WORKSITE

A. Site availability and access to worksite

1. The Contractor(s) shall confine operations at the site to areas permitted by law, ordinances, and permits.

2. Keep existing driveways, entrances and exits serving the site, and facilities on the site, clear and available at all times, except as otherwise specified (see Section 01500).

3. The Contractor shall not interfere with SEPTA or public circulation by the storage or staging of equipment or material. SEPTA reserves the right to require the Contractor to relocate equipment or material immediately and at any time even if the current location has been previously approved.

4. Keep the predefined portions of the worksite available for SEPTA's operations during the construction period as noted in the construction phasing plan and other submittals. SEPTA reserves the right to take control of any part of the work at any time without prior notice.

B. Storage of materials and equipment and deterring vandalism


1. Consider the safety of the Work, and that of people and property on and adjacent to the worksite, when determining amount, location, movement, installation, and use of materials and equipment on worksite. All storage and staging areas must be approved by the SEPTA PM.

2. Do not load finished Work with equipment and products that would endanger the integrity of the finished Work

3. Move stored products as often as necessary if it interferes with foreseeable operations of SEPTA, public and private utilities, and other Contractors at no additional expense to SEPTA. Security of stored materials shall be the Contractor's sole responsibility. Secure additional storage and work areas if needed for construction operations at no additional expense to SEPTA.

4. The Contractor shall take precautions to prevent vandals from placing loose construction debris, supplies and equipment into positions that might foul the track or otherwise interfere with the operation of SEPTA vehicles. These steps shall include, but not be limited to, securing movable items, like construction fencing and scaffolding, and storing debris and material in fenced & locked enclosures.

5. Failure to take adequate steps may result in the Contractor having to go to the job site and secure these materials during non-construction hours, at no cost to SEPTA. SEPTA will hold the Contractor responsible for any damage or injury caused, or contributed to, by failure to take these precautions effectively.

C. Protection of the public & SEPTA

1. Protection of the general public and SEPTA operations from construction-related activities shall always have the highest priority. Any work on streets or access ways which could affect traffic or pedestrian access must receive prior approval by SEPTA and other agencies as required by law. Conduct work on streets and access ways on SEPTA property in a manner, which will ensure that pedestrian and vehicular traffic will either not be obstructed or obstructed to the least possible degree. Employ appropriately trained and authorized flagmen where required by ordinance or to create a safe job site.

D. Construction operations requiring SEPTA service interruptions and/or utility interruptions must meet the following requirements:

1. Should any temporary disruption of SEPTA's operations and/or use of the electric, water or telephone utilities at such site be necessary, it will be undertaken only pursuant to reasonable notices (not less than 21 days) given to the SEPTA PM and shall not continue beyond the previously agreed-upon period, without further written concurrence from SEPTA.

1.07 SEPTA OPERATIONAL CONSTRAINTS

A. SEPTA will prohibit service shut downs, and diversions on certain Holidays, Holiday weekends, and any potential unforeseen, or unscheduled, large, city-related events. Holidays include Memorial Day weekend, the Welcome America Celebration one week before the Fourth of July weekend, the Fourth of July (and the Fourth of July weekend, if applicable), and Labor Day weekend. Outages, shutdowns and diversions shall not be permitted during the “Holiday Season” which is defined as the period starting 5:01 am on the Wednesday before Thanksgiving Day until January 2, inclusive.


B. SEPTA reserves the right to return any track to service without prior notification at any time and make other adjustments as needed to facilitate operations.

1.08 WORK SEQUENCE AND CONSTRUCTION PHASING

A. The main priority in developing a construction sequence for this project will be to keep at least two SFCs in operation at all times with a third in stand-by.

B. The second priority will be to avoid construction traffic exposure to any unit while in operation. Presently, the SFC rooms function strictly to contain power block equipment and associated buswork, and walking through a room while the SFC is functioning shall be kept to a minimum. However, during construction, it is strongly discouraged to keep SFC room doors open or allow construction materials to be transported through the room while the SFC is operating. In order to avoid exposure to construction traffic, a wall and doors will be constructed in front of the SFC power block equipment in order to isolate the sensitive equipment from dust and debris, as well as personnel.

C. The work sequence for the project is as follows:

1. Prepare the site on the north side of the existing SFC filter yards and building.

2. Construct the new SFC #4 building, including 60 Hz and 25 Hz power feeder duct banks, 25 Hz output circuit breaker, and make connections to the existing Wayne Junction 25 Hz traction power substation. The new SFC #4 converter room will have a wall with doors between the SFC power electronics and the power distribution/control equipment. Commission the new SFC unit.

3. Establish a new station computer in the existing Control Room. Depending on SFC Contractor options, the existing computer equipment will need to be removed one unit at a time or it can be left in place until the final new SFC is commissioned.

4. Demolish the SFC #3 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and provide new cabling in the existing 25 Hz and 60 Hz duct banks, as required. All existing filter equipment in the 60 Hz and 25 Hz Filter Yards will be removed, but the existing foundations and associated equipment with the open-air bus system will remain.

5. Install a new wall and doors in the SFC #3 building. Install the new SFC #3 equipment, 25 Hz transformer, 60 Hz transformer/reactors, 25 Hz circuit breaker, and route any new power feeders in existing duct banks. Commission the new SFC unit.

6. Demolish the SFC #1 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and provide new cabling in the existing 25 Hz and 60 Hz duct banks, as required. All existing filter equipment in the 60 Hz and 25 Hz Filter Yards will be removed, but the existing foundations and associated equipment with the open-air bus system will remain. Note that the reason that SFC #1 is selected to be demolished after the construction of SFC #3 is so that all debris to be carried from SFC #2 demolition will only occur after constructing a wall in front of SFC #1 power electronics equipment.

7. Install a new wall and doors in the SFC #1 building. Install the new SFC #1 equipment, 25 Hz transformer, 60 Hz transformer/reactors, 25 Hz circuit breaker, and route any new power feeders in new and/or existing duct banks. Commission the new SFC unit.


8. Demolish the SFC #2 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and provide new cabling in the existing 25 Hz and 60 Hz duct banks, as required. All existing filter equipment in the 60 Hz and 25 Hz Filter Yards will be removed, but the existing foundations and associated equipment with the open-air bus system will remain.

9. Install a new wall and doors in the SFC #2 building. Install the new SFC #2 equipment, 25 Hz transformer, 60 Hz transformer/reactors, 25 Hz circuit breaker, and route any new power feeders in new and/or existing duct banks. Commission the new SFC unit.

10. After all new SFCs are commissioned, the existing computer system can be removed. The final Control Room will either have a complete new computer system or a HMI interface that coordinates control of all new SFCs.

D. Construction of New SFC building

1. The construction of the new proposed building for SFC #4 will be performed prior to any other building-related work at Wayne Junction. As part of the construction sequence, installing and commissioning the SFC #4 building will be performed prior to decommissioning any other SFCs in order to keep at least two SFCs available for operation at all times.

2. The new SFC #4 building construction requires building the entire structure using conventional steel construction with columns, girders and beams. A brick veneer with an 8” CMU backup is utilized for the building enclosure.

3. The SFC #4 building is located closest to the existing parking lot on the north side of the existing SFC #3 building. Its construction should not affect the continued operations of SFCs #1, #2, and #3. However, connections to electrical utilities will come from the existing Control Building and be routed under SFC #3, through existing conduits, trays, and openings in the SFC #3 basement walls. When working in the SFC #3 basement, SFC #3 would need to be de-energized and tagged out.

4. There are no overhead lines that would impair the construction of the new building. Review of existing drawings and results of site investigations show that there are no major utilities running under the proposed new building construction area other than part of a stormwater line. Since the new building will be constructed on piles, relocation of this line is not anticipated.

E. Construction of Duct Banks

1. SFC #4 will require new duct banks. A new duct bank and stub-ups will be constructed between the 230 kV Control Building and the new, 60 Hz open-air bus structure. Additionally, new duct banks will be constructed between the new, 60 Hz open-air bus structure to the extension of the SFC Building to support the SFC #4 transformer/reactor, power, control and communications. Duct banks will be constructed between the new, 25 Hz output transformer and new, 25 Hz open-air bus structure to support the new 25 Hz SFC circuit breaker. Finally, a new duct bank system will be constructed between the new, 25 Hz SFC circuit breaker and existing 25 Hz traction power substation.

2. After the removal and demolition of filter equipment associated with SFC #1, #2 and #3 on the 60 Hz and 25 Hz sides of the SFC Building, all existing filter


foundations will remain. Existing duct banks and conduits supporting SFC #1, #2 and #3 will also remain.

3. Any duct bank that contains 60 Hz auxiliary power and control cable is planned to remain.

F. Construction of Oil Containment Pits

1. If 60 Hz SFC transformers are required by the selected SFC Contractor, a new oil containment pit will be implemented for SFC #4. The existing oil containment systems for SFCs #1 and #3 will need to be upgraded or replaced if oil-filled SFC transformers are utilized for this project. SFC #2 presently has no oil containment pit; a new one will be constructed. The construction and modification of the oil containment pits will follow all applicable standards in accordance with IEEE 980, Guide for Containment and Control of Oil Spills in Substations.

G. Repair of Existing Foundations and Buildings

1. The repairs of existing foundations and SFC building components will be performed right after each SFC unit has been demolished, with repairs occurring prior to beginning any installation of electrical or mechanical equipment in that particular SFC building. Repairs in the Control Room building should be scheduled during the construction of the SFC #4 building.

H. Installation of New SFCs

1. The SFC power blocks must fit through existing doorways and within the existing and new SFC rooms. Installation of each new SFC must occur independently of others that remain in operation.

I. Testing and Commissioning of New SFCs

1. SFC equipment routine tests are to be performed in the SFC Contractor's factories as well as field tests to be completed at the site. Time must be allocated for SEPTA to witness factory testing, and the construction schedule must allow time for testing and fully commissioning SFC units on an individual basis. Each SFC unit must be completely commissioned prior to beginning construction on the next unit.

J. Operation in Parallel with Existing Converters

1. For active power load sharing, the SFCs will follow a synchronous machine model. The existing cycloconverter uses a similar model and, therefore, load sharing can be done by use of the same parameters. For reactive power, the SFCs will use a reactive power versus voltage curve that can be adapted to the parameters of the cycloconverter. Load sharing between existing and new units during construction may not be optimal, but it must be functional and allow the station to meet the varied load demand that occurs on a second-by-second interval.

2. It is not expected that the existing load sharing computer will need to be integrated with the new SFC control system. As existing units are removed from service, they will simply be set to “off” in the existing load sharing computer system.

K. Rigging and Transportation Constraints

1. It is anticipated that the dimensions of new equipment, such as large power transformers, SFC equipment, and outdoor circuit breakers, for example, will be similar to the existing equipment.


2. Proper rigging and transportation instructions must be provided by the equipment vendors.

3. It is preferred not to modify the existing access roads on the east and west sides of the SFC building. This will allow for access to the 25 Hz and 60 Hz transformer areas.

4. The Contractor must coordinate rigging, transportation, and usage of cranes with SEPTA to determine equipment electrical outage requirements and minimum distances allowed to energized equipment (see Section 01060).

5. For transporting equipment into the existing SFC rooms, access is anticipated through the existing doorways, and no new access ways will be created. If SFC power electronic equipment is transported in prefabricated assemblies, these will need to be disassembled if transportation into the SFC rooms is not possible through existing doorways. Modifying the existing building is not within the scope of this project, e.g., cutting holes in the building in the transformer bays to allow SFC equipment to pass into the building on prefabricated assemblies.

6. Special rigging may be required to locate the roof top air-handling equipment, cooling units, heat exchangers, structural steel, and roofing materials on the roof of the SFC building.

L. Protection of Equipment During Excavation, Demolition, and Construction

1. Adequate temporary protection will be required during excavation, selective demolition, and construction in order to prevent failure of any existing or new equipment. The Contractor will prepare detailed construction phasing drawings that will identify boundaries of construction and will take into account permitting requirements should SFCs be required to be de-energized and tagged out.

2. Additionally, SFC equipment will require either a temporary or permanent form of protection from dust during demolition and construction. This project will install walls separating the main SFC rooms from their adjacent power distribution/control areas. These walls will create corridors, allowing protection from dust and equipment damage during the construction and demolition phases. It will also provide a passageway for personnel during normal equipment operation.

M. The actual construction activities interfering with SEPTA operations and passenger movement shall not begin until:

1. The Contractor provides a written plan (site specific work plan) to SEPTA indicating impact to passenger flow and SEPTA operations. Such plan shall include remedial solutions acceptable to SEPTA.

2. The plan is approved in writing by SEPTA. Contractor shall be responsible for revision and resubmittal of the plan until it is approved by SEPTA.

N. If the plan calls for the Contractor to gain access to track or facilities, operational constraints may delay actual occupancy, or require the Contractor to give up occupancy early, for a period usually not exceeding one hour.

O. Before starting work on a construction phase, the Contractor will submit a written request to SEPTA to amend or adjust the phasing plan. The criteria detailed on paragraph 1 below must be satisfied in the proposed amendment.

1. Operational Criteria:


a) Keep at least two SFCs in operation at all times, meaning both units must be able to operate at full power either independently or sharing load.

b) A third SFC must be in stand-by at all times, meaning it must be ready to operate at full power within 30 minutes.

2. Review Procedures:

a) SEPTA safety procedures.

1.09 DAMAGES FOR FAILURE TO RETURN WAYNE JUNCTION SFCS TO SERVICE

A. The damages for failure to return two SFCs to full operation within 30 minutes is $ _________ per hour.

B. The damages for failure to return one SFC to standy-by operation within 30 minutes is $ _________ per hour.

1.10 SEPTA OCCUPANCY AND USE

A. Portions of the Work may be placed in operation by SEPTA in advance of the completion of all Work. Occupancy and/or utilization of parts of the Work by SEPTA will not relieve the Contractor of responsibility for proper integrated completion of all parts of the Work, nor shall it act to relieve the Contractor of any responsibilities under the Contract Documents for warranty of the Work.

1.11 CONCURRENT OR FUTURE WORK

A. SEPTA Wayne Junction Traction Power Substation

1. There is concurrent work occurring at the adjacent SEPTA Wayne Junction Traction Power Substation (TPSS) that connects the SFC station to the traction power system. It is anticipated that all work at Wayne Junction TPSS will be completed prior to beginning construction on this project.

B. Power Plant Connection at Wayne Junction 13.2 kV, 60 Hz, 3-phase Switchgear

1. There is the potential for future work that may coincide with this project in the 230 kV Control Building on the 13.2 kV, 60 Hz, 3-phase switchgear. This future work may install two 13.2 kV feeder circuits to provide additional power supply to the Wayne Junction SFC Station from a remote combined heat and power (CHP) generation facility. It is anticipated that this CHP project will not affect or disrupt the design criteria, construction, or commissioning of this project.

1.12 EXISTING CONDITIONS

A. The existing conditions represented in the Contract Drawings are based on the best available information obtained from one or any combination of the following sources: field survey, as-built documents, reference drawings, and visual investigations.

B. The Contractor shall perform an underground investigation to determine interferences with existing electrical conduits, ductbanks, storm water drains, and other utilities prior to finalizing the means and methods for installing the designs provided in Contract Documents.

C. The Contractor is responsible for verifying the conditions presented. If verified conditions are close to those represented on the Contract Drawings, the Contractor shall, in addition


to reporting the verification to the SEPTA PM, proceed with the Work at no additional cost to SEPTA. If conditions are significantly different to those presented on the Contract Drawings, the Contractor shall, in addition to reporting the verification to the SEPTA PM, submit a detailed scheme and associated cost for completing the required work for review and comment. The Contractor shall allow 30 days for review and comment.

D. The Contract Documents establish specific criteria and standards of performance. The Contractor shall use its discretion to determine means of compliance and is responsible for coordinating with other Contractors at the site in order to achieve compliance.


SECTION 01010

SUMMARY OF WORK - APPENDIX A – DIVISION OF WORK SUMMARY MATRIX

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General

Power and control from 230 kV Control Building to SFC Input Transformer high-voltage bushing

x x

SFC system from 60 Hz input transformers to 25 Hz output transformers

x x x x

Power and control equipment from SFC Output Transformer to 25 Hz Traction Power Substation

x x

Site civil work x x

Cable trenches and duct banks x x

Foundations - removal and construction x x

Building construction x x

Building structural x x

Building mechanical and plumbing x x

Building electrical x x

Building fire detection and annunciation x x

Building fire suppression x x

Underground investigation x

Environmental remediation x

Survey x

Field Trailers x x

Mobilization and demobilization x x

Non-SFC testing and commissioning x x x


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SFC system testing and commissioning x x

Protection and shielding from energized equipment x x

New Static Frequency Converter System

Input transformers/reactors x x x x

Surge arresters x x x x

60 Hz filters x x x x

Precharging transformer/breaker x x x x

SFC power block x x x x

SFC interconnection wiring x x x x

SFC control system x x x x

SFC protection system x x x x

Sequence of events recorder x x x x

RTUs for local and station control x x x x

SCADA system x x x x

Power distribution and UPS for SFCs x x x x

Output transformers x x x x

25 Hz filters x x x x

Cooling system x x x x x

Design of SFC system x

System description, studies, reports, drawings x x

Installation of SFC system x x

Testing and commissioning of SFC system x x

END OF SECTION


SECTION 01011

SUMMARY OF PROJECT

PART 1 - GENERAL


A. Work Included: Three (3) separate Prime Contracts representing significant elements of related work for each Prime Contractor for the Wayne Junction Static Frequency Converter (SFC) Rehabilitation Project, as indicated on the drawings and specified herein. The work shall be performed concurrently and in close coordination with the respective Prime Contractors and other trades working at the site. The three (3) Prime Contractors for this project are:

1. The General Contractor (GC) is responsible for the site/civil work to include, but not limited to general site grading and construction; construction of a building addition; repairs in existing buildings; and foundation removals, repairs, and construction. Refer to Article 1.05 for specific responsibilities.

2. The Mechanical Contractor (MC) is responsible for mechanical work to include, but not limited to the furnishing, installing, and field testing of the mechanical systems in the existing and new SFC Building. Refer to Article 1.06 for specific responsibilities.

3. The Electrical Contractor (EC) is designated as the Coordinating Contractor, under Exhibit III of the Agreement and Section 01011 and is hereby assigned the full responsibility to ensure that the work to be performed by other Prime Contractors under this Project is coordinated in a manner to eliminate any impact to the schedule, and any installation sequencing conflicts. Refer to Article 1.07 for specific responsibilities. The EC is responsible for work to include, but not limited to the removal of three existing static frequency converter (SFC) systems and the installation and integration into full service four new SFCs. The SFC systems will be designed, supplied, tested, and commissioned by a Static Frequency Converter Contractor (SFCC). Installation supervision will also be provided by the SFCC.

B. A separate Contract will be awarded for the design, supply, installation supervision, testing, and commissioning of the SFC system (to be known as “Static Frequency Converter Contractor” - SFCC).

1.02 RELATED SECTIONS

A. Drawings and general provisions of the Contract, including General and Supplemental Conditions and other Division 1 Specifications Sections, apply to this section.

B. Section 01010 – Summary of Work

C. Section 01041 – Project Coordination

D. Section 01300 – Submittals

E. Section 01305 – Request(s) for Information


G. Section 15010 – Basic Mechanical Requirements


H. Section 16010 – Basic Electrical Requirements

1.03 ADMINISTRATIVE AND PROCEDURAL SECTIONS (APPLICABLE TO ALL CONTRACTORS)

A. Agreement and Exhibit III scheduling requirements

B. Section 01025 – Measurement and Payment


D. Section 01060 – Regulatory Requirements and Related Safety

E. Section 01065 – Railroad Safety Requirements

F. Section 01200 – Project Progress Meetings

G. Section 01300 – Submittals

H. Section 01305 – Request for Information

I. Section 01400 – Quality Requirements

J. Section 01500 – Construction Facilities and Temporary Controls

K. Section 01600 – Material and Equipment

L. Section 01700 – Contract Close Out

M. Section 01720 – Project As-built Documents

1.04 TEMPORARY FACILITIES AND SERVICES

A. The GC is responsible for the following:

1. Mobilization

2. Temporary Barriers and Enclosures (those related to the access roads, foundation demolition, excavations, and waste removal). This includes any temporary fencing with gates until the permanent fencing is installed.

3. Temporary Construction signage at access roads and at the GC field office (Section 01580)

B. The MC is responsible for the following:

1. Mobilization

C. The EC is responsible for the following:

1. Mobilization

2. All Project Identification Signs (Section 01580), except where noted otherwise

3. SEPTA Field Office (Section 01590)

4. Temporary power and lighting (Section 01500)

5. Temporary fencing around the substation compound and field offices with gates for access.

1.05 GENERAL CONTRACTOR (GC)

A. The General Contractor is responsible for those sections previously specified, and for the following sections as defined in Division 1 to include, but not limited to:


1. Section 01041 – Project Coordination

2. Section 01045 – Cutting and Patching

3. Section 01050 – Field Engineering

4. Section 01100 – Special Project Procedures

5. Section 01380 – Construction Photographs (of GC work)

6. Section 01710 – Final Cleaning

B. The General Contractor work includes but not limited to the following:

1. Furnish and instal l work associated with the General Requirements including but not limited to the following:

a) Construction Permits associated with GC work

b) Project Staffing and coordination

c) Cutting and Patching for work associated with GC work as described in Division 2 through 7

d) Regulatory requirements and safety including temporary traffic and pedestrian signs

e) Construction Photographs of all GC responsible work.

f) Maintenance and protection of vehicles and pedestrians

g) Project record documents

h) Site survey and stakeout: of all construction boundary lines, building lines, sidewalk-cut, wall-cut, and access road.

i) Snow removal as necessary for continued construction operations.

j) Temporary fencing with gates until the permanent fencing is installed.

2. Site preparation, selective demolition and clearing for the following:

a) Clearing and grubbing including removal of debris, rubbish, and abandoned scrap metal, rail, and ties.

b) Demolition of duct banks and manholes identified for demolition on the drawings, but after EC removes existing cables.

c) Selective demolition of pipes, conduits, duct banks, manholes and metal cases.

d) Recycle scrap metal

e) Dispose of as hazardous waste scrap ties, treated utility poles, and contaminated soil.

f) Demolition and removal of electrical equipment foundations.

g) Asbestos abatement.

3. Furnish and install Site Work including but not limited to the following:

a) Earthwork including excavation, backfilling, dewatering, excavation support and protection, and all earthwork materials involved, except earthwork identified to be done by EC.


b) Dynamic timber pile testing and installation.

c) Furnishing, installing, maintaining and removal of erosion and sedimentation control.

d) Trenching, bedding and installation of drainage systems: to include inlet structures, manhole structures (except electrical) and reinforced concrete pipe (RCP) with connections. Also construct bio-retention areas as indicated.

e) Backfill and compact from 1 foot above ground grid to final grade, except to subgrade elevation below 12” depth of stone in substation compound.

f) Rough and final grading

g) Subgrade preparation, subbase, aggregate paving and asphalt paving for parking area and access road.

h) Access road fencing and substation security wall with foundations and fencing including gates.

i) Landscaping

j) Geo-textile and crushed stone for substation compound

k) Hazardous waste disposal, except for waste created from EC Operations.

l) Replacement of sewer line pipes if existing piping damaged during construction

4. Furnish and install Concrete Work including incidental steel reinforcement, but not limited to the following:

a) Cast-in-place concrete including formwork, reinforcement, concrete materials, mix designs, placement procedures and finishes. This includes retaining walls, sidewalks and curb cuts.

5. Furnish and install Pre-cast Concrete Work including, but not limited to, the following:

a) Drainage manholes, inlets and catch basins and retaining wall components

6. Furnish and install Masonry Work including but not limited to the following:

a) Masonry assemblies including bricks, concrete masonry units and cast stone masonry

b) Masonry reinforcement, anchorages and accessories

c) Masonry mortar and grout

d) Masonry walls and columns associated with the substation fence system

7. Furnish and install Metal Work including but not limited to the following:

a) Metal fasteners, joining and welding

b) Structural steel for the building

c) Metal fabrications, grating stairs, hand rails, railings, and gratings

d) Metal doors, frames and hardware

8. Furnish and install Wood Work including but not limited to the following:


a) Wood grounds, blocking, and nailers

b) Plywood mounting boards at electrical/mechanical rooms

9. Furnish and install Thermal and Moisture Protection Work including but not limited to the following:

a) Dampproofing and waterproofing

b) Membrane roofing

c) Sheet metal flashing and trim

d) Roof accessories

10. Furnish and install Finish Work including but not limited to the following:

a) Acoustical ceilings

b) Paints and coatings

11. Furnish and install Signage including but not limited to the following:

a) Indoor signs for rooms and doorways

b) Outdoor signs for building, road, and site identification

12. Furnish and install Special Equipment including but not limited the following:

a) Rooftop fall protection anchorage system

b) Complete oil containment basin system, where required, including basin, grating, oil stop valve separator and associated piping as indicated. Test entire system.

1.06 MECHANICAL CONTRACTOR (MC)

A. The Mechanical Contractor is responsible for those sections specified previously and the following sections as defined in Division 1:

1. Section 01041 – Project Coordination


3. Section 01830 – Operation and Maintenance Data

B. The Mechanical Contractor work includes, but is not limited to, the following:

1. General requirements associated with mechanical work including permits, project staffing and coordination, record documents, commissioning of mechanical systems and finalizing instruction manuals for operation and maintenance, including:

a) Obtain local permits

b) Provide (furnish and install) and commission mechanical systems

c) Provide final documentation

2. Furnish and install Mechanical, Plumbing, and HVAC systems as specified and as indicated in the drawings. Major elements include the following:

a) Fire extinguishers, cabinets, and accessories


b) Plumbing equipment, including eyewash, shower, and hot water heater equipment

c) Fire protection deluge system equipment and accessories

d) Fire protection clean agent suppression system (FM-200) equipment, accessories, and controls

e) Mechanical identification and labels

f) HVAC ductwork and installation

g) Heating, ventilating, and air conditioning equipment

h) HVAC building system controls

3. Provide the following additional services for testing, adjusting and balancing:

a) Check, test, and make final adjustments to the HVAC system

b) Balance the HVAC system

c) Check and test ventilation ductwork and diffusers

d) Check and test electric unit heaters

e) Check and test exhaust fans in switchgear building, including battery room

f) Check and test louvers and vents

g) Check and test roof drains

h) Check and test emergency eyewash and shower

i) Check and test the sensors, alarms and controls

1.07 ELECTRICAL CONTRACTOR (EC)

A. The Electrical Contractor shall be the Coordinating Contractor for all the Prime Contracts involved in the project. As such, the EC shall coordinate all work including those of the GC, MC, and SFCC. The EC shall be responsible for the coordination of all shop drawings for items having major elements involving interfacing between general, mechanical and electrical work. As Coordinating Contractor, the EC shall prepare and maintain the project construction schedule, as per the Agreement, Exhibit III.

B. The Electrical Contractor is responsible for those sections specified previously and the following sections as defined in Division 1:

1. Section 01045 – Cutting and Patching

2. Section 01100 – Special Project Procedures

3. Section 01380 – Construction Photographs (of EC and MC work)


5. Section 01830 – Operations and Maintenance Data

C. The Electrical Contractor work includes but is not limited to the following:

1. Furnish and install work associated with the General Requirements including but not limited to the following:


a) Permits associated with EC work

b) Project Staffing and coordination

c) Cutting and Patching for work associated with EC work

d) Field Engineering

e) Construction Photographs of all EC and MC responsible work and a complete site set at project closeout

f) Maintenance and protection of vehicles and pedestrians

g) Project identification signs

h) SEPTA field office

i) Project record documents

j) Commissioning of systems

k) Instruction manuals for operation and maintenance of equipment furnished by the EC, including mechanical systems. Mechanical systems documentation must be complete prior to handing it over to the MC for verification and final submission.

l) Training of SEPTA personnel in the operation and maintenance of electrical equipment and systems.

2. Site Preparation:

a) Provide (furnish and install) field offices.

b) Provide temporary Electrical Power, Lighting and Telephone/Communications.

c) Perform removal, demolition and recycling of metals for existing cables in manholes and duct banks slated for demolition.

d) Excavate, construct, and backfill for steel-reinforced power, control, and communications duct banks, completed with new manholes, as required on Contract drawings.

1) New duct banks for SFC #4 will be installed between the 230 kV Control Building and the east side of the SFC Building for 13.2 kV power, 480 V power, control, and communications.

2) New duct banks for SFC #4 will be installed between the west side of the SFC Building, the new 25 Hz circuit breaker location, and the existing Wayne Junction 25 Hz Traction Power Substation for 24/12 kV power, control, and communications.

3) Other locations may require reconstruction and repair of existing duct banks.

e) Provide and pull new power and control cables and new copper and fiber optic communications cables into duct banks. SEPTA will terminate new cables onto existing cables in the 25 Hz traction power substation at cutover splice and termination points.

f) Provide padmounted transformer equipment pads.


g) Provide circuit breaker concrete equipment pads.

h) Provide reactor and filter concrete equipment pads.

i) Provide concrete pads at landings for stairs and any other equipment pads located within the substation area.

j) Provide the grounding system, including the ground grid, ground rods, and test wells.

k) Hazardous waste disposal for waste created from EC or MC Operations.

3. Furnish and install Concrete Work including incidental steel reinforcement, but not limited to the following:

a) Cast-in-place concrete including formwork, reinforcement, concrete materials, mix designs, placement procedures and finishes. This includes the auxiliary power, traction power, control system, and communications system duct banks, and electrical equipment foundations.

4. Furnish and install Pre-cast Concrete Work including but not limited to the following:

a) Electrical manholes and hand holes.

5. Furnish and install Masonry Work including but not limited to the following:

a) Integration of luminaires and conduit into the GC provided new building.

b) Masonry mortar and grout incidental to the above work.

6. Furnish and erect steel including, but not limited to, the following:

a) Power and control cable supporting structures on side of 230 kV Control Building.

b) Supporting structures around 60 Hz and 25 Hz SFC transformers.

c) Supporting structures, trays, and conduits in 25 Hz traction power substation.

7. Furnish and install Auxiliary Power System work to include but not limited to:

a) New 480 V feeder circuits from the 230 kV Control Building to the SFC Building.

b) Trenching, bedding, duct banks, and installation of auxiliary power conduits and cables.

c) Raceways and boxes.

d) Indoor disconnect switches, switchboards, panelboards, cables, and conduits.

e) Dry-type transformers.

f) Battery equipment in battery room, disconnect switches, and dc panelboards, transfer switches, and battery chargers.

8. Furnish and install all Lighting and General Power work, but not limited to the following:


a) Exterior site lighting poles with LED fixtures and reinforced concrete foundations.

b) Lighting conduits and cables.

c) Panel boards to control ventilation, indoor lighting, heaters, exhaust fans, battery charger, etc.

d) Disconnect switches.

e) Receptacles.

9. Furnish and install all Communication and SCADA system work but not limited to the following:

a) Communication conduits and cables.

b) Indoor communication conduits including cable pulling.

c) Replace the existing station RTU system and coordinate with SEPTA Control Center.

d) Interface the new RTU system with the SFC station control system provided by the SFCC.

e) Replace existing security system in the SFC Building.

10. Removal of existing and installation of new SFC system, including but not limited to the following:

a) Remove from service the existing SFC system and install the new SFC system one SFC unit at a time. The SFC system components will be supplied by the SFCC and installed, integrated, tested, and commissioned under the SFCC's supervision.

b) Perform required work in the 230 kV Control Building to supply the new SFC #4 with 13.2 kV power feeders, circuit breaker, protective relaying, and integration into existing system.

c) Perform required work in the 60 Hz filter yard to remove existing equipment and route new 13.2 kV and control cables from 230 kV Control Building to SFC Building. Repair, install, or replace duct banks and electrical manholes as required on Contract drawings. Add new open-air bus for SFC #4, including new grounding switch and surge arresters.

d) Remove existing 60 Hz SFC transformers and install new 60 Hz SFC transformers, surge arresters, instrument transformers, pre-charging circuit breakers, padmount transformers, filters, reactors, and associated interconnections as required by the SFCC.

e) Modify existing SFC Control Room as required by the SFCC. Remove all existing SFC control equipment and install new control cables and equipment in the SFC Rooms, Basements, and Control Room.

f) Remove SFC power electronics equipment and buswork from SFC Rooms and Basements. Install new SFC power electronics equipment, power distribution panels, control panels, bus work, cables, and accessories.

g) Remove existing 25 Hz SFC transformers and install new 25 Hz SFC transformers, filters, and reactors as required by the SFCC.


h) Perform required work in the 25 Hz filter yard to remove existing equipment and install new SFC output circuit breaker, surge arresters, instrument transformers, disconnect switches, and associated interconnections.

i) Perform required work in the 25 Hz filter yard to repair, install, or replace duct banks and cables from the 25 Hz SFC transformers to the 25 Hz traction power substation concrete-encased conduit risers.

11. Furnish and install the 25 Hz traction power substation work, including but not limited to the following:

a) Install new 25 Hz, 12 kV, 24 kV, and rail return cables from the new SFC #4 concrete-encased conduit riser to the existing overhead structure in the 25 Hz substation.

b) Install cable tray and supports.

c) Install new isolation switch for SFC #4, including motor operator and controls.

d) Install new protective relaying equipment in 25 Hz substation control building.

e) Install new fiber optic communications cable in 25 Hz substation control building, including interfacing connections to the SEPTA Control Center at 1234 Market St., Philadelphia, PA.

12. Install a new fire detection and annunciation system in the SFC Building and the 230 kV Control Building.

13. Design, procure materials, manufacture, test in the factory, deliver, install, test in the field, commission, and bring into revenue service all components necessary for implementation of the Wayne Junction SFC Rehabilitation Project, unless otherwise within the scope of the SFCC.

1.08 STATIC FREQUENCY CONVERTER CONTRACTOR (SFCC)

A. The SFCC will provide detailed design, manufacturing, delivery, installation supervision, testing, and commissioning of the SFC system and equipment specified herein. Refer to section 16262 for complete details on the following systems and equipment:

1. SFC power block equipment

2. SFC input and output transformers

3. SFC harmonic and power factor correction filters

4. SFC pre-charging circuit breakers and auxiliary transformers

5. SFC control system

6. SFC cooling system, including pumps, piping, and heat exchangers

7. SFC power distribution system and UPS equipment

8. SFC protection system equipment

9. Sequence of events recorder

10. Transient disturbance recorder


11. Remote terminal units (RTUs)

12. SFC interconnecting cabling, conduits, and accessories

1.09 WORK REQUIRING INTERFACING BETWEEN PRIME CONTRACTORS

Extensive coordination is required between the prime contractors, especially between the GC and EC. Exact locations of the conduits at the equipment, penetrations through the floor slabs and foundation walls, routing of the conduits, floor embedment for the switchgear, supporting arrangement for the cable tray, etc., would be known only after selection of the traction equipment supplier by EC. All prime contractors shall coordinate amongst themselves to ensure proper installation of the equipment. Following is the illustrative, not exhaustive, list of the interface required:

A. Cutting and Patching:

1. Each Prime Contractor shall be responsible for cutting and patching associated with its own work including cutting of existing pavement, trench excavation and backfill.

2. The GC shall be responsible for the final restoration of all pavement affected within the construction site prior to closeout

B. Storm Drainage System:

1. The GC shall be responsible for all work associated with storm drainage system.

2. The EC is responsible for constructing the transformer pad containment basin including the associated grating and piping.

3. The GC shall be responsible for all related roadway drainage system outside the building structure.

C. Mechanical Equipment:

1. The EC shall be responsible for providing electrical power wiring and disconnect switches for the mechanical equipment, up to each disconnect.

2. The MC shall be responsible for providing motor starters, control devices, control wiring, and the final electrical connection to the equipment from the disconnect switch provided by the EC. Where the power panel from which the equipment is powered is located within the line of sight and within 30 feet of the equipment, the circuit breaker may serve as the disconnect switch provided it can be locked and tagged ‘out’. The EC shall provide conduit for and distribution wiring beyond the disconnect. The line-of-sight refers to the final conditions, with the switchgear and all other equipment installed in position. The MC shall make the wiring connections other than at the power supply disconnect and at the fire alarm relays.

3. The MC shall furnish to the GC the mounting curbs and framing, structural support brackets and mounting devices, with complete documentation on HVAC equipment mounting, to the GC in time for the GC to fabricate those items into the building structure at the factory.

4. The MC shall be responsible for providing equipment mounting anchors to the GC, and structural members that rest on each roof mounted equipment pad for HVAC equipment.

D. Excavation and Backfill:


1. The GC will rough grade to 1 foot above ground grid elevation with the limits of the grounding grid. The EC shall excavate for and provide the necessary backfill to restore the ground above the ground grid to1 foot above the ground grid as indicated on the drawings, including placement of buried conductor marker tape. The GC shall complete the earth work above this elevation and provide the 12” depth of stone to the limits indicated surrounding the substation compound.

E. Equipment Pads:

1. The GC shall interface with the EC in constructing the concrete equipment pads, as indicated on the Contract drawings or as modified if so required by the MC or EC equipment contractors.

F. Wall and Floor Penetrations:

1. EC shall coordinate with all trades regarding dimensions and locations for each conduit stub-up duct run for wall and floor penetrations through the wall or floor for entry to the switchgear and other building systems.

2. GC shall interface with all trades regarding dimensions and locations of placed concrete to accommodate embedded support beams for the switchgear building.

G. Conduits for Traction Power Equipment:

1. EC shall coordinate with all trades for the placement of conduits for traction power equipment after selection of the vendor and approval of shop drawings.

2. The GC shall consult the EC before placing sleeves through the foundation of the substation knee wall/ fence system for accommodating placement of the substation ground grid.

H. Static Frequency Converter System

1. EC shall coordinate the receipt, installation, testing, and commissioning of the complete new SFC system with the SFCC.


SECTION 01011

SUMMARY OF PROJECT - APPENDIX A

Task Description

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230 kV Control Building

Install existing 13.2 kV circuit breaker to supply SFC #4. x x

Use existing overcurrent relays. Complete wiring for existing overcurrent relay schemes in 13.2 kV switchgear for SFC #4.

x x

Install new conduits from 13.2 kV switchgear out top of switchgear, across room, out wall.

x x

Use existing 13.2 kV circuit breakers and run two new feeder circuits for SFC #4 to converter building switchgear room.

x x

Keep station auxiliary transformers. Test existing auxiliary transformers to determine their health. Provide a report and recommendations to SEPTA.

x

Add conduits and modify control building wall for the 13.2 kV power feeders for the SFC #4 supply.

x x

Replace the existing Pyrotronic suppression/fire alarm control panels with new updated addressable fire alarm system and a suppression activation panel in the 230 kV control building

x x

60 Hz Filter Yard

Remove control and instrumentation cables between the 230 kV Control Building and SFC Building that are no longer used.

x


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Keep duct banks between 230 kV control building and open-air bus (under access road next to auxiliary transformers). Remove cables between 230 kV control building and 60 Hz input transformers. Remove open-air bus and replace with duct banks.

x x

Install new duct banks to be joined to existing duct banks. Repair existing duct bank as required.

x x

Route new cables in existing and new duct banks from 13.2 kV switchgear to 60 Hz transformers.

x x

Repair SFC #2 13.2 kV cable risers in transformer bay, if duct bank not replaced.

x x

Install new duct bank for SFC #4. x x

Install new cables for SFC #4. x x

Replace existing 480 V power and control cables for SFC #1, #2, and #3 if damaged.

x x

Add new two new 480 V power circuits from 480 V switchgear in 230 kV control building to converter building switchgear. Use existing duct banks, if possible.

x x

Remove all existing equipment and foundations that will not be re-used.

x

Add grounding grids where specified on drawings. x x


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60 Hz Transformer Area

Remove 60 Hz transformers and bus duct. x

Modify existing 60 Hz transformer foundations. x x

Build new foundations where required for new equipment. x x

Add new oil retention pits for SFC #2 and SFC #4 if vendor has oil filled equipment.

x x

Repair or rebuild oil retention pits for SFC #1 and SFC #3 if vendor has oil filled equipment.

x x

The existing fill at the base of the wing wall will need to be excavated and recompacted

x x

Disassemble and remove deluge system if not required by code or system design.

x

Replace deluge system, piping, and spriknler heads, as necessary, if new transformers are installed.

x x

Modify existing openings for new transformers or reactors. x x

Add grounding grid around new transformers and/or reactors. x x


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Control Building Fire Pump Room

Replace Halon system with FM-200 clean agent fire suppression system.

x x

Replace deluge valves and control system for SFCs #1, #2, and #3. x x

Install new deluge valve and controls for SFC #4. x x

SFC Control Room

Replace the existing Pyrotronic suppression/fire alarm control panels with new updated addressable fire alarm system and a suppression activation panel in the SFC building

x x

Remove obsolete equipment and cabling in control room once new converters are commissioned.

x

Replace SCADA/RTU system x x x x

Replace control room ceiling. x x

Replace exhaust fans on control building. x x

Replace roof top units if there is an increase in loads. x x


Task Description

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Install fire dampers. x x

Install new direct digital control (DDC) system to control the heating, ventilation, and air-condition (HVAC) systems.

x x


x x

Replace the existing SFC control system and protective relays with those required for the new SFC system, including all interconnecting cabling

x x x x

SFC Building

Remove three SFC 480 V auxiliary power transfer switches and associated main breaker switchboards. Splice new 480 V power feeders from power distribution room to SFC power distribution equipment for each SFC.

x x

Remove existing 480 V, 3-ph feeders between 480 V switchboards and 480-208Y/120 V transformers.

x

Add one new 480 V, 3-ph switchboard with main breaker for each SFC in SFC Hallways. Each switchboard shall be supplied by the SFCC for use with their equipment, but will also be used to supply the SFC Room HVAC equipment located on roof tops.

x x

Add new 208Y/120 V, 3-ph, 4-wire lighting panel for each SFC in SFC Hallways. Each lighting panel shall be supplied by the SFCC for use with their equpiment, but will also be used to supply the SFC Room lighting.

x x


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Add new 480 V, 3-ph feeders from new 480 V switchboards in SFC Hallways to existing 480-208Y/120 V, 3-ph transformers in Switchgear Room.

x x

Upgrade batteries and chargers to supply 125 V dc to 25 Hz circuit breaker controls.

x x

Replace shower and eye wash system. x x

Add SFC #4 room to fire alarm system x x

Replace door alarm and security system. x x

Add designated tie-off points on SFC building room. x x

Replace roof on three SFC buildings and control building. x x

Replace coping on roof. x x

Provide OSHA compliant fall protection at HVAC units x x

Abate roofing materials as an asbestos-containing material. x x

Clean façade to remove efflorescence x x

Repair CMU cracks to eliminate water infiltration. x x


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Repair parapet walls as necessary x x

Scrape, prime and paint areas of peeling paint x x

Remove and replace damaged sealant. x x

Repair walls that have open and cracked mortar joints. x x

Add weep holes to allow for water to exit CMU wall cavity. x x

Repair lower deteriorating building walls. x x

Repair roof flashing. x x

Repair spalled penetrations. x x

Seal wall penetrations x x

Repaint interior walls. x x

Repair cracked interior walls where water damage is present. x x

Repair interior ceiling in hallway of SFC #1 and SFC #3. x x

Replace HVAC register x x


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Replace paper towel dispenser x x

Remove and cap water fountain (classified as non-potable). x x

Paint battery room ceiling. x x

Install a new wall and set of doors in each SFC room to separate the corridor from the high-voltage SFC equipment.

x x

Install vendor-provided SFC heat exchangers on roof. These are sized by SFC vendors. Structural engineering to provide supporting structures to support heat exchangers.

x x x

Repair tripping hazards in the middle section of the interior floor slab in the switchgear room and in the corridor between the battery room and the workshop storage room.

x x

Modify building lighting locations where required by positions of new SFC equipment. Replace all non-LED type lighting with LED-type lighting.

x x

Add lighting for new SFC #4 building. x x

Replace three roof top air-conditioning units. x x

Install three split-system heat pumps to serve the SFC corridors. x x

Remove two make-up air units. x

Modify ventilation ducts as required for new converter system bus work.

x x


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Remove existing outside air louvers and patch wall opening to match existing.

x x

Build addition from standard CMU & Brick construction x x

Replace weather stripping with air tight seal and install automatic closers at all exterior doors.

x x

Replace exterior envelop louvers with automatic airtight closing louvers

x x

The Contractor shall develop their own site-specific HASP for protection of their workers.

x x

Modify site grading and drainage as required x x

Replace backflow valves, if required x x


x x

SFC System

Design and supply the new SFC system. x x

Fully integrate the new SFC system with the existing SFC system so that the complete SFC station is functioning and operable at all times.

x x x


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Identify all system interface points required in order to remove each existing SFC independently and integrate each new SFC into the existing system.

x x

Design and supply all required systems and equipment to interface and integrate the new SFC system with the existing SFC station

x x x

Supply all interconnecting cables, splices, and wire terminations for all SFC related systems and equipment

x x x x

Route and install all interconnecting cables, splices, and wire terminations for all SFC related systems and equipment

x x x

Remove existing SFC equipment one unit at a time. x x

Remove, repair, or replace 60 Hz transformer foundations and oil containment structures

x x

Remove, repair, or replace 60 Hz transformer oil-water separator system

x x

Remove existing electrical bus work from SFC #1 and #3 basements.

x x

Remove equipment no longer needed for the new SFCs from the SFC #1 and #3 basements and SFC #2 crawl space.

x x x

Install new 60 Hz SFC input transformers, reactors, filters, precharging breakers, and padmount transformers per SFC Vendor design.

x x x x

Install new SFC power block equipment, including power electronic racks, power electronic modules, local controls, and all interconnecting system equipment.

x x x x


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Install new SFC control equipment, including station controller, SCADA system, RTUs, sequence of events recorder, and protective relays.

x x x x

Install new SFC power distribution equipment. x x x x

Install new SFC cooling system pumps, heat exchangers, and piping. x x x x

Remove, repair, or replace 25 Hz transformer foundations and oil containment structures

x x

Remove, repair, or replace 25 Hz transformer oil-water separator system

x x

Install new 25 Hz SFC output transformer, reactors, and filters. x x x x

Remove existing control wiring from cycloconverters. x x

Install new fiber optic cables to connect new converter system. x x x x

Route new fiber optic cable from 25 Hz traction power substation to SFC control room.

x x

Remove existing SFC power wiring from cycloconverters. x

Add new 480 V, 3-ph power feeder from converter switchgear room to SFC power distribution equipment in each SFC room.

x x x


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25 Hz Transformer Area

Remove 25 Hz transformers and bus duct. x

Add new oil retention pit for SFC #2, if required by SFC vendor. x x

Repair/replace oil retention pits for SFCs #1 and #3, if required by SFC vendor.

x x

Build new oil retention pit for SFC #4, if required by SFC vendor. x x

The existing fill at the base of the wing wall will need to be excavated and re-compacted

x x

Disassemble and remove deluge system if not required by code or system design.

x

Replace deluge system parts as necessary if new transformers are installed.

x x

Modify existing openings for new transformers or reactors. Larger openings in depth will not require structural work. Larger openings in width will require structural work to replace header and lintel.

x x

Reuse existing foundation and modify, if possible. x x

Build new foundations, where required. x x

Add grounding grid for SFC #4 x x


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Modify existing foundations for new 25 Hz transformers x x

Construct new wing walls for SFC #4 x x

Install new piles to support a bridge for transformer foundation x x

New deluge system x x

25 Hz Circuit Breaker and Filter Yard

Remove all existing filter equipment and other items shown on Contract drawings. Keep filter foundations.

x x

Replace existing SF6 live-tank breakers with new ABB magnetically operated circuit breaker. Manufacture to provide input for foundation design.

x x

Replace disconnect switches. x x

Replace instrument transformers. x x

Replace surge arresters. x x

Build new foundations or modify existing foundations as required. x x


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Grading and drainage. x x

Remove cables that are no longer necessary x

Add new control cables for new ABB magnetically operated circuit breakers and instrument transformers.

x x

Replace all power cables between existing 25 Hz transformers and 25 Hz circuit breakers. Re-use existing duct banks. Repair duct banks, where required.

x x

Install new duct banks from new 25 Hz SFC #4 output transformer to 25 Hz circuit breaker, then a new duct bank to 25 Hz traction power substation with new cables.

x x

Add ground grid where required (where personnel will operate switches, breakers, or touch metal objects such as transformers and fences)

x x

25 Hz Traction Power Substation

Add power cable connections to transfer bus, including trays and conduits.

x x

Add disconnect switch and controls. x x

Add structure to support cables. x x

Add surge arresters. x x


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Add new current transformers (CTs) to 25 Hz traction power substation bus.

x x

Add new protective relay in 25 Hz traction power substation control house.

x x

Add auxiliary control equipment, switches, and relays to support new SFC #4.

x x

END OF SECTION


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SECTION 01025

MEASUREMENT AND PAYMENTS

PART 1 - GENERAL


A. This section specifies general requirements for measurement of quantities and schedule of values required to process payment applications according to the provisions set forth in the Agreement.

B. Provide a detailed breakdown of the Contract Sum showing values allocated to each of the various parts of the Work, as specified herein, and as required by other provisions of the Contract Documents.


A. Exhibit III of the Agreement.

B. Pertinent sections in Division 1 and technical Divisions 2 through 16.

1.03 MEASUREMENT OF QUANTITIES

A. The Work performed under the Contract will not be measured, except to establish percentage of completion for each value line payment item.

1.04 SCOPE OF PAYMENT

A. Payment for work performed under the Contract will be paid in accordance with the agreement, for the Wayne Junction SFC Rehabilitation Project.

B. Complete in place and in conformance with the Contract Documents.

1.05 QUALITY ASSURANCE

A. Prior to applying for first application of payment, secure SEPTA’s approval of the Schedule of Values.

B. During progress of the Work, including any change order work, modify the Schedule of Values, as required, and as approved by SEPTA.

C. Provide data, including detailed bid preparation documents to substantiate each value line.

1.06 SCHEDULE OF PAYMENTS

A. Submit a schedule of values in accordance with the requirements specified in the Agreement.

END OF SECTION




SECTION 01041

PROJECT COORDINATION

PART 1 - GENERAL


A. This specification covers project coordination responsibilities of each separate Contractor for this Project.

1. Throughout the progress of the Work, perform coordination responsibilities as defined herein and as noted in related sections of the Specification.

2. Coordinate the Work of its own employees and subcontractor(s).

3. Coordinate the work with the Work of other Contractor(s).

4. Expedite coordination process to assure compliance with the project schedule.


A. Exhibit III of the Agreement


C. Section 01011 – Summary of Project

D. Section 01045 – Cutting and Patching

E. Section 01060 – Regulatory Requirements and Safety


G. Section 15010 – Basic Mechanical Requirement

H. Section 16010 – Basic Electrical Requirements

1.03 COORDINATION AND MEETINGS

A. The Coordinating Contractor, as designated under Exhibit III of the Agreement and Section 01011, is hereby assigned the full responsibility to ensure that the work to be performed by other Separate Contractors under this Project is coordinated in a manner to eliminate any negative impact to the schedule and any installation sequencing conflicts.

B. The Coordinating Contractor shall conduct regular construction coordination meetings and prepare written memoranda regarding coordination activities. These memoranda shall include such items as required notices, resolution of conflicting activities reports and attendance at meetings. The Coordinating Contractor shall distribute these memoranda to each Contractor performing Work at the site and provide copies to SEPTA's Project Manager within seven (7) days of the meeting date. In addition to other responsibilities noted elsewhere in this specification, the Coordinating Contractor shall:

1. Establish administrative procedures and distribute these procedures to each Contractor within fifteen (15) days from the date of the Notice to Proceed.

2. Arrange and conduct pre-installation meetings affecting all Contractors at site, as may be required for quality control, access and sequencing.


3. Resolve schedule and installation conflicts among Separate Contractors (see Section 1.04 below).

4. Establish control for the use of site, maintenance of traffic, and Quality Control (QC) monitoring during construction.

5. Monitor and enforce general discipline among the Contractors at site concerning safety, site protection and cleaning. The Coordinating Contractor is responsible for coordinating and monitoring activities among the Separate Contractors to secure, protect and waterproof unfinished and exposed work.

6. Inform SEPTA’s PM of the time and place of each construction coordination and pre-installation meeting. SEPTA may elect to have a PM’s representative present.

1.04 COORDINATION MEETINGS AMONG CONTRACTORS

A. All Contractors are alerted to the importance of coordination and cooperation among themselves. It is essential to the expeditious and accurate completion of this project that the Contractors meet at an early stage in the work for the purpose of allocating their construction space requirements.

B. In such areas where their installations are in close proximity, or are likely to be in conflict or interfere with one another, it is mandatory that the Coordinating Contractor set up regular meetings as shop drawings are developed. The meetings shall be for the purpose of modifying work schedules to adjust for conflicts and to arrive at an orderly sequence of operations agreeable to all Contractors so delays may be avoided. The meetings are also intended to determine the need to prepare coordination drawings for the use and guidance of each Contractor.

C. The meetings will be arranged through and managed by, the Coordinating Contractor, and shall be separate from, and in addition to, the regular job progress meetings. If it is desired that the Architect/Engineer be present at such meetings, a request to this effect should be directed to SEPTA’s Project Manager with at least 7 days’ notice. Unless specifically excused by the Coordinating Contractor, attendance by all of the separate Contractors and their subcontractors/vendors (as needed) is mandatory. The Contractors’ representatives at the meetings shall have the competence and authority to make any necessary decisions and their statements shall commit the Contractors to the agreed procedures, sequence of operations and time schedules.

1.05 FIELD COORDINATION AMONG CONTRACTORS

A. In deciding construction conflicts in the field, the following is the order of priority for construction space (Note – Finished ceiling heights to be maintained as indicated on the Contract Documents):

1. 1st - Duct work

2. 2nd - Fire Protection Piping

3. 3rd - Other Piping

4. 4th - Electrical Conduit

B. If a structure and/or enclosure is to be constructed over equipment, the Contractor shall deliver, set and protect equipment and materials before erection of confining enclosures. All equipment and materials so confined shall be inspected and tested prior to delivery. Should equipment or materials fail to meet the requirements of the Specifications, the


Contractor who did not provide the specified testing shall replace equipment or materials and pay all costs, including costs for modifications of completed areas that are required to provide passage.

C. Failure to be represented at any of these meetings shall subject the absent Contractor to liability for any and all damages, delays, costs of alterations, etc., which result from the fact that its representative was not present to coordinate its work with the other Contractors.

D. If a conflict develops as a result of coordination failure of any Contractor, SEPTA will determine which Work shall be relocated or replaced, regardless of which was installed first, and the cost shall be the sole responsibility of the Contractor(s) who failed to properly coordinate.

1.06 COORDINATION DRAWINGS

A. Coordination drawings must be prepared using field verified dimensions including clear dimensions, elevations, and locations relative to the building lines and/or baselines, and other adjacent structures. The Coordinating Contractor shall prepare the coordination drawings in English unit’s scale of equipment, piping, ductwork, etc. to be installed at site, and submit drawings to all other Contractors for review, comments, coordination and approval before any Contractor begins work.

B. The Coordinating Contractor must ensure that coordination drawings and related shop drawings are submitted for SEPTA’s review after the drawings have been reviewed and approved by the other Separate Contractors. Coordinate work with architectural and structural drawings for exact space conditions; where not readily discernable, request information from the Architect/Engineer before proceeding.

C. Where procedures have been agreed upon and coordination drawings accepted by all Contractors concerned, the coordination drawing(s) must be transmitted to the SEPTA PM as a formal shop drawing, and it shall become binding upon all Contractors to follow the coordination drawings and procedures. A responsible supervisor from the staff of each Contractor shall supervise the work of his contract.

1.07 PRE-INSTALLATION MEETINGS

A. The Coordinating Contractor is responsible to coordinate the Work of all separate Contractors at the site to eliminate any scheduling conflicts in the installation of each unit of work.

B. Each Contractor shall schedule and conduct pre-installation meetings with its own subcontractors, suppliers, manufactures, fabricators and other affected trades for each unit of work affecting the quality or proper sequencing of Work, prior to the construction coordination meeting with the Coordinating Contractor.

C. Each Contractor will provide SEPTA with three (3) days’ notice for all pre-installation meetings so that SEPTA may participate if it chooses.

D. The pre-installation meetings must at least include following topics of discussions:

1. Requirements of the Contract Documents and the approved shop drawings, product data and quality (see 1.04 above) control samples.

2. Coordination with other Contractors. Possible installation conflicts and resolutions with existing and new work not resolved during the construction coordination meetings.


3. Delivery Schedule and Site Access.

4. Weather limitation

5. Space and access limitations

6. Regulatory requirements

7. Safety during installation

1.08 COORDINATION WITH OTHER CONTRACTORS AT SITE

A. There may be other active contracts (refer to Section 01010, Article 1.08) on the project site engaged in activities not directly associated with the Work of this project. The Coordinating Contractor (CC) will consider these other contracts when developing the project schedule. SEPTA's PM and/or Architect/Engineer will be responsible for the day-to-day coordination of the Work of the other Contractors as required.

B. SEPTA will not consider any time extension or monetary compensation for delays or damages as a result of the Coordinating Contractor’s failure to adequately document or communicate the other Contractor’s activities in the integrated schedule or the separate Contractor(s)’ failure to act on the information furnished by the CC. SEPTA may only consider a time extension to the Contract if it is documented by the CC, to the satisfaction of SEPTA that the Contractor has responsibly complied with these coordination requirements.

C. If the damage to the project's Work occurs as a result of the other Contractor’s activities, the Contractor shall promptly settle the matter with the other Contractor to avoid impacting the schedule and warranty provisions of this Contract.

END OF SECTION


SECTION 01060

REGULATORY REQUIREMENTS & SAFETY

PART 1 - SAFETY

1.01 DESCRIPTION

A. This Section specifies the safety & environmental requirements for Contractor personnel involved in construction, maintenance, and rehabilitation projects on SEPTA property. The Contractor is required to assure that all employees, subcontractors, and suppliers/vendors, while on the Work site comply with the provisions of this Section.

B. At those facilities to remain in operation during construction, or are adjacent to SEPTA right of way, the Contractor shall take every precaution necessary to assure the safe access and egress of all SEPTA customers and employees, the safe and continuous operation of all SEPTA vehicles, ensure the appropriate protection of the environment as well as the safety and general welfare of the public at large. Depending on the configuration of the project, the Contractor may be responsible for providing temporary pedestrian access including access which is accessible to those with disabilities. Under no circumstances is the Contractor to block or restrict public or SEPTA entrances or the SEPTA vehicle right of way without prior written approval of the SEPTA Project Manager.


A. Section 01010 – Summary of Work



D. Section 01065 – Railroad Safety Requirements

E. Section 01100 – Special Project Procedures

F. Section 01300 – Submittals

G. Section 01400 – Quality Requirements

H. Section 01500 – Construction Facilities and Temporary Controls

1.03 SUBMITTALS

A. The Contractor shall furnish a copy of the Contractor’s project/site specific safety plan (and corporate program if referenced) and protocols to the Project Manager within 30 days from receipt of the Notice to Proceed. The SEPTA Project Manager may prohibit and/or restrict any work on site until this plan has been received and approved.

B. If these Specifications call for certification or licenses from the Commonwealth of Pennsylvania, it is understood that certification or licensure shall be from the state where the work is occurring and in the case of work in multiple states, then licensure from multiple states may be required.


A. The Contractor shall be responsible for ensuring compliance with the regulations of all applicable occupational safety and health statutes and regulations of all of the applicable political jurisdictions where the work is being performed including those relating to the


U.S. Department of Labor, FRA, FTA, and Occupational Safety and Health Administration (OSHA) standards. The Contractor shall conduct daily monitoring and document the compliance and performance of the requirements set forth in this document and those required by applicable governmental agencies. This documentation will be based on the applicable code requirements and shall be made available upon request of the SEPTA PM.

B. SEPTA Project Managers (SEPTA PM), Authority employees, and SEPTA’s Construction Manager will monitor compliance with all applicable internal safety and environmental regulations and environmental contract specifications.

C. The Contractor’s employee safety program, which must be site specific, shall include but not be limited to the following (as applicable):

1. Work Site Orientation

a) Safety and health hazards present in the work assignment and the general work area.

2. OSHA - written programs applicable to scope of work.

3. Required training, licensing or certification, and documentation of same

4. Workers’ Compensation Reporting

5. Fall Protection equipment and requirements

6. Personal Protective Equipment

7. Confined Space Procedures

8. Hazardous Materials Handling and Disposal

9. Trenching and Excavation including shoring and sheeting

10. Cranes

11. Electrical Protection

12. Drug and Alcohol prohibitions and testing

13. Public, SEPTA Employee, and Passenger Protection

14. Site Emergency Procedures and Contact Information

a) Emergency contact numbers

b) Emergency escape routes and evacuation meeting place

15. Nearest hospital, including directions from the site with route maps

D. The Contractor shall provide a designated qualified safety officer who shall be responsible for all safety-related activities until the completion of the Work. The Contractor is also responsible for all safety related activities for all their subcontractors and suppliers working at the work site.

E. The safety officer shall report all on-the-job injuries at once to the SEPTA Project Manager and submit all paperwork pertaining to such injuries, within 24 hours or as required by the SEPTA PM.

F. The Contractor’s safety officer shall, as a minimum hold weekly (tool box) safety meetings with all of the Contractor’s personnel. Subjects, time, and location may be set at the Contractor’s convenience. At least three (3) days prior to each meeting, SEPTA requires an agenda be submitted to the SEPTA Project Manager, including the time and location of


each meeting. Copies of signed attendance sheets and the meeting minutes shall be submitted to the Project Manager at each regularly-scheduled project coordination meeting.

G. The Contractor is required, by Agreement, to maintain an alcohol and drug free environment. The Contractor shall describe in their employee safety program on how this contract stipulation is to be accomplished and maintained. Please note that SEPTA reserves the right to restrict access to its property, because of the inherent safety hazard to its employees and general public. Any person shall be immediately removed and barred from SEPTA property if in the opinion of SEPTA’s Project Manager, and/or other appropriate SEPTA representative, that person constitutes a safety risk.

1.05 GENERAL SAFETY REQUIREMENTS

A. The Contractor shall supply and furnish all required personal protective equipment (PPE) for their employees. The Contractor is also responsible for ensuring that PPE is worn correctly by all employees while on the work site. The Contractor’s employees shall wear compliant safety equipment including, but not limited to, hard hats, work shoes/boots, safety vests, safety glasses, and fully body cover clothing, including flame retardant (FR) clothing where and when it is required.

1. The minimum PPE standards must be met as outlined below:

a) Hard hats shall be ANSI-Z89.1 2003, Class E. Hard hats shall be worn at all times while on the work site.

b) Work shoes (ASTM 2413-11 C75 / I75) shall have non-slip soles. Permanent metal plates or cleats on the sole or heel of shoes are prohibited. Shoelaces are to be kept short so they do not pose a tripping hazard. Athletic shoes, sandals, open-toed shoes, moccasins and/or shoes with heels higher than 1” are not permitted.

c) Contractor personnel shall wear eye protection at all times on the work site. Eye protection shall be safety glasses with rigid side shields that comply with ANSI Z-87.1. Prescription eyewear shall also meet the same requirements as described above, or the individual shall wear equivalent eye protection over their prescription glasses or contact lenses.

d) The safety vest shall be ANSI 107, Class 2 high-visibility with a yellow-green background and 2-inch retro-reflective striping for work on SEPTA owned property within any public right-of-way, where exposed to vehicular traffic, or otherwise required by rules or regulations.

e) The Contractor’s personnel shall wear long pants (without cuffs) and, at a minimum, short sleeve shirts. Sleeveless shirts are prohibited.

f) All workers within the SFC facility and site are required to wear flame retardant (FR) clothing as their outer-most garment.

g) Approved hearing protection shall be worn in all designated areas identified by signs or when operating high noise level equipment. The contractor is responsible for providing acceptable hearing protection for their employees as outlined in OSHA 29 CFR 1910.95.

h) The Contractor is responsible for providing acceptable respiratory protection for their employees as outlined in OSHA 29 CFR 1926.103.


i) Gloves shall be worn where hand injuries are likely to occur based on the hazard present.

B. The Contractor shall take all necessary precautions and provide protective measures to prevent injury to the public and damage to property of others. To prevent unauthorized access to the work zone and storage areas, the Contractor shall furnish and erect construction fencing or barricades and signage, as specified in the Contract Documents or as directed by the SEPTA PM, for the safeguarding of the public against accident or damage before commencing operations. The Contractor shall maintain the protective measures and/or construction fencing in good condition as evaluated by the SEPTA PM, until removal.

C. The Contractor shall dismantle, remove and/or relocate construction fencing and barricades when directed by the SEPTA Project Manager.

D. The Contractor must ensure personnel, including subcontractors and vendors, receive the required SEPTA Safety Training for the affected mode(s) before starting work. This covers the rules and procedures for personnel and equipment including but not limited to, working in or about stations, yards, tunnels, or adjacent to the track right-of-way. All personnel who are present at the job site at any time must have this training. All personnel are required to wear / display their safety training card.

E. The Contractor is required to comply with OSHA’s Noise Standard 29 CFR 1910.95 and any local noise ordinances.

F. Where it is permitted to store materials on streets, the Contractor shall place such materials in a secured place in accordance with local jurisdictions so as to cause minimum obstruction to traffic and public safety. The Contractor shall not place materials within 15 feet of fire hydrants nor obstruct drainage gutters and inlets. The Contractor shall obtain and pay for all required permits relative to materials storage.

G. Material stored on site must be secured to prevent vandals from placing debris or material on the right-of-way. Material placed on the right of way must be removed by the Contractor immediately upon notification, at any time, at no cost to SEPTA. At no time shall any merchandise, material, or other articles be permitted to remain piled or assembled on the ground or on platforms adjacent to any track at a distance of less than ten feet, (10’-0") from the center line of such track.

H. Copies of Safety Data Sheets (SDS) and the quantity of each chemical must be provided to the SEPTA Project Manager for review and approval before chemicals can be brought to any SEPTA property. The SDS will be reviewed by SEPTA’s System Safety and Risk Management Department for approval.

I. All SDS must comply with OSHA’s Hazard Communication Standard 29 CFR 1910.1200. In addition, all Contractors must be trained per the Hazard Communication Standard. The Contractor is responsible for maintaining all SDS used at the work site.

J. The storage of hazardous and flammable materials on SEPTA property is restricted and permission for each material must be granted by the SEPTA Project Manager. When storing flammable and hazardous materials and hazardous waste, they must be stored in compliance with all applicable regulations. Flammable materials shall not be stored in confined spaces or other similar areas such as tunnels, underground rooms and building basements.


K. If hazardous substances are present, such as wastes, or if the potential for a hazardous release exists, the Contractor is responsible for following their Site Safety Plan covering policies and procedures to protect workers and the public from the potential hazards.

L. Firearms or any items classified as concealed weapons will not be brought onto SEPTA’s property.

M. All tobacco use is prohibited within the construction project and all areas subject to restrictions by SEPTA or by local, state and federal law. Smoking within SEPTA indoor facilities is prohibited.

N. The Contractor may not block or obstruct access to emergency equipment such as first aid kits, AED units, eyewash stations, fire extinguishing equipment, fire hydrants, transformers, or emergency generators. Emergency equipment must not be disconnected or relocated by the Contractor without permission from SEPTA’s Project Manager.

O. All electronic devices must be turned OFF or placed in airplane mode when working within the fouling envelope of the right of way. If an individual must make a phone call, they must first step outside the fouling envelope of the right of way to make or receive the call or otherwise use an electronic device. The Contractor and his personnel are liable for all fines assessed by the Federal and/or state regulators for a violation of this regulation. Violation of this regulation can result in the individual being prohibited from working on the project.

P. The use of head phones, ear buds, etc. are prohibited while in a construction area.

1.06 ACCIDENT AND INJURY REPORTING

A. The Contractor is responsible for reporting and investigating all work related accidents and incidents. This shall be completed in a timely manner with recommendations for corrective actions to prevent similar accidents or incidents. Accidents and incidents include:

1. Personal Injury

2. Property Damage

3. Near Misses

4. Actual or potential exposure to toxic substances

5. Hazardous material spills and releases

6. Fires

B. The Contractor must immediately notify the SEPTA Project Manager for all accidents and incidents that occur on SEPTA property.

C. SEPTA reserves the right to conduct an independent investigation of all accidents and incidents that occur on the work site with the full cooperation of the Contractor, subcontractor and employees.

D. At accident locations where conditions are immediately dangerous to life and health, work shall be suspended until corrective actions are taken to the satisfaction of the appropriate SEPTA representative.

1.07 EMERGENCY PROCEDURES

A. The Contractor shall set up emergency procedures and prepare written guidelines discussing such procedures for the following categories:


1. Fire

2. Injury to Contractor’s and/or SEPTA employees

3. Injury to general public

4. Property damage, including property of utilities, i.e., gas, water, sewage, electrical, telephone or pedestrian and vehicle routes.

5. Hazardous/toxic material spill, discharges and/or exposure.

6. Site evacuation.

B. Copies of all guidelines for emergency procedures shall be written and posted prior to the initiation of actual construction. Posting shall include emergency telephone numbers and directions to and from the nearest hospital. The Contractor shall have standing arrangements for the transportation and hospital treatment of any employees who may be injured, are exposed to hazardous material, or who may become ill. These guidelines shall be included in the Contractor’s written safety program and shall be submitted to SEPTA.

C. The Contractor shall provide a fully equipped first aid kit at the site. This kit will be made available to the SEPTA PM for their inspection and approval at any time.

D. The Contractor must discuss site emergency procedures at the beginning of the project, with the addition of a new worker to the site, and at least monthly with all personnel at tool box safety meetings. Any changes to the work site emergency procedures must be documented and employees, vendors and the SEPTA Project Manager notified.

E. SEPTA operational emergencies will be handled by the senior SEPTA Operations personnel present. This individual, designated “The Incident Commander” is responsible for summoning the number of persons required by the situation and assignment of all recommended procedures.

1.08 PROTECTION OF SEPTA FACILITIES

A. The Contractor shall be cognizant of and bound by SEPTA’s safety rules and regulations specified herein and conduct operations in strict accordance with same.

B. SEPTA shall be the sole judge of protection necessary for the safe operation of its facilities. SEPTA reserves the right to alter this protection at any time.

C. SEPTA’s Facilities and/or Structures shall not be utilized by the Contractor for temporary scaffolding and/or support for the construction effort without permission. A Contractor may request SEPTA’s consideration for such action. The Contractor shall provide a detailed plan to utilize SEPTA’s Facilities and/or Structures. The plans will be submitted for SEPTA’s review and approval prior to the initiation of any work. SEPTA also reserves the right to have the drawings and supporting calculations sealed by a Professional Engineer registered in the Commonwealth of Pennsylvania, or appropriate jurisdiction, at no cost to SEPTA.

D. Before any work is done in the vicinity of an existing structure, SEPTA must be notified and may require a plan for stabilizing and underpinning the structure prepared and sealed by a Professional Engineer licensed in Pennsylvania, or appropriate jurisdiction, at no expense to SEPTA.


1.09 CRANE, MATERIAL HANDLING, AND ERECTION SAFETY

A. The Contractor shall take care to prevent any structure from being loaded with a weight, for any duration, which will endanger its stability, or the safety of persons.

B. The Contractor shall adhere to all Local, State, and Federal laws pertaining to crane operations.

C. All cranes must be inspected annually as well as monthly. The most recent reports shall be submitted to SEPTA prior to the use of the cranes on any work site. SEPTA’s Project Manager must ensure that daily safety inspections are completed. The monthly reports for the crane must be submitted to the SEPTA Project Manager on a pre-determined schedule as long as the crane is operating on the project.

D. The Contractor shall ensure all crane operators and riggers are trained and competent in the use of such equipment. The Contractor shall provide a competent person to oversee and/or perform lifting operations as required by OSHA. Personnel qualifications will be made available to SEPTA upon request.

E. The Contractor shall submit for review to the Project Manager, sketches defining the operations of all cranes, material handling equipment, and erection activities used in support of construction during periods of train operations. The Contractor shall submit, at the Project Manager’s request, similar information for cranes or other equipment in use and capable of encroachment.

1. These sketches shall include planned locations and movements of the equipment, calculations demonstrating the adequacy of the capacity of the crane for the loads, the interface between the footprint of the equipment the movement of the boom and loads relative to the existing structure and surrounding buildings, the support grillages and the protection of existing utilities and facilities, and any other pertinent details required by the Project Manager.

2. The following data shall be required for all hoisting operations adjacent to active SEPTA operations and facilities and shall be prepared by and sealed by a Professional Engineer licensed in Pennsylvania.

a) Plans and sections showing locations of cranes, horizontally and vertically, operating radii, with delivery of disposal locations shown. The location of the SEPTA Right of Way and all active facilities shall also be shown.

b) Crane rating sheets showing cranes to be adequate for 150% of the actual weight being lifted. A complete set of crane charts, including crane, counterweight, and boom nomenclature is to be submitted.

c) A location plan showing all obstructions such as wires, poles, adjacent structures, etc., and that the proposed lifts are clear of these obstructions.

d) A data sheet shall be prepared listing the type, size, and arrangements of slings, shackles, or other connecting equipment, all to be designed for 150% of the actual weight being lifted. Copies of a catalog or information sheets for specialized equipment shall be included.

e) A complete procedure is to be included, indicating the location and order of lifts and any repositioning or re-hitching of the crane or cranes.

f) Temporary support of any components or intermediate stages is to be shown and detailed.


g) A time schedule of the various stages must be shown as well as a schedule for the entire lifting procedure.

F. Specialty slings and hooks shall not be used to set steel or move materials over workers. All sling and crane load line hooks shall have safety latches installed or shall be moused, except for specialty slings and hooks such as sorting or shake out slings or self-adjusting pipe slings.

G. The Contractor shall not leave suspended loads unattended. When moving loads, the operator shall ensure a clear path free of personnel or other barriers.

H. The Contractor shall establish a restricted work area using barricades and other appropriate controls to minimize the hazards to personnel, customers, and equipment from swinging or falling objects.

1.10 SNOW REMOVAL

A. The Coordinating Contractor shall remove all snow and ice within the project site as required for the proper protection and prosecution of the Work, and to protect SEPTA employees and the public. The Coordinating Contractor shall at all times provide and maintain adequate protection against weather so as to preserve all Work, materials, equipment, apparatus, and fixtures free from damage.

B. The Coordinating Contractor shall not use sodium chloride (or any chloride) on any facilities adjacent to SEPTA electric rail lines where the possibility exists that melting mixture may leach onto the contact rail within the Right of Way.

1.11 WELDING, CUTTING AND OTHER HOT WORK

A. Gas or electric cutting, burning, or welding shall be done in accordance with the guidelines of NFPA 51 B, the International Fire Code, federal, state, and local rules and regulations, or the provisions below, whichever is more restrictive.

1. If hot work is to be executed at a job site, the Prime Contractor’s safety officer must have a copy of the current version of NFPA 51B at the job site.

2. The Prime Contractor’s safety officer shall act as a Permit Authorizing Individual (PAI) and complete the checklist to fulfill the requirements of by 51 B for all torch work. The Contractor shall obtain the current copy of SEPTA’s “Hot Work Checklist” for this purpose.

3. The SEPTA PM shall be notified at least 48 hours in advance of any hot work on site. A copy of each checklist completed for that period shall be delivered to the SEPTA PM at the next job progress meeting.

4. Spark shields and a fire watch must be posted when executing hot work and for a period of at least four hours after all activity has been completed. The SEPTA PM reserves the right to extend the duration of the fire watch in special circumstances. A supply of water and an approved fire extinguisher shall be readily available to the location where the work was done.

5. All oxygen/acetylene bottles must be removed and stored outside of all tunnels, underground stations and other confined spaces at the end of the workday. While in use in a tunnel, underground station or other confined space, they shall be attended at all times. At no times when not in use shall oxygen and acetylene bottles be stored together.


6. Anti-flashback devices must be installed on the fuel side of all gas and oxygen cutting torches.

1.12 GAS CYLINDERS

A. Compressed gas cylinders shall be handled and properly supported and secured in an upright position away from heat or flame sources. Cylinders that are not being transported must have their caps in place.

B. Regulators, hoses, and torch assemblies must be in working order and checked for leaks prior to initial use or installation. If a leak is discovered, the cylinder must be removed to a safe location.

C. Cylinders must be labeled and stored according to compatibility with signs posted.

D. Oxygen and acetylene cylinders, empty or full, shall not be stored together. Full oxygen cylinders must be separated from acetylene cylinders or other fuel-gas cylinders or combustible materials a minimum distance of 20 feet or by a noncombustible barrier at least 5 feet high having a fire-resistance rating of at least one-half hour.

E. All cylinder valves must be closed when cylinders are not in use and the hose pressure bled down.

F. All cylinders must be removed from confined spaces at the end of each work day.

1.13 UTILITIES

A. Before any excavation begins, the Contractor must determine the location of all utility installations such as but not limited to sewer lines, telephone lines, fuel lines, underground electric lines, water lines, or any other underground installations that may be present during excavations.

B. As per 73 P.S., § 176, et seq., the Contractor is required to notify utilities prior to all excavations. The Contractor shall be held responsible for any damage done to any utility in the prosecution of the Work. The Contractor shall exercise any precautions necessary to prevent damage in working underneath or adjacent to any underground structure. If it becomes necessary for a utility company, through emergency procedures or because of unforeseen conditions, to repair, reconstruct, relay or relocate utilities within the contract area, after work has commenced by the Contractor, then the said utility company and the Contractor shall make suitable arrangements to overcome such interference. All work shall be accomplished at no extra cost or charge to SEPTA. No compensation shall be allowed the Contractor for the disruption to his work. A no-cost time extension may be granted in accordance with the Contract to the Contractor by SEPTA for the delay that has occurred.

1.14 HOUSEKEEPING

A. The Contractor shall maintain their work area in an orderly manner.

B. The Contractor shall provide containers for trash and scrap metal unless prearranged with the SEPTA Project Manager before the start of the project.

C. The Contractor is responsible for the proper disposal of hazardous, flammable, trash, and/or excess waste material. All waste must be removed or secured on site daily. See SEPTA’s Contractor Environmental Safety Requirements for more information on hazardous waste.


D. The Contractor is responsible for maintaining all disposal records, including chain of custody records for hazardous or untested material, and providing copies to the SEPTA Project Manager where applicable.

E. No on site burning or burying of waste or material is permitted.

1.15 ELECTRICAL

A. The Contractor directly involved with electrical work, or work adjacent to electrical hazards shall do so only after details of the work has been planned and approved by SEPTA.

B. All electrical work shall comply with OSHA 29 CFR 1926.400 (Electrical Standard), OSHA 29 CFR 1910.147 (Lockout/Tagout), The National Electric Code (NEC), NFPA 70E (latest editions), and any SEPTA standards.

C. All equipment and cords must be free from damage. Frayed or cut electrical cords, or cords with damaged plugs or missing ground plugs shall immediately be removed from service, rendered unusable, and removed from the work site.

D. All electrical tools and equipment must be grounded.

E. Before working on a de-energized circuit, it must be electrically tested to ensure it is de-energized.

F. The Contractor must complete lockout/tagout procedures for all machines, equipment, and systems that require service or maintenance as required by 29 CFR 1910.147.

1. A lock or tag can only be removed by the individual or their designee.

G. After the Contractor performs repairs, maintenance or installations, and before SEPTA employees attempt to re-energize the electrical equipment, verification shall be performed in the presence of the SEPTA PM to ensure that the electrical equipment components are operationally intact and that no electrical hazard is present up on re-energizing.

1.16 CONFINED SPACE

A. The Contractor shall be required to have competent and trained personnel for restricted or confined space entry work.

B. All confined spaces at SEPTA are permit required spaces and the Contractor is required to utilize SEPTA’s confined space permit.

C. Confined spaces refer to a space which by design has limited openings for entry and exit but large enough to enter to perform work, the potential for toxic atmosphere or one that can produce a toxic atmosphere, and is not designed for continuous occupancy. Confined spaces at SEPTA can include, but not limited to, storage tanks, boilers, trenches, manholes, lift stations, and valve pits.

D. The Contractor shall coordinate and obtain approval from the SEPTA Project Manager for all confined and restricted space activities.

E. The Contractor must provide emergency rescue based on the work being conducted. Documentation on the rescue procedures, authorized rescuers, training and equipment must approved by SEPTA and be available on site prior to conducting confined space entries.


1.17 EXCAVATION AND TRENCHES

A. The Contractor shall provide training to all personnel required for safe trenching and excavation projects on SEPTA property and comply with OSHA Excavation Standard 29 CFR 1926 Subpart P.

B. Prior to any excavations or trenching, the Contractor shall be responsible for utility marking to ensure the area impacted is free from underground hazards.

C. Excavations and trenches over 4-feet deep must have appropriate protective systems such as but not limited to sloping, trench shields, and shoring. If soil conditions are unstable excavations less than 4 feet deep must have protection. This requirement is in addition to any other regulatory requirements including OSHA requirements.

D. Daily inspections of excavations, adjacent areas, and protective systems must be made by the Contractor to ensure safety systems are functional and effective.

E. The Contractor shall place warning signage and barricades or fencing to prevent unauthorized or accidental access to the site.

F. The Contractor shall cease work immediately and contact the SEPTA Project Manager if suspect material such as strong odors, discolored soils, pipes, pipe covering or other material indicating the potential presence of asbestos, or other hazardous materials is encountered.

1.18 LADDER SAFETY

A. All ladders and their use must comply with OSHA 29 CFR 1926.1053 and ANSI specifications.

B. Metal or other conductive ladders are prohibited.

C. Ladders must be inspected before use and must be in good condition and free of any broken or defective parts. Defective ladders must be removed from service.

D. The Contractor must provide training to all employees using ladders in their proper use, how to recognize ladder hazards and how to correct identified safety hazards.

E. Job fabricated ladders are prohibited.

1.19 FALL PROTECTION

A. The Contractor shall provide fall protection and proper training for its employees, as required by 29 CFR 1926.500. Fall protection is required in areas where the fall hazard is 6 feet or greater from the worker’s foot level.

B. The Contractor shall isolate work areas to protect persons from falling objects and to prevent unauthorized access to the work site.

C. The Contractor shall perform documented inspections of their fall protection equipment before each use.

D. Work being conducted within six feet of a floor opening (skylight, hole, open hatch, etc.) requires the appropriate fall protection.

E. Work being conducted on a roof within six feet of the edge requires the appropriate fall protection. The Contractor shall not work on or access roofs without prior approval from SEPTA Project Manager.


1.20 SCAFFOLDS

A. All scaffolding, staging, and work platforms must satisfy OSHA 29 CFR 1926.450 and the manufacturer’s requirements.

B. The Contractor shall ensure that scaffolding be erected and inspected by trained personnel.

C. The Contractor shall perform documented pre-use inspections for erected scaffolding.

1.21 POWERED EQUIPMENT/WORK PLATFORMS

A. The Contractor shall not use SEPTA owned or leased powered equipment or aerial work platforms unless approved by the SEPTA Project Manager.

B. The Contractor shall ensure only trained and authorized personnel operate any powered equipment such as but not limited to forklifts, extendable boom lift, scissor lifts, and cranes.

C. The Contractor shall perform documented inspections of equipment prior to each day’s use to ensure safe operating condition. Defective equipment must be segregated and not be used on the work site.

D. The Contractor must ensure all its employees and subcontractors have had appropriate and effective training in compliance with OSHA 29 CFR 1910.178 (Powered Industrial Vehicles) and 29 CFR 1926.453 (Aerial Lifts) and the manufacturer’s recommendations.

1.22 FIRE SAFETY

A. The Contractor’s personnel should be familiar with the location of fire alarm pull stations, portable fire extinguishers and exit routes from the work area. The Contractor shall not obstruct access to exits, exit routes, or fire equipment or prop-open stair well doors.

B. Fires shall be reported by activating the nearest fire alarm station and calling 911.

C. The Contractor’s personnel shall be trained in the proper use of a portable fire extinguisher in the event fire watch duties are required.

D. Flammable and combustible materials at a minimum must be labeled, properly stored, and disposed of. Please see the Contractor Environmental Requirements.

E. The Contractor must follow requirements listed in the “Welding, Cutting and Other Hot Work” section of this document, if welding, torch cutting, soldering or other forms of “hot work” will be performed.

F. The Contractor must take precautions to prevent damage to fire protection systems. All damage must be reported immediately to the SEPTA Project Manager.

G. The Contractor must not disable a fire protection system (sprinklers, fire alarm system components, etc.) unless prior approval has been provided by the SEPTA Project Manager and local fire department. If a system is disabled, fire watch personnel must be present until that system is reconnected or other arrangements have been made and approved by the SEPTA PM.

H. Materials or equipment must not be temporarily or permanently suspended on sprinkler pipes, valves, or supports.

1.23 PROTECTION OF EXISTING WATER AND SEWER LINES

A. When the equipment axle load exceeds 15 tons, the Contractor shall provide and work from timber mats placed over existing underground water lines and sewer lines.


B. SEPTA reserves the right to require additional protection and/or protection plans sealed by a professional engineer.

PART 2 - ENVIRONMENTAL

2.01 SUBMITTALS

A. The Contractor shall furnish for review by SEPTA the Contractor’s Environmental and/or Waste Management Program within thirty (30) days from receipt of the Notice to Proceed.

B. Prior to the start of work, Contractor shall furnish for review by SEPTA a Means and Methods Plan describing the day-to-day activities the Contractor will employ to complete construction in accordance with the Specification requirements. The Means and Methods Plan shall include the following:

1. A detailed, stepwise description of the construction process organized sequentially;

2. A description of any specialized equipment to be utilized to complete the work;

3. Identification of potential hazards in the construction process; and

4. A description of the construction mitigation measures that the Contractor will implement to mitigate identified hazards.

C. Prior to the start of work, Contractor shall furnish for review by SEPTA a copy of asbestos and lead survey findings/reports. If asbestos abatement or lead removal is conducted, Contractor shall further furnish to SEPTA prior to the start of those activities, all relevant submittals including but not limited to notifications, work plans, and health and safety plans. Within thirty [30] days of completion of work, waste disposal records documenting disposal at a SEPTA-approved facility shall also be submitted to SEPTA.


A. The Contractor shall daily monitor and document the compliance and performance of the requirements set forth in this Section consistent with appropriate SEPTA Work rules and Federal, Commonwealth of Pennsylvania, and Local rules and regulations. The Contractor shall document the Contractor’s compliance with applicable codes and regulations.

B. The Contractor’s Environmental and/or Waste Management Program, as a minimum, shall include but not be limited to the following as applicable to the Work:

1. Sustainability and Recycling

2. Waste Management and Disposal

3. Hazardous Materials

4. Soils Management

5. Erosion and Sedimentation Control

6. Noise Control (if applicable)

C. The Contractor shall provide a qualified environmental safety officer who shall be responsible for all environmental safety-related activities until the completion of the Work. The environmental safety officer shall report all on-the-job environmental incidents at once to the Project Manager and submit all paperwork pertaining to such incidents as required.


2.03 EMERGENCY PROCEDURES

A. The Contractor shall set up emergency procedures and prepare written guidelines discussing response and notification actions related to hazardous/toxic material spills, discharges, or releases. Such guidelines shall be incorporated into one or more Contractor’s required site-specific plan submittals, such as the Health and Safety Plan, Work Plan, Contingency Plan, or Environmental/Waste Management Program.

2.04 STORAGE AND HANDLING OF MATERIALS

A. Materials Handling:

1. All scrap material of any kind, type, or nature shall be placed into designated confined areas or containers specifically supplied for this purpose. Containers shall be removed from the job site when full.

2. The Contractor shall assure that all chemicals, paints, solvents, and cleaners are maintained per OSHA’s hazard standards. Discarded chemicals shall be disposed of in accordance with applicable Commonwealth of Pennsylvania Department of Environmental Protection (PaDEP) and/or Environmental Protection Agency (EPA) requirements. Copies of all Material Safety Data Sheets (MSDS), OSHA Form 20, and the Product Use sheets shall be given to SEPTA’s Project Manager before or at the time of material delivery. All training shall be done in accordance with OSHA’s Hazard Communication Standard.

3. Materials handling shall be conducted in accordance with the Contractor’s Environmental / Waste Management Program.

2.05 ENVIRONMENTAL PROTECTION

A. Environmental protection considerations consist of, but are not limited to, the following factors:

1. Natural resources, including air, water, and land.

2. Solid Waste disposal.

3. Noise.

4. Control of toxic substances, hazardous materials, and radiation.

5. The presence of chemical, physical, and biological elements and agents that adversely affect and alter ecological balances.

6. Degradation of the aesthetic use of the environment.

7. Historical, archaeological, and cultural resources.

B. General Requirements:

1. The Contractor shall provide and maintain environmental protection as defined herein or as required by regulation, whichever is more restrictive.

2. The Contractor’s operation shall comply with all applicable Federal, Commonwealth and Local laws, ordinances, and regulations pertaining to environmental protection.

3. Compliance of subcontractors and suppliers with the provisions of this and all other sections of these Specifications shall be the responsibility of the Contractor.


4. The Contractor shall not use equipment from which factory-installed antipollution and noise control devices have been removed, altered or rendered ineffective intentionally or through lack of proper maintenance.

5. Unless the Contractor has tested and established the safety of existing paints and coverings, he shall provide adequate pollution controls for painting and surface preparation in compliance with the PaDEP Regulations.

C. Protection of Natural Resources:

1. General

a) It is intended that the natural resources within the project boundaries and outside the limits of permanent Work performed shall be preserved in their existing condition or be restored to an equivalent of the existing condition, as approved by the Project Manager upon completion of the Work. The Contractor shall confine its on-site construction activities to areas defined by the Contract Drawings and Specifications or as directed by the Project Manager.

2. Protection of Project Site and Existing Roadways:

a) Debris or rubbish of any kind shall not be dumped onto the site or roadways. This shall include paint splatters, cleaning, stripping and surface preparation chemicals and spillage during painting operations. Care shall be taken to prevent damage and injury to personnel, vessels, and vehicles using roadways, or areas accessible to pedestrians. Devices shall be provided and maintained by the Contractor as required to prevent such occurrences. Material or items falling onto roadways shall be promptly removed at the Contractor’s expense. All damage to third party property shall be restored by the Contractor to the owner’s satisfaction at no cost to SEPTA.

b) The operator shall remove from the site, recycle, or dispose of all building materials and wastes in accordance with the PaDEP solid waste management regulations at 25 PA code 260.1 et seq., 271.1 et seq. The Contractor shall not illegally bury, dump, or discharge any building material or wastes at this site.

3. Land Resources:

a) Except in areas indicated to be cleared or excavated, the Contractor shall not remove, cut, deface, injure, or destroy trees, shrubs, or vegetation. No ropes, cables, or guys shall be fastened or attached to any existing nearby trees for anchorage unless specifically permitted by the Project Manager. Where such use is permitted, the Contractor shall be responsible for any resulting damage.

b) The use of pesticides or herbicides is not permitted unless approved in writing by the SEPTA PM.

c) The Contractor shall submit a plan for protecting existing trees and vegetation that are to remain and that may be injured, bruised, defaced, or otherwise damaged by construction operations. Rocks that are displaced into uncleared areas shall be removed. Monuments, markers, and works of art shall be protected prior to the start of the operations. A preconstruction survey, including photographs, shall be performed by the


Contractor in the presence of the SEPTA PM, and a written report of the survey shall be furnished to SEPTA within five (5) days of its request by the Project Manager.

d) Repair and Restoration: All trees, vegetation and other man made or natural landscape features that are to remain and become scarred or damaged by the Contractor’s equipment or operations shall be repaired and restored to their original condition at the Contractor’s expense. The Project Manager shall approve the repair and restoration program prior to its initiation and after completion.

4. Water Resources: At all times, measures shall be taken to prevent oil, gasoline and other hazardous substances and pollutants from entering the ground, drainage areas, sewers, streams, and other local bodies of water.

5. Wildlife Resources: The Contractor shall not disturb native habitat adjacent to the project construction area.

D. Erosion and Sediment Controls:

1. Site burning of any kind, including ground vegetation, is not permitted.

2. The Contractor shall conform to all applicable requirements of the PaDEP and the County with respect to erosion and sediment control measures to prevent discharge into storm water discharge systems and active waterways.

E. Toxic Substances:

1. The Contractor shall comply with the Toxic Substance Control Act, P.L. 94-469 (TSCA).

a) No toxic chemical substance, mixture, equipment, container, sealant, coating, or dust-control agent shall be used except in accordance with all provisions of the TSCA as interpreted by the rules and regulations of 40 CFR 761.

b) Any toxic chemical substance, mixture, equipment, container, sealant, coating, or dust-control agent found stored within the project area shall be immediately reported to the Project Manager in writing and work shall be stopped in the area. The Project Manager shall make arrangements for the removal of the toxic materials and will ensure that the area is safe for the Contractor to continue work in the area.

F. Control and Disposal of Chemical and Sanitary Wastes:

1. Trash shall be picked up and placed in containers that shall be emptied on a regular schedule. Handling and disposal shall be so conducted as to prevent contamination of the site and other areas, and shall not be disposed of in wetlands or burned on the right-of-way. On completion, the area shall be left clean and in natural condition.

2. Disposal of rubbish and debris shall be as follows: The Contractor shall transport all waste, including excess excavated material, off the site and dispose of it in a manner that complies with the Federal, Commonwealth of Pennsylvania, and Local requirements. The Contractor shall secure a permit or license prior to transporting any material off the site. Waste materials shall not be burned on the site. The Contractor shall be responsible for the disposal of waste material to a pickup point or disposal area.


3. Chemical waste shall be stored in corrosion-resistant containers, removed from the project site, and disposed of as necessary, as but not less frequently as monthly. Disposal of chemical waste shall be in accordance with standard established practices as approved by the Project Manager. Fueling and lubricating of equipment and motor vehicles on the site shall be conducted in a manner that affords the maximum protection against spills and evaporation. Lubricants to be discarded, including burned oil, shall be disposed of in accordance with approved procedures meeting Federal, Commonwealth of Pennsylvania, and Local regulations. For oil and hazardous material spills that may violate Federal, Commonwealth of Pennsylvania, or Local regulations, the Project Manager shall be notified immediately.

G. Dust Control:

1. Airborne dust shall be minimized at all times, including non-Working hours, weekends, and holidays. Soil at the site, station platforms, haul roads, and other areas disturbed by the Contractor’s operations and materials stockpiled for the project shall be treated with dust suppressors or covered to control dust. Dry power brooming shall not be permitted. Vacuuming, wet mopping, wet sweeping, or wet power brooming shall be used instead. Air blowing shall be permitted only for cleaning off non-particle debris, such as that from reinforcing bars. Sandblasting shall not be permitted except as otherwise specified elsewhere. Only wet cutting of concrete block, concrete, and asphalt shall be permitted.

2. The Contractor shall comply with all applicable provisions of the National Emission Standards (40 CFR 61).

3. The Contractor shall inspect all vehicles for dirt prior to their leaving the construction site. Dirt, soil, and rubble likely to be dislodged during transit shall be removed from the trucks and other vehicles prior to leaving the site.

4. The Contractor shall ensure that equipment transporting material to and from the site that may become airborne is covered.

5. The Contractor shall not cause or permit fugitive particulate matter to be emitted into the outdoor atmosphere from any source such that emissions are visible beyond the project property line.

H. Noise Control:

1. The Contractor shall research and determine the applicable jurisdiction requirements for noise control in the project area. In the event a project site lies in two or more jurisdictional areas and the requirements conflict, the strictest will govern. City of Philadelphia Air Management regulations govern for any work within Philadelphia. In absence of specific jurisdictional instructions regarding noise control, OSHA 29 CFR §1910 will apply.

I. Asbestos and Lead Containing Materials:

1. Prior to the commencement to work, Contractor shall coordinate performance of a survey of the project area for asbestos containing materials and lead-based paint by asbestos and lead inspectors/investigators properly licensed and certified to perform such work in Pennsylvania (and the City of Philadelphia where applicable). Contractor shall submit to the SEPTA Project Manager with a copy of the findings/report. Given the age of many SEPTA properties it is always possible to encounter suspicious material.


2. The Contractor shall comply with all applicable Federal, Commonwealth, and Local laws including but not limited to the City of Philadelphia Asbestos Control Regulations, 29 CFR 1926.1101, 40 CFR 763 Subpart E, 29 CFR 1910.120, 29 CFR 1910.134 and 29 CFR 1910.1200, 29 CFR 1926.62, 29 CFR 1910.1025, 40 CFR 745, 40 CFR 262.11 and 25 Pa Code 261.

3. All asbestos abatements shall be conducted by licensed abatement Workers and Supervisors and air monitoring shall be conducted by third party licensed Building Inspector and/or Asbestos Project Inspector (depending on location as determined by System Safety) and the specification shall be written by a licensed Asbestos Project Designer.

4. All submittals including but not limited to notifications, work plans, and health and safety plans shall be submitted to SEPTA for review prior to the commencement of work. Within thirty [30] days of completion of work, waste disposal records documenting disposal at a SEPTA-approved facility shall also be submitted to SEPTA.

5. All newly installed materials shall be asbestos and lead free.

END OF SECTION


SECTION 01065

RAILROAD SAFETY REQUIREMENTS

PART 1 - GENERAL


A. This Specification covers the general requirements and safety regulations governing the Contractor’s activities when its Work impacts an active SEPTA Railroad.


A. Section 01041 – Project Coordination

B. Section 01060 – Regulatory Requirements and Safety

C. Section 01100 – Special Project Procedures

D. Section 01400 – Quality Requirements

E. Section 01500 – Construction Facilities and Temporary Controls


A. Refer to Section 01060, paragraph 1.04.

1.04 SAFETY REQUIREMENTS

A. General:

1. The information contained in this Section is intended to provide guidance and safety precautions to the Contractor when working on a live SEPTA rail line. The Contractor is advised that SEPTA will operate trains adjacent to the project site during the performance of Work under the Contract, except as otherwise specified. The Contractor shall comply with all parts of this Section and all parts of SEPTA’s Roadway Worker Protection manual (SRW).

B. Responsibility:

1. The Work covered by the Contract involves safety of persons and property on a live electrified rail line. Therefore, relevant skill and experience is required of the Contractor to do its Work safely. The Contractor shall be responsible for the safety of its construction operations. The Contractor shall be required to post adequate watchperson and/or protective devices to protect its work crews, equipment and the work site as directed by the Employee-in-Charge of railroad safety. Pertinent safety rules that shall be followed are listed in, but not limited to, Paragraphs F, G & H of this subsection. The Contractor shall exercise proper care at all times.

C. Operations:

1. When work is being performed under active train operations, the safety and continuity of operation of the trains by SEPTA shall be of the first importance. They shall, at all times, be protected and the Contractor shall arrange the work accordingly. Whenever the Work may affect the safety or movement of trains, the method of doing such Work, together with the proposed sequence of operations and time schedules for same, shall be submitted to the Project Manager for prior approval.


a) No work shall be started or prosecuted until such approval has been obtained. However, such approval of the Project Manager, or duly authorized representative shall not be considered as a release of Contractor from responsibility for any damage to SEPTA by the acts of the Contractor, its employees, and/or its subcontractor’s employees.

b) In the event of an unplanned discontinuation of train service due to the Contractor’s operations, the Contractor is not only liable for any injury or damage that might occur, but also for the full cost of any detour of train traffic, shuttle bus service and any associated costs.

D. SEPTA Personnel:

1. Employee-in-Charge: SEPTA will designate an employee to be responsible for providing a safe operation and On-Track protection. The Employee-in-Charge (EIC) may be a senior foreman, track supervisor, Flagperson and/or any other qualified individual. The Project Manager will coordinate the activities of the EIC with the Contractor’s Safety Officer and/or the Contractor’s designated On-Track Protection Assurance Representative.

a) The EIC will determine the method of providing protection to be used according to the SEPTA operating rules.

b) The EIC will conduct a job briefing as prescribed by the operating rules before any track is fouled. The job briefing is not complete until all Contractor’s employees acknowledge an understanding of the On-Track protection procedures being used.

c) The EIC will not release the working limits until all affected Contractor’s workers have been notified and are either clear or are protected by train approach warning.

2. Flag person: SEPTA Flag persons are responsible for the safety and Continuity of operations. The SEPTA Flag persons shall have authority to direct the stoppage of trains. Any sharing of protective duties between SEPTA and the Contractor within the Work site can be considered coincidental.

3. Electric Traction Protection Personnel: SEPTA’s electric traction Class A employees are responsible for the coordination and de-energization of catenary and power circuits. Wires and attachments of wires shall be treated as live (energized), unless noted by SEPTA that the wires have been de-energized and grounded. If the Contractor wishes to de-energize the system, the Contractor must request SEPTA Class A employee.

4. Pilots: If the Contractor wishes to occupy live or operating tracks with On-Track equipment, the Contractor shall request a SEPTA pilot who will obtain exclusive track occupancy on the live track.

5. Project Manager: The Project Manager, or a duly authorized representative, has complete authority in matters related to the safety of SEPTA’s Operations and Facilities. The Project Manager, or a duly authorized representative, is also responsible to support the Contractor’s planning and coordination of their safety effort related to SEPTA’s Operations and Facilities.

6. The Contractor is responsible for submitting an outage or fouling request in a timely fashion in order to avoid delays to the Work. SEPTA requires as a minimum


two (2) week notice to assign personnel once a fouling or outage request is approved.

E. Contractor’s Personnel:

1. Protection Assurance Representative: The Contractor’s Protection Assurance Representative (representative) may be the Superintendent, Safety Officer or responsible foreperson. The representative shall be present at all times when the Contractor’s employees are working within the SEPTA operating envelope. The representative must ensure that the requisite On-Track protection job briefings are held and all employees engaged in work requiring On-Track protection attend. In general the representative shall be responsible for day to day oversight of the Contractor’s gang watchperson and employees so that they are working safely according to all parts of this Section and to coordinate construction activities with the EIC.

2. Gang Watchperson: The role of the Contractor’s gang watchperson is solely for the purpose of safety for the Contractor’s employees when external influences, i.e., rail traffic or highway traffic, may expose the workers to a safety hazard. One or more gang watchperson shall be on site with each work crew at all times. If it becomes necessary for a watchperson to leave the site, work shall be suspended until he/she returns or is replaced by another qualified gang watchperson.

F. Right of Way Restrictions:

1. Fouling: An operating track is fouled for operating safety purposes when any SEPTA employee and/or object is closer than four (4) feet from the near rail of the track, and ten (10) feet for third party Contractors. Equipment shall be considered as fouling the tracks when working in such a position that any movement whether intentional or unintentional or failure of the equipment, with or without load, will foul the track. The Contractor is advised that the use of equipment which has the potential to foul live or operating tracks shall require the need of a flag person, or fence (approved by SEPTA) erected ten (10) feet from the closest rail. Any potential fouling work shall be restricted to weekday non-peak hours – and/or weekends.

2. The Contractor is hereby advised that certain types of equipment shall not be permitted to work under live wires. No extras shall be allowed because of equipment restrictions. Refer to Paragraph H.

3. The Contractor shall ensure that the Contractor’s equipment will not foul any track until proper protection has been afforded. While trains or cars are passing on an adjacent track, any work that has the potential to foul shall be stopped.

4. The Project Manager shall have the right to restrict the operations of fouling or On-Track equipment when, in the Project Manager’s opinion, the equipment is not in satisfactory condition to be safely operated or where operation will adversely affect the track structure. The Project Manager shall also have the right to prohibit the operation of any fouling or On-Track equipment by any Contractor-employed operator who is, in the Project Manager’s opinion, not qualified or able to operate said equipment in a safe manner.

5. When any excavation extends below the bottom of the crossties, or where the stability of the railroad embankment and/or structure may be affected by excavation, such excavation shall be adequately braced by the Contractor. Prior


to starting any such excavation, detailed drawings of the proposed bracing method shall be prepared and submitted to the Project Manager for his approval. When deemed appropriate by SEPTA’s Project Manager, the shop drawings shall be accompanied by structural calculations sealed by a Professional Engineer licensed in the Commonwealth of Pennsylvania.

G. General Safety Rules:

1. The following safety rules are considered especially applicable to all of the Contractor’s employees with regard to conduct while on SEPTA property. The Contractor’s foreperson or gang watchperson will be responsible to insure the safety of all the Contractor’s personnel. The Contractor shall furnish and equip its foreperson and/or gang watchperson with the equipment as specified in the SRW to warn the Contractor’s personnel of the approach of trains.

a) All Contractor Employees prior to working in any capacity that has the potential to foul, and/or working within ten (10) feet of railroad tracks shall attend a SEPTA safety seminar on safety rules and operating procedures (SRW Course). The Contractor’s employees must demonstrate an understanding of and proficiency in the SRW manual. Contractor’s employees who are added during the course of the project shall also be required to attend this seminar and demonstrate an understanding of and proficiency in the SRW manual before being able to work. The attendance certification (current date) from this seminar shall be logged into the SEPTA Database. Re-certification is required on an annual basis.

b) Contractor-employed supervisors, foreperson, and gang watchpersons shall be responsible for the safety, safety instructions and safe performance of all employees under their immediate supervision. They must see that all employees working under their supervision receive warnings of approaching trains and other equipment in time to reach a safe place as per the SRW. Inexperienced employees must be instructed by immediate supervisors of the safe methods of performing their duties.

c) All Contractor employees working on or near an active track must attend an On-Track protection job briefing. This briefing shall be held, prior to performing any work that has the potential to foul track, or at a minimum, would require the individual to be within 10 feet of any active track or any time job conditions change such that On-Track protection procedures differ from those covered in the initial job briefing. An active track is any track that has the potential for train or On-Track equipment operations.

1) The EIC will conduct the job briefing to explain the On-Track safety procedures being utilized.

2) The Contractor’s Protection Assurance Representative responsible for the overall supervision of Contractor employees shall ensure that the requisite job briefings are held, that all employees attend, and sign the job briefing form. At a minimum, the job briefings must cover the following information, if applicable:

The identification of the EIC.

A review of operational and safety conditions.


The means by which On-Track safety is to be provided.

The positioning of any individuals responsible for providing warning to roadway workers.

The type of signals that will be used to convey the warning of an approaching train.

The location where roadway workers will be required to go to clear for trains.

The identification of the SEPTA employee responsible for communicating with trains.

The type of signals that will be used to signal it is safe to resume work.

3) SEPTA will maintain a written record of all individuals who attend the job briefing.

d) No Contractor shall perform any work that has the potential to foul an active track, or at a minimum, would come within 10 feet of an active track, without the approval and/or presence of a qualified and authorized SEPTA representative.

e) The Contractor shall require employees to carry hand held lights when working from dusk to dawn, in tunnels or when visibility is restricted.

f) The Contractor’s employees shall consider all tracks as operating tracks and be on the alert for trains operating in either direction at all times, and walk facing the direction from which trains in regular operations will approach. In the event that track area visibility remains poor after institution of remedial measures (as described in 5 above), work in the track area may be restricted.

g) The Contractor’s employees shall STOP before crossing any tracks and look for trains approaching in either direction. The Contractor shall instruct employees not to cross tracks unless there is time to walk slowly, not to take chances, and not to step on the head of the rail.

h) The Contractor’s employees shall ensure that clothing cannot catch onto any part of a moving car.

i) The Contractor’s employees shall not step on track behind stopped rail cars, particularly those arriving at stations, due to the possibility of rail cars being moved in reverse directions.

j) The Contractor’s employees shall not attempt to carry heavy materials across tracks without permission of proper authorities.

k) The Contractor’s employees shall keep hands and feet clear of power switches, switches, switch equipment and frogs.

H. Catenary & Overhead Electrical Lines:

1. When handling work near overhead wires, the Contractor’s employees shall observe the following:


a) All overhead wires, including catenary, transmission, and signal lines in electrified zones, shall be considered energized at all times.

b) Insulating covering of wire shall not be depended upon for protection against shock.

c) No employee of the Contractor shall do any work near electrical wires or apparatus where it is possible for any part of the employee’s body or tools and material with which the employee is working to come within ten (10) feet of such wires, unless a SEPTA Overhead Maintenance employee is assigned to observe the safety of the operation. Use of metal ladders is forbidden.

d) When equipment is used in electrified territory or in the vicinity of Verizon Telephone, PECO, as well as SEPTA overhead wires, the Contractor must exercise special care to safeguard all persons in the area. Special attention must be given in the vicinity of overhead bridges and other structures where the wires may be depressed. If, in the opinion of the Project Manager, the required clearances cannot be maintained or any hazards are involved, a SEPTA Overhead Maintenance employee (Class A Employee) must be requested. All required protection personnel shall be SEPTA employees.

2. If a safety situation arises requiring an immediate power shutdown, notify the SEPTA Railroad Operation (RROC) - Superintendent at 215-580-8668, and the SEPTA Project Manager.

3. In a case of electrical contact, personal judgement and initiative has to be used, bearing in mind that the rescuer’s safety should not be imperiled. Contact with a live overhead wire may prove fatal in a matter of seconds. The most important thing is to stop the flow of electricity through the victim’s body and then apply mouth-to-mouth resuscitation (or CPR when necessary and if qualified to do so) until he or she recovers consciousness or trained help arrives. Once a victim is freed from the overhead wire, do not move him or her unless they can do so under their own power. Except for qualified rescuers, moving an injured person may result in further injury.

1.05 COMPLIANCE WITH ROADWAY WORKER PROTECTION MANUAL (SRW)

A. In addition to the above, the Contractor must follow all requirements of the Roadway Worker Protection Manual (SRW). If there is doubt as to the meaning of any procedures specified, the EIC shall be consulted prior to the commencement of work, which requires fouling of any track.

END OF SECTION


SECTION 01100

SPECIAL PROJECT PROCEDURES

PART 1 - GENERAL


A. This specification outlines the procedural requirements so the Contractor may plan, and be granted concurrence, for service disruptions specified under this Contract.

B. Work crews and equipment which SEPTA will make available to a Contractor.



B. Section 01060 – Regulatory Requirements and Safety

1.03 SUBMITTALS

A. Requests for service disruptions and Site Specific Work Plans (SSWP) shall be submitted to the Project Manager by the Contractor for concurrence twenty-eight (28) calendar days prior to the need for the service disruption. The PM will respond within seven (7) calendar days of receipt of the submittal.

B. Once reviewed by SEPTA, any changes to the SSWP will be subject to a subsequent review by SEPTA. These submittals must be annotated and re-issued weekly to reflect changes in the scope or schedule created during the twenty-eight (28) day period between the original issue and the date of operation. Not later than twenty-eight (28) days before a planned service disruption, a new revision of the submittal incorporating all changes and reflecting the final work plan must be submitted to the PM.

C. Should the Contractor desire to cancel an approved service disruption, the written cancellation request shall be received by the PM a minimum of seven (7) calendar days prior to the service disruption date, so that affected SEPTA operations can be rescheduled. Late cancellation requests shall result in the outage costs being assessed against the Contractor.

1.04 REQUEST FOR POWER OUTAGES (OUTAGES AND SHUTDOWNS)

A. In addition to the requirements for a Site Specific Work Plan as described in these specifications, all construction operations that interfere with the normal operations or that require track and power outages shall be described using a time-scaled logic network. This network is to fully detail the extent of work proposed and the Contractor’s plan and means for its accomplishment. Specific separate operations and planned service disruptions should be highlighted in these submittals:

1. The Site Specific Work Plan (SSWP) shall provide a description of work, time scaled hourly logic network, breakdown of labor force, and the type of equipment that will be utilized. The SSWP shall include Contractor’s watchperson (if required), required SEPTA flagging and assistance, construction methods, arrangements for emergency clearing and restoration of service, and sketches for defining the configuration of rail service and other operational elements at the end of the Contractor’s outage.


2. All work by SEPTA Force Account Track, Power, Signals, etc. or other contracts that are defined in Section 01010 and subsequent reviews that has the potential of delaying either the work by this Contractor, or the restoration of service, must be identified clearly in terms of scope and schedule for coordination with others.

3. The proposed work at Wayne Junction may require track and will require power outages consisting of cutovers for circuit breakers, feeder connections, disconnect switches, insulators and conductors/taps.

4. All track and power outages as requested by the Contractor are restricted to the window between 1:30 a.m. and 4:30 a.m. (this window includes the necessary switching and grounding required by SEPTA forces).

5. Additional outages may be requested by the Contractor. These times do not include a time for the necessary switching and grounding required by SEPTA forces.

6. The Contractor shall minimize the amount of work that affects or requires overhead catenary outages or track access.

B. Request for power outages or shutdowns must be submitted four (4) weeks in advance for SEPTA’s review and approval. SEPTA will not grant outages or shutdowns until the Contractor’s SSWP has been reviewed by the Engineer and approved by SEPTA in writing.

C. The Contractor shall not perform any of the work requiring outages or shutdowns until written approval has been received from SEPTA.

1.05 REQUEST FOR SEPTA SUPPORT

A. Power: The Contractor shall communicate with the Project Manager, in a manner acceptable to SEPTA, regarding the de-energizing and re-energizing of the feeder circuits and busses. Reference SEPTA Operational Constraints, provided in Section 01010, Summary of Work (Paragraph 1.07).

1.06 DAMAGES FOR FAILURE TO RETURN TO SERVICE

A. All costs, such as protection or operating costs, if a Contractor fails to properly utilize a track outage or service diversion at no fault to SEPTA and additional outage hours are required to return the track(s), facility and/or services within an allotted time, shall be assessed against the Contractor.

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION

NOT USED

END OF SECTION


SECTION 01200

PROJECT PROGRESS MEETINGS

PART 1 - GENERAL


A. To enable the orderly review of the progress of the Work, and to provide for systematic discussion of problems, the SEPTA Project Manager, or a designee, will conduct project meetings throughout the construction period.

B. The progress meetings are in addition to the coordination, pre-construction and scheduling meetings noted elsewhere in the Contract Documents.

1.02 RELATED WORK:

A. Agreement and Division 1.

B. The Contractor’s relations with its subcontractors, and discussions relative thereto, are the Contractor’s responsibility and are not to be agenda items in the project progress meetings.

C. The discussions and minutes of meeting shall exclude any claims-related issues not directly impacting the progress of the Work, and other items for which SEPTA has provided clarifications/directives/change order(s), or otherwise closed, but remain disputed by the Contractor.

1.03 SUBMITTALS

A. Agenda items:

1. To the maximum extent practicable, the Contractor shall advise the Project Manager at least forty-eight (48) hours in advance of project meetings regarding items to be discussed during the meeting.

2. Technical questions or issues requiring a response from the designer of record must be submitted in writing at least three (3) business days before the meeting.

B. Minutes:

1. The Project Manager will compile minutes of each project meeting, and will furnish one copy to the Contractor(s).

2. The Contractor may copy and distribute other copies as required.

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION

3.01 MEETING SCHEDULE

A. Project meetings will be held every two weeks.

B. The Project Manager will coordinate with the Contractor(s) to establish a mutually acceptable meeting schedule.


3.02 MEETING LOCATION

A. The Project Manager will determine meeting location. To the maximum extent practicable, meetings will be held at the job site.

3.03 PROJECT MEETINGS

A. Attendance:

1. Contractor’s Superintendent shall attend and participate in each project meeting and shall represent the Contractor consistent with Contract and commit the Contractor to solutions agreed upon during the project meetings.

2. Subcontractors, and others may be invited to attend those project meetings in which their aspect of the Work is involved.

3. If notified of the need five (5) days in advance, the SEPTA PM will request the attendance of the appropriate members of the design team to participate in technical discussions.

B. Minimum agenda for each meeting:

1. Review and revise the minutes of previous meetings.

2. Safety including the presence of hazardous materials and other environmental issues.

3. Quality Control Issues including outstanding non-conformance reports/issues.

4. Review progress of the Work since last meeting, including status of submittals for approval.

5. Status of coordination and installation meetings with other prime and sub-contractors engaged in the Work of the project.

6. Identify problems which impede planned progress.

7. Develop corrective measures and procedures to regain planned schedule, if applicable.

8. The status of Requests for Information (RFI) and all Potential Change Orders (PCO) shall be discussed and updated. The Contractor’s PCO listing shall conform to SEPTA’s listing.

9. Contractor shall provide and discuss “30 day look ahead” activity schedule if the work is not progressing per the early start/finish activity dates as noted in the latest update of the approved schedule.

10. Discuss and review As-Built Drawings/Specification Status.

11. Complete other current business.

C. Revisions to minutes:

1. Unless published minutes are challenged in writing, within five (5) working days of the distribution date they will be accepted as properly stating the activities and decisions made at the meeting.

2. Any individual challenging published minutes shall provide proper supporting documentation acceptable to the Project Manager to verify that the challenged item was truly discussed during the subject meeting.


3. Challenges to minutes shall be settled as priority portion of “old business” at the next regularly scheduled meeting. SEPTA’s Project Manager’s decision concerning challenged item(s) shall be binding on the Contractor.

END OF SECTION




SECTION 01300

SUBMITTALS

PART 1 - GENERAL


A. This section covers all submittals, including design drawings, specifications, shop drawing submittals, samples, manufacturer’s cut sheets and “or equal” submittals. It complements the requirements of Paragraph VIII.N of the Agreement.

B. Some products and procedures only require a submittal for information, and may not require a response from SEPTA.

1. Products which match exactly something specified by manufacturer’s name and catalog model number.

2. Other items at the SEPTA Project Manager’s discretion including but not limited to any of the following:

a) Products list

b) Test Section

c) Manufacturer’s installation instructions

d) Manufacturers’ certificates

e) Shop Drawing

f) Manufacturer’s Samples

g) Certifications

h) Testing

i) Warranties

j) Equipment

C. SEPTA reserves the right to not formally respond to any submittal which is not required.

D. The Contractor may require subcontractors to provide drawings, installation diagrams, and similar information to help coordinate the Work, but such data shall not be reviewed by SEPTA unless it is required by other pertinent sections of the Specifications.

E. The Contractor is required to submit all information in an electronic format as approved by the SEPTA PM.

F. In addition to any other documentation responsibility, the Contractor shall provide copies of all approved and/or incorporated submittals in an electronic format as defined by the SEPTA PM to fulfill Contract close-out requirements.

1.02 RELATED WORK:





D. Section 01400 – Quality Requirements

E. Section 01410 – Testing and Inspection Services

F. Section 01700 – Contract Closeout

G. Section 16262B – SFC Document Submittal Schedule

1.03 SUBMITTAL PREPARATION

A. The Contractor, within two (2) weeks of the receipt of the Designer of Record’s computerized listing of Contractor(s) submittals, shall review, revise and/or amend, if applicable, and resubmit the revised listing of submittals.

B. The Contractor will assess material availability and all long lead items shall be identified.

C. After checking and verifying all field measurements and, after complying with the applicable procedures of the Contract, the Contractor shall submit shop drawings, catalog cuts, samples and substitution(s) for review and action.

D. The Contractor shall be responsible for coordination between the Contractor/Fabricator/Detailer and SEPTA for each complex submittal requiring detailed coordination, including all structural items. This coordination may be executed in a meeting called at the request of the Contractor, or SEPTA. The purpose of the meeting(s) shall be to establish guidelines for details and information necessary to prepare the shop drawings.

E. All submittals will be sent directly to the SEPTA PM, unless the PM specifically directs the Contractor to do otherwise.

1.04 SUBMITTAL REVIEW

A. The results of review of submittals will be designated as follows:

1. NO EXCEPTIONS TAKEN

2. PROCEED AS NOTED

3. PROCEED AS NOTED; REVISE AND RESUBMIT

4. DO NOT PROCEED; REVISE AND RESUBMIT

5. REJECTED

6. NOT APPLICABLE

B. Submittals not in compliance with the Contract will be returned to the Contractor for revision. Any losses of time and additional costs associated with resubmittal(s) are the Contractor’s responsibility.

C. An Excel spreadsheet log of submittals shall be developed and maintained throughout the entire project, showing Contractor transmittal number, submittal numbering and title, revision history, dates of transmission and response, and ultimate submittal disposition.

D. Each submission and re-submission shall give specific written notice on the transmittal of each variation that the shop drawings or samples may have from the requirements of the Contract Documents and, in addition, shall cause a specific notation to be made on each shop drawing submitted for review and approval of each such variation.

E. Each resubmission(s) shall clearly identify and make specific notation(s) on each shop drawing concerning the:


1. Changes that are made as a result of comments on the previous submittal(s).

2. Changes that are not made, but commented on the previous submittal(s). The Contractor shall provide detailed explanations and justifications as to why the comments are not addressed.

3. Changes that are solely made by the Contractor, but were not commented on the previous submittal(s). The Contractor shall provide a detailed explanation and justification for such changes.

F. Submittals that are “Proceed as Noted” are for the purpose of expediting procurement/fabrication/Installation of the intended work. If re-submittal is required, the Contractor shall incorporate all corrections and resubmit original drawings and required copies of drawings to SEPTA, within 30 days. If re-submittal is not required, then it is understood that the Contractor will proceed in accordance with the comments.

G. For “Proceed as Noted; Revise & Resubmit” items, payment for completed work that is related to these items will not be made until the corrected and final resubmittal is accepted in writing by SEPTA.


A. SEPTA reserves the right to require mock ups of any material and/or assembly, at any time during the construction process. Once approved, the mock-up will set a minimum standard of performance and/or appearance for the work. Mock-ups will be provided at no cost to SEPTA. The approved mock-up may, at the discretion of the SEPTA Project Manager become part of the work.

B. Electronic Submittals:

1. SEPTA uses software to track submittals. The Contractor’s forms, e.g. transmittal etc., will be submitted in a form compatible with this software.

2. For its records, SEPTA requires that all approved submittals be converted to electronic format (at no additional cost to SEPTA) for SEPTA’s document retention purposes.

C. Coordination of Submittals:

1. Prior to making each submittal, the Contractor shall carefully review and coordinate all aspects of each item being submitted. Shop drawings of systems containing closely related items and components must be submitted, as a single submission showing the interrelationship of the components required for that system.

2. The Contractor shall verify prior to submission that each shop drawing is well prepared and that the submittal conforms in all respects with the specified requirements. The drawings shall provide complete information regarding proper fabrication and installation.

3. The Contractor shall sign each submittal or shop drawing original and copies and affix a stamp with specific written indication that the Contractor has reviewed the submittal and is satisfied that it conforms to the requirements of the Contract Documents. For submittals which are substitutions, see 1.06 below.

4. Shop drawings shall be tailored to the specific project need including coordination of various trades and should include material descriptions, quantities, dimensions, design criteria and similar data to enable review information as required. The shop


drawings must show clear and complete information for the fabrication and installation of materials.

5. Where feasible, orient the plan(s) on the shop drawing(s) in the same manner as the plans on the Contract Drawings.

6. Shop drawings with reproduction(s) of the Contract Drawings will not be accepted.

7. Structural fabrication and erection drawings shall be prepared, checked, signed and sealed, by a Professional Engineer licensed in the Commonwealth of Pennsylvania with proven qualifications and similar experience.

8. Unless the Contract Documents indicate specific steel connections, the Contractor shall design steel connections, stamped and sealed by an engineer licensed in the State of Pennsylvania, and provide sufficient details for the SEPTA’s review and approval.

D. Responsibility: The Contractor is solely responsible and accountable for:

1. Means, methods, techniques, sequences and procedures of construction including fabrication, assembly, installation/erection, safety precautions and programs incidental to any submittal.

2. Accuracy of all submittals and shop drawings and final installation.

3. Arranging submittals and shop drawing standards review meetings with SEPTA.

4. Converting all approved submittals to an agreed on electronic format (PDF unless otherwise noted) and providing these files to SEPTA at no cost to SEPTA.

1.06 SUBSTITUTIONS

A. “Or Equals” Substitutions:

1. Restricted Items (sole sourced items) - Where the Contract Documents specifically require the use of certain equipment and/or materials they will indicate that substitutions will not be allowed.

2. Equals Considered – Unless otherwise noted, whenever a material or article required is specified or shown on the plans by using the name of the proprietary product or of a particular manufacturer or vendor, any material or article with matching characteristics, will be considered equal and satisfactory provided the material or article has equal properties and function in the opinion of SEPTA’s Project Manager. It shall not be purchased or installed without SEPTA’s Project Manager’s written approval.

3. The Contractor shall document each request with complete data substantiating compliance of the proposed Substitution with the Contract Documents. “Or Equal” requests will be considered only when substantiated by the Contractor’s submittal of data documenting the “or equal” nature of material or article within thirty-five (35) calendar days after the date of receipt of Notice to Proceed. A request constitutes a representation that the Contractor:

a) Has investigated the proposed product and determined that it meets or exceeds the quality level of the specified product.

b) Shall provide the same warranty for the substitution as for the specified product.


c) Shall coordinate installation and make changes to other work, which may be required for the Work to be complete with no additional cost to SEPTA.

d) Shall waive claims for additional costs or time extension, which may subsequently become apparent.

e) Shall reimburse SEPTA (if applicable) for review or redesign services associated with review and approval by SEPTA, if the substitution is rejected as not being equivalent.

B. Other Substitutions:

1. For any reason, including a lack of availability of the original material, the Contractor may ask permission to substitute a material or assembly which is not fully equal to the one specified. This will be processed as a change order (a no cost change order only if there is no cost difference compared to the original specified material). All substitutions will be evaluated following Value Engineering principles. The results of SEPTA’s evaluation will be final, and SEPTA is has the right to make a final determination over which items are judged to be acceptable.

2. The Contractor shall document each request with complete data substantiating compliance of proposed Substitution with Contract Documents. A request constitutes a representation that the Contractor:

a) Has investigated the proposed product and determined that it meets or exceeds the quality level of the specified product.

b) Shall provide the same warranty for the substitution as for the specified product.

c) Shall coordinate installation and make changes to other Work, which may be required for the Work to be complete with no additional cost to SEPTA.

d) Shall waive claims for additional costs or time extension, which may subsequently become apparent.

3. The Contractor shall provide substitutions in a timely manner and in accordance with the construction contract, so as to not have a negative impact on the construction schedule.

PART 2 - PRODUCTS

2.01 SHOP (FABRICATION/INSTALLATION) DRAWINGS

A. Shop drawings shall be based on field dimensions and other information gathered by the Contractor and his agents. When SEPTA or the designer of record takes no exceptions to the drawings or directs the Contractor to proceed as noted, it is only claiming that there are no apparent deviations from the design intent of the Contract Documents.

B. Final fit and placement may be affected by fabrication and field installation tolerances as well as other factors beyond the knowledge of SEPTA and the designer of record. Installation and final fit remains the sole responsibility of the Contractor. Language placing this responsibility on SEPTA or the designer of record is strictly prohibited.

C. Scale and measurements: Shop drawings shall be made accurately to a scale sufficiently large to show all pertinent aspects of the item and its method of connection to the Work.


SEPTA reserves the right to demand additional detail and information to facilitate the submittal process.

D. Required Copies:

1. Shop drawings shall be submitted in the form of one (1) reproducible copy and five (5) prints of each shop drawing for review, in a media acceptable to SEPTA. After review, the reproducible copy will be returned to the Contractor.

2. When shop drawings are returned for correction, they shall be corrected and resubmitted for approval as described above, and such procedure will not be considered as grounds for delay in completing work.

3. When shop drawings are approved, three (3) additional prints of the approved shop drawings shall be immediately sent to SEPTA.

E. Review comments will be shown on one set which will be returned to the Contractor. The Contractor may make and distribute such copies as are required for its purposes.

F. Failure of the Contractor to supply the required number of approved shop drawings for field use can constitute reason to reject work or material at the job site.

G. Before the final payment is made, the Contractor shall deliver to SEPTA for SEPTA’s permanent file, two complete bound sets of the final approved shop drawings applicable to the Contract.

H. Contractor shall standardize size of shop drawings as far as practicable for all submissions.

I. Submittals not meeting the requirements of Part 3.01 of this section shall be summarily rejected.

J. Submittals which are marked “approved as noted” shall be resubmitted for final approval after compliance with the comments relating to the qualified part of the approval.

K. Submittals involving design and calculations by the Contractor or supplier should be signed and sealed by a registered professional engineer, if appropriate.

2.02 MANUFACTURER’S LITERATURE (INCLUDING CATALOG CUTS) / PRODUCT DATA

A. The term “product data” includes manufacturer’s specifications, catalog cuts, performance and test data, applicable standards such as AASHTO, ANSI, ASTM, IEEE, AREMA and other industry standards of compliance, assembly and erection diagrams, parts lists, and where applicable, Certificates of Compliance, verifying compliance with the specified and referenced standards as specified herein and in Section 01400.

B. Product data submittals shall indicate all modifications made to the manufacturer’s standard product, including deletions of descriptive information not applicable to the Contract. The product data shall include dimensions, clearances, performance characteristics, capacities, and any other information or diagrams, as applicable. All product data submittals shall include the following:

1. Contract title and number

2. Applicable Contract Drawing numbers

3. Applicable Specification Section numbers

4. Applicable standards, such as ASTM or Federal Specification number, AREA, AASHTO and pertinent railroad authority specifications or standards


5. Identification of deviations from the Contract Drawings and Specifications

6. Contractor’s stamp, initialed or signed, certifying:

a) Dimensional compatibility of the product with the space in which it is intended to be used.

b) Review of submittals for compliance with Contract requirements.

c) Compatibility of the Work shown thereon with that of affected trades.

C. Certificates of Compliance shall be submitted for those products for which no samples and test results are specified. A copy of the certificate shall also accompany the product for which the certificate is prepared. The certificates shall:

1. State that the product complies with the respective Specification and Contract Drawing requirements;

2. Be accompanied by a certified copy of test results pertaining to the product;

3. Show the submittal date, Subcontractor’s name and address, Contract Title and Number, product represented and its location in the Contract, producer’s name, product trade name and catalogue number, place of product origin, test date, testing organization’s name and address, quantity of the product to be furnished, and related Contract Drawing and Specification Section numbers; and

4. Be signed by an officer or another authorized representative of the producer.

D. Procedures for submittal and approval of product data shall follow the procedures for shop drawings as specified in Article 3.01, of this Section.

E. Product submitted for approval shall be highlighted from product data sheet.

F. The Contractor shall submit the original printed literature and product data sheets available from the manufacturer(s) and as many copies as are required. SEPTA will keep the original copy of all items submitted.

G. Where contents of submitted literature from manufacturers includes data not pertinent to the submittal, the Contractor shall clearly show on all copies which portions of the contents are being submitted for review.

H. The Contractor shall submit the number of copies which are required to be returned, plus five (5) copies for SEPTA’s use and distribution.

2.03 SAMPLES

A. The Contractor shall provide sample(s) identical to the precise article proposed to be provided. Identify as described under "Identification of submittals" below.

B. Number of samples required:

1. Unless otherwise specified, the Contractor shall submit two samples, one of which will be retained by SEPTA.

2. By prearrangement in specific cases, a single sample may be submitted for review and, when approved, be installed in the Work at a location agreed upon by SEPTA.


2.04 COLORS AND PATTERNS

A. Unless waived in the specific section of the Contract Documents, whenever a choice of color or pattern is available in the specified products, the Contractor shall submit accurate color and pattern charts for selection.

B. SEPTA reserves the right to require samples and/or a mockup of any material, to determine actual appearance.

C. Unless waived elsewhere, two copies of each sign face in accurately color matched proofs of all permanent signage, at a scale specified by the SEPTA PM, will be submitted.

PART 3 - EXECUTION

3.01 IDENTIFICATION OF SUBMITTALS

A. The Contractor shall assign a date and unique number to each submittal and an indication that the Contractor has reviewed the submittal for conformance to the Contract Documents. This information shall appear on each submittal original and copy.

1. Each submittal subject to approval must receive a separate number not shared by any other component, information or process. Only one approval/rejection will be given per submittal number.

2. Each submittal number must include the specification section that the submittal most applies to, followed by a hyphen and a sequential number (the first submittal for Section 05500 would be 05500-1, and so on).

3. When a resubmittal is made for any reason, the Contractor shall transmit under a new letter of transmittal with a new submittal number in the form of the original number plus the letters a, b, c and so on for each subsequent resubmittal (05500-1a, using the above example) and a new date for that resubmittal.

B. The Contractor shall maintain an accurate submittal log for the duration of the Work, showing current status of all submittals at all times. The Contractor shall make the submittal log available for review by SEPTA upon request.

3.02 GROUPING OF SUBMITTALS

A. Unless otherwise specified, the Contractor shall make submittals in groups (with separate numbers) containing all associated items to assure that information is available for checking of each item when it is received.

B. Each grouping shall be accompanied by a dated transmittal letter which lists each transmittal by number and the number of copies submitted.

C. Partial, confusing and poorly prepared submittals will be rejected as not complying with the requirements of the Contract. The Contractor will be liable for delays so occasioned.

D. Milestone submittals at the 30%, 60%, 90% and 100% level shall be provided in their entirety in a complete submission of design deliverables. Submittals will not be accepted if specific project deliverables are at an advanced level of design (i.e. 90%) when other submittals are still at a previous level of approval (i.e. 60%). All milestone submittals shall be submitted at one time, in their entirety.


3.03 TIMING OF SUBMITTALS

A. The Contractor shall make submittals consistent with early start dates shown on the approved baseline schedule, but sufficiently in advance of early scheduled dates for installation to provide the necessary time required for reviews, for securing necessary approvals, for possible revisions and resubmittals, and for placing orders and securing delivery.

B. In scheduling, the Contractor shall allow twenty-one (21) calendar days for review and processing by SEPTA following its receipt of the submittal. This review time will be increased for the submittal(s) that are so extensive that twenty-one (21) days of turn around period is unreasonable as determined by SEPTA. This determination shall be binding on the Contractor.

C. Continued submission of material and repetitious submittals which clearly fail to meet the requirements of the Contract Documents which may cause delays in the completion of the Contract and any such delays be the sole responsibility of the Contractor.

3.04 SEPTA’S REVIEW

A. Review and Processing shall not relieve the Contractor from responsibility for errors, which may exist in the submitted data.

B. SEPTA does not confirm dimensions or make any representation that parts will fit together properly if fabricated in the sizes shown on the shop drawings. SEPTA requires that the Contractor take all necessary site measurements and that the shop drawings represent an accurate documentation of these dimensions.

C. The Contractor assumes responsibility to exercise control over all construction tolerances and ensure that these tolerances do not result in construction which violates regulations, codes or clearances.

D. Revisions:

1. The Contractor shall make required revisions as noted on initial the submittal.

2. If the Contractor considers any required revision to be a change, it shall so notify SEPTA as provided for in the Agreement. Such notification shall be made no later than 10 calendar days from the date of return of such submittals by SEPTA to the Contractor.

3.05 SHOP DRAWING AND SUBMITTAL CONFLICTS WITH THE CONTRACT DOCUMENTS

A. Unless the Contractor submits data as a substitution as specified in section 1.06 above, submitted information which departs from the Contract Documents will be understood to be Contractor/subcontractor errors and have no effect on the Contract, even if not identified by SEPTA during the review process.

3.06 FINAL ELECTRONIC SUBMISSION

A. As part of the Contractor’s Closeout Documentation requirements, the Contractor shall submit to the SEPTA PM all approved submittals and other documentation in an electronic format (PDF files unless otherwise approved by the SEPTA PM).

END OF SECTION




SECTION 01305

REQUEST(S) FOR INFORMATION

PART 1 - GENERAL


A. This section stipulates procedural requirements for processing of Contractor Request(s) for Information (RFI) and complements the requirements of the Contract Agreement, Paragraphs V.B and VIII.B.

B. An RFI is a written communication originated by a construction Contractor to request clarification of the intent of the Contract Documents. It results in an exchange of information only. If the Contractor believes the response triggers a change in the project scope he must submit a change order request. No response to an RFI may be interpreted as a change order request, or approval.

1.02 RELATED WORK

A. Agreement




E. Section 01300 – Submittals


G. Section 01410 – Testing and Inspection Services

H. Section 01700 – Contract Closeout

I. Section 01720 – Project As-Built Documents

J. Attachment – Request for Information Form

1.03 SUBMITTALS

A. The Contractor shall comply with the provisions of Section 01300.

B. The Contractor shall submit RFIs using the attached RFI form and shall provide specific reference to the section of the Contract Documents to which the RFI refers. RFIs that are incomplete, unsigned or otherwise not submitted in compliance with the Contract, will be returned to the Contractor.

C. Any losses of time and/or additional costs associated with frivolous RFI submittals are the responsibility of the Contractor.


A. All RFIs will be signed by the Contractor’s representative and submitted to SEPTA in “hard” copy.

B. The primary purpose of an RFI is to clarify the Contract Documents.


1. The Contractor has the responsibility to be familiar with the Contract Documents. RFIs that request clarification of items that in the judgment of the PM, are clearly evident in the Contract documents, shall be rejected by SEPTA.

2. The Contractor shall not use RFIs for the following:

a) To facilitate construction coordination between contractors and subcontractors/vendors.

b) To initiate substitutions in material, methods and or systems.

c) To transfer their responsibility for reviewing Contract Documents to SEPTA and/or the Architect/Engineer.

3. RFIs, which fail to reference the specific Contract Documents in question, will be rejected. If the Contractor uses an RFI for the purposes described above in 1.04 B2, it will also be rejected. In these cases, the Contractor will be directed to meet the requirements specified in Section 01300 by the PM.

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION

3.01 IDENTIFICATION OF REQUEST(S) FOR INFORMATION

A. The Contractor shall consecutively number all RFIs. Because this project has separate contracts, each Contractor shall include a prefix (G, E, M etc.) in their numbering sequence to designate the submittal as originating from the “General”, “Electrical” or “Mechanical” Contractor. RFIs shall be submitted using the attached form. When an RFI must be resubmitted for any reason, it shall be sent using a new RFI number with reference provided to the previous RFI.

3.02 TIMING OF REQUEST(S) FOR INFORMATION

A. The Contractor shall submit RFIs sufficiently in advance of early construction schedule “Start” dates for fabrication and/or installation activities in order to provide the necessary time required for reviews, possible revisions and subsequent resubmittals.

B. For scheduling purposes, the Contractor shall allow seven (7) days for review and response by the Architect/Engineer and/or SEPTA following their receipt of the RFI. This review time will be increased for RFIs that are sufficiently extensive or complex that the above turnaround period is unreasonable as determined by the Architect/Engineer and SEPTA. This determination shall be binding on the Contractor.

C. The Contractor shall be solely responsible for delays in the completion of the Contract that result from the submission of RFIs which clearly fail to meet the requirements of this Section.

3.03 SEPTA’S REVIEW

A. All RFIs will be submitted to the SEPTA PM. The designer of record is responsible for reviewing Contractors’ RFIs to provide clarifications and/or interpretations as they relate to design documents. The SEPTA PM is responsible to provide clarifications and/or interpretations to RFIs that are related to the Agreement or SEPTA operational issues and service. An answer to a RFI shall never be considered as an approval for extra work and/or


a change in scope or any other directive which results in a change to the Construction Contract cost. All such changes must follow the change order process.

B. If the Contractor considers any clarifications to an RFI to be a change; it shall so notify SEPTA in the manner provided for in the Agreement. Such notification shall be made no later than fourteen (14) calendar days from the date of the return of such clarifications by the designer of record or SEPTA to the Contractor.

END OF SECTION


REQUEST FOR INFORMATION (RFI) PROJECT:

1. RFI Number

Responsible Contractor

Date

Description: Requested By (Signature): Due Date

2. A/E Response, or SEPTA Comments(if applicable):

A/E (Signature):

Date

Contract Document Impact Yes No Revisions Attached Yes No

3. Transmitted to Contractor

4. PCO Yes No Impact

PCO Number:

CD&C PM (Signature): Date


Filling out the RFI Form 01: This section is to be completed by the Contractor. The SEPTA Project Manager (PM) shall provide

RFI Forms to the Contractor(s) at the Pre-construction Meeting.

02: This section is to be completed by the A/E. All technical inquiries are to be responded to by the

A/E. The section must be signed and dated within the contractual time frame. The SEPTA PM may use this space to add comments or directly respond to non-technical queries, involving contractual matters or SEPTA Operational issues.

03: This section is to be completed by SEPTA project staff to return the RFI to Contractor. The

distribution must include the Project File. 04: This section is to be completed by SEPTA project staff. The RFI response will be reviewed for its

potential to result in a Change Order. This box should be appropriately completed as a result of this review.




SECTION 01400

QUALITY REQUIREMENTS

PART 1 - GENERAL

1.01 SUMMARY

A. The Contractor shall establish and maintain a project specific Quality Assurance/Quality Control (QA/QC) system documented by a program manual and supporting plans and/or procedures. These documents will address the methods to be used to control the quality related aspects of all materials, components and assemblies to be furnished and installed under the Contract Documents.

B. Each Prime Contractor shall have the primary responsibility for the quality of all its work and shall ensure that the pertinent requirements for the achievement of quality are included and implemented in all relevant sub-contracts.

C. The QA/QC program shall include a description of the organization the Contractor will establish and shall identify the responsibilities and accountabilities of all personnel performing quality-affecting activities.

D. The QA/QC program and/or procedures shall include those checklists and test & inspection forms the Contractor will use to properly document the activities performed to achieve the quality of the Work. Each Prime Contractor will be responsible for completing the checklists and activities called for in SEPTA’s Construction Inspection/Monitoring Program as part of their Quality Control program.

E. Each Prime Contractor will cooperate fully with SEPTA’s QA/QC efforts including, but not limited to, providing requested information in a timely fashion when SEPTA executes quality audits of the project. All information generated during the project, of a non-confidential nature, including but not limited to the internal QA/QC audits executed by the Contractor must be made available to SEPTA in a timely manner.

1.02 DEFINITIONS

A. The Following definitions pertain to requirements of this section:

1. Quality Assurance (QA): QA is a program of planned and systematic actions that provide adequate confidence that all activities affecting quality have been accomplished in accordance with governing codes, standards and contract requirements. QA oversight of activities affecting quality is accomplished through field and manufacturing facility surveillance, audits or other documented measures conducted to verify that requirements have been met.

2. Quality Control (QC): Quality Control is the act of examining, witnessing, inspecting, checking and/or testing of in-process or completed work to determine conformity with specified requirements and documenting the results.

3. QA Audit: A documented activity performed by written procedure or checklist to verify that selected elements of the Quality Assurance/Quality Control Program have been developed, documented, and implemented in accordance with specified requirements.

4. Calibration: Comparison of two instruments or measuring devices, one of which is of known accuracy traceable to national standards, to detect, correlate, report or


eliminate by adjustment any discrepancy in the accuracy of the instrument or measuring device being compared with the standard.

5. Certification: The action of determining, verifying and attesting, in writing, to the qualifications of personnel, materials, and/or equipment.

6. Inspection: A phase of Quality Control, which by means of examination, observation, or measurement, determines the conformance of materials, components , parts, appurtenances, systems, processes, installations, or structures to predetermined quality requirements.

7. Source Inspection: Source inspection consists of the review, monitoring, observation, and/or inspection, random or consistent, or at selected stages of manufacture or construction, of manufacturer or sub-manufacturer's personnel, material, equipment, processes, or tests.

8. Site Inspection: Site Inspection consists of reviewing, monitoring, observing and inspecting the Work at the project site.

9. Surveillance: Term used to describe a review performed for the purpose of verifying that applicable quality requirements are properly accomplished.

1.03 RELATED WORK

A. Requirements of the Agreement

B. Section 01410 – Testing and Inspection Services

C. Section 01700 – Contract Closeout

D. Specific requirements of Agreement Paragraph XVIII

1.04 SUBMITTALS

A. SEPTA reserves the right to require mock-ups of any material and/or assembly, at any time during the construction process of a size determined by the SEPTA PM. Once approved, the mock-up will set a minimum standard of performance and/or appearance for the Work. Mock-ups will be provided at no cost to SEPTA. The approved mock-up may, at the discretion of the SEPTA Project Manager, become part of the Work.

B. The Contractor will create a job specific Quality Assurance and Control Plan (QACP) which clearly and comprehensively specifies the actions the Contractor will take to achieve the quality required by the Contract Documents. This plan will be submitted no later than fifteen (15) days from the Notice to Proceed. No Work may take until the QACP has been accepted by SEPTA. The following areas will be addressed in this plan:

1. The Quality Assurance procedures shall define the organizational structure within which the programs are to be implemented, and delineate the responsibility and authority of the various personnel involved.

2. Shop Fabrication: The Contractor shall develop and submit inspection and test plans and procedures for all elements of the Work that will be shop fabricated and tested. The inspection plans/procedures shall include source inspection and testing that will be performed, accept/reject criteria and the witness/hold points to be implemented to control the quality of Work.

3. Site Construction/Installation: The Contractor shall develop and explain inspection and test plans and procedures for all elements of the Work that will be site


constructed and installed, including the storage and installation of shop fabricated items. The installation plans and procedures shall include checklists, which outline the sequence of construction/installation activities and describe the verification checks for each step in the sequence, which must be found acceptable prior to proceeding. The plans and checklists shall be submitted to SEPTA for the identification of hold and/or witness points by SEPTA.

4. The Contractor shall develop and explain a Quality Assurance program and surveillance methods to verify that reviewed inspection, testing and documentation activities have been performed to assure that shop fabricated and site construction/installation comply with the quality standards defined in the contract documents.

5. SEPTA's review of the QA/QC program shall not relieve the Contractor from its primary responsibility for the quality of the Work.

1.05 QUALITY ASSURANCE RESPONSIBILITIES OF THE CONTRACTOR

A. Engage an adequate number of skilled professionals who are thoroughly trained, experienced and familiar with the specific requirements and methods needed for the proper performance of the Work.

B. Establish technical and administrative surveillance and/or audit methods to ensure the highest degree of quality, and to correct potential problems without affecting the Contract schedule.

C. Verify that the required quality control inspection, testing and documentation activities have been performed to assure that the equipment, materials and construction comply in all respect to the requirements of the contract documents.

D. Monitor quality control over suppliers, manufacturers, fabricators, products, services, site conditions, workmanship and installation to produce work of the quality required by the Contract Documents.

E. Take corrective actions in a timely manner to identify conditions adversely affecting the quality of Work and the Contract schedule.

F. All test results shall clearly include a statement that the item tested or analyzed conforms or fails to conform to the Contract requirements. Each report shall be conspicuously stamped on the cover sheet in large red letters a minimum of ½ inch high “CONFORMS” or “DOES NOT CONFORM” to the Specifications, as the case may be.

G. All test reports shall be signed by a testing laboratory's authorized person and counter signed by the Contractor. The testing agency shall provide all tests, reports, certifications and other documentation sent directly to the SEPTA PM at the same time results are made available to the Contractor.

H. The quality assurance functions shall include, but not be limited to: · Contract Review · Factory and Field Testing · Document Control · Handling and Storage · Procurement · Packaging and Shipping · Shop Fabrication · Quality Records · Field Fabrication · Non Conformance Reporting


· Field Installation · Corrective Action(s) · Field Assembly · QA Audits · Receiving Inspections · Training · Final Inspection · Control of In Process Activities · In process inspections · Identification and Traceability

I. The Contractor shall promptly reject work that does not comply with the requirements of the Contract Documents. If the Contractor elects to propose that SEPTA accept work that is nonconforming, the Contractor shall reimburse SEPTA for the costs associated with the review of the nonconforming work by the designer of record.

J. Develop quality assurance forms in a format acceptable to SEPTA for all major elements of the Work including any additional elements.

K. The Contractor shall perform audits periodically, no less than four (4) times a year, to maintain level of quality. The results of these audits must be documented and shown to SEPTA on request.

1.06 SOURCE QUALITY CONTROL RESPONSIBILITIES OF CONTRACTOR

A. Document that each material, manufactured product and fabricated item is produced and tested to comply with quality standards required by the Contract Documents. The Contractor shall perform audits periodically, no less than four (4) times a year, to maintain level of quality.

B. Do not deliver material, manufactured product or fabricated item until certified quality assurance documents are satisfactorily reviewed by SEPTA.

C. Do not schedule any factory tests/inspections by SEPTA until these documents are satisfactorily reviewed by SEPTA. Twenty-one (21) day’s prior written notice is mandatory for (re) scheduling any factory tests or inspections by SEPTA.

D. SEPTA reserves the right to source inspect the material, manufactured product or fabricated item after acceptance of the certified quality assurance documents. Any and all costs related to re-inspection(s) by SEPTA shall be the responsibility of the Contractor.

E. The quality assurance documents shall identify any changes made to the material, manufactured product or fabricated item as compared to the Contract requirements and approved shop drawings. The Contractor shall describe as to how each change will affect the installation, space and subsequent operations.

F. SEPTA’s review of quality assurance documents and inspections shall not relieve the Contractor from its “primary” responsibility for the quality of Work.

1.07 CONTRACTOR QUALITY MANAGER (QM)

A. The Contractor shall identify an individual (QM) within its organization at the site of the Work, who shall be responsible for overall management of Contractor’s Quality Assurance/Quality Control (CQC) system. An individual who has no other duties shall fill the function of the QM.

1. The QM shall be experienced in the performance and supervision of the inspections and tests required by the Specifications.


2. The QM shall be on the work site at all times that work is taking place and have complete authority to take any action necessary to ensure conformance with the Contract.

3. The QM will be the point-of-contact for all quality matters. The QM is expected to represent the Contractor with respect to all QA audit and review activities performed on the Contractor by outside parties.

4. The QM shall be appointed by letter and may not be replaced without written permission form SEPTA.

5. The QM may take daily direction from the Contractor’s Superintendent, however unless prohibited by organizational size, the QM shall independently report to an official within the Contractor’s organization who is separate from direct responsibility for the outcome of the project.

6. The QM shall be responsible for the documented incoming inspection and determination of acceptability in conformance with Contract requirements of all material arriving at site.

7. Receiving inspection(s) shall include the review of associated documentation where necessary to verify the compliance of the item. Segregate and remove from the site, any nonconforming material.

1.08 SITE QUALITY CONTROL RESPONSIBILITIES OF CONTRACTOR

A. Unless otherwise specially allowed elsewhere in the Contract, do not deliver reconditioned material to site. Protect all stenciled markings, labels and any other type of identification(s) to clearly identify the originality of the material.

B. As soon as the material arrives at site, (but before beginning installation) provide to SEPTA the original Bill of Lading and Certification that the material complies with the requirements of the contract documents.

C. Installation shall comply with approved shop drawings. Do not begin installation until relevant installation shop drawings have been appropriately reviewed by SEPTA. If for any reason the material or component cannot be installed according to the approved shop drawing and the installation instructions provided by the manufacturer/fabricator the Contractor is to alert the SEPTA immediately and not begin installation without concurrence from the SEPTA PM.

D. Perform necessary and specified tests and document the results. Replace material that fails the tests at no cost to SEPTA.

E. Remove and replace material that is damaged in storage or in the performance of Work, unless specifically accepted in writing by SEPTA’s Project Manager.

F. No Work shall be performed at the site if the Contractor’s Superintendent or his authorized representative, as approved by SEPTA, is not present at the location where Work is being performed.

1.09 NON-CONFORMANCE REPORTS

A. A non-conformance report (NCR) shall be issued when any material or component does not meet the requirements of the Contract documents in the opinion of the SEPTA Project Manager, or other approved SEPTA personnel.


B. Once issued, the Contractor has ten (10) days to challenge the NCR in a written response to the SEPTA PM.

C. Any NCR not withdrawn in writing by the SEPTA PM or other approved SEPTA personnel, must be corrected in a timely manner.

D. The Contractor is obliged not to proceed with any Work which would cover or reduce access to the non-conforming Work.

1.10 CONSTRUCTION INSPECTION AND MONITORING PROGRAM

A. The Contractor will be required to complete checklists, usually in the presence of a member of the SEPTA project team, at specific critical points of the project’s execution to verify quality assurance procedures. SEPTA reserves the right to provide these checklists and require their completion in a timely manner without prior notification.

1.11 SUGGESTED CONTENTS OF QA/QC PLAN

A. The Contractor’s inspection and testing plan must be specific and not generic; tailored to the actual requirements of the project. Most plans will include many of the following items:

1. Organization & Responsibilities:

a) Provide an organizational chart showing who has responsibility for quality control functions and how they interact with the rest of the project team. The QA/QC team must report directly to upper management and not to the Project Manager overseeing day to day activities of the project.

b) Supply brief resumes of key personnel.

c) Document how the QA/QC personnel will oversee the QA/QC activities subcontractors and fabricators.

2. Procedures and Documentation:

a) Samples of logs and checklists to be used in QA/QC activities.

b) A schedule of tests, inspections and mock-ups required by the Contract Documents and governmental authorities

c) Procedures which guarantee that any material which must meet a specific test or other definition of quality is delivered to the job site accompanied by written verification that the material does meet these requirements. Included in this procedure is the process of gathering this information and retaining it by the Contractor.

d) Procedures which ensure that handling and storage instructions are obtained and followed for all material.

e) Procedures that insure that the Contractor effectively controls documents at the job site. Included in this responsibility is a requirement that a copy of the most current construction documents is present at the job site at all times; including but not limited to drawings, specifications, addendum items, change orders and RFIs.

3. Inspection and Testing Activities:


a) List of inspection devices to be used by the Contractor or a subcontractor which must be calibrated, the proposed frequency of calibration and who will calibrate them.

b) Procedures to ensure that testing and inspections will be done in a timely manner and will not negatively impact the progress of the Work.

c) Procedures to ensure that mock-ups and pre-installation conferences are done in a timely manner and give the SEPTA PM sufficient time to participate and review them without negatively impacting the schedule.

d) Procedures that insure that material which fail tests or inspections is identified and segregated.

4. Audit Activities:

a) Define how and how often the QA/QC efforts for key construction activities will be audited and how the results of this audit will be presented to the job superintendent.

b) Define when anticipated audits may be implemented.

END OF SECTION




SECTION 01410

TESTING AND INSPECTION SERVICES

PART 1 - GENERAL


A. The Contractor shall employ a testing and inspection agency fully licensed and competent in the field of testing and inspecting specific elements of the project. The Contractor shall submit all testing agencies and their qualifications for SEPTA’s prior written approval before any testing begins.

B. The required testing and inspections shall include the tests commonly used in the construction industry, including, but not limited by those called for in the attached technical sections.

C. The Contractor shall pay for all necessary testing and inspection services.

1.02 RELATED WORK

A. Agreement

B. Section 01400 – Quality Requirements

1.03 SUBMITTALS

A. Prior to start of Work, submit testing and inspection agency name, address, and telephone number, and names of full time specialists and/or registered Engineers and responsible officer.

B. Submit information on the agency’s participation in accreditation program(s) such as those run by the Construction Materials Testing Laboratory Accreditation Program of the National Institute of Standards and Technology and AASHTO Materials Reference Laboratory in the AASHTO Accreditation Program (AAP) in construction materials engineering and testing. Non-participation in appropriate third party accreditation programs may result in rejection.

C. Provide a schedule of agency’s activities commitment with the Contractor(s) schedule and work to be provided.

D. Other information and qualifications to allow SEPTA to determine their appropriateness for the tasks involved.

1. After each inspection and test, the testing agency must promptly submit a copy of draft results directly to the SEPTA PM without Contractor review.

2. Include:

a) Date issued,

b) Project title and number

c) Name of inspector,

d) Date and time of sampling or inspection,

e) Identification of product and specifications section,

f) Location in the Project,


g) Type of inspection or test,

h) Date of test or inspection,

i) Results of tests or inspection,

j) A statement of Conformance or Non-Conformance with the Contract Documents.

3. When requested by SEPTA, provide a written clarification and interpretation of test/inspection results.


A. The testing and inspection agency shall be approved by SEPTA.

B. The Laboratory shall comply with requirements of most current edition of ASTM.

C. Laboratory: Authorized to operate in the Commonwealth of PA.

D. Laboratory Staff: Maintain a full time registered Engineer on staff to review services.

E. Testing Equipment: All equipment must be calibrated at reasonable intervals with devices of an accuracy traceable to either the National Bureau of Standards or accepted values of natural physical constants defined by industry standards.

F. Testing, when required, shall be the strictest of all pertinent codes and regulations, including selected standards of the American Society for Testing and Materials.

G. All site testing and taking of specimens and samples shall be performed in the presence of the Contractor’s Superintendent and the SEPTA PM, unless the PM waives the right to be present, in writing.

H. No testing required by the contract documents or common industry practice may be waived or altered without the written permission of SEPTA’s Assistant General Manager of Engineering, Maintenance and Construction or SEPTA’s Chief Engineer.

1.05 PRODUCT HANDLING

A. The Contractor shall comply with pertinent provisions of Section 01600.

B. The Contractor shall promptly process and submit required copies of test reports and related instructions to assure necessary retesting and replacement of materials without any possible delay in the progress of the Work.

1.06 CONTRACTOR’S RESPONSIBILITIES

A. Representatives of the testing and inspection agency shall have access to the Work at all times and at all site and off site locations, including manufacturing and fabrication facilities. The Contractor shall provide whatever support is required to enable the agency to perform its functions properly.

B. By advance discussion with the testing agency, the Contractor shall determine the schedule required for the agency to perform its tests and inspections and to issue each of its findings. The Contractor is solely responsible for any delays caused by testing and inspection services.

C. The Contractor shall provide all required testing and inspection time within the approved construction schedule.


D. Deliver to agency at designated location, adequate samples of materials proposed to be used which require testing, along with proposed mix designs.

E. Provide incidental labor and facilities:

1. to provide access to Work to be tested or inspected,

2. to obtain and handle samples at the site or at source of Products to be tested,

3. to facilitate tests and inspections,

4. to provide storage and curing of test samples.

F. Notify the SEPTA PM, forty-eight (48) hours prior to expected time for operations requiring inspecting and testing services.

G. When initial tests indicate non-compliance with the Contract Documents, subsequent retesting occasioned by the non-compliance shall be performed by the same testing agency, at no additional cost to SEPTA.

H. Inspecting and testing performed exclusively for the Contractor’s convenience shall be the sole responsibility of the Contractor.

END OF SECTION




SECTION 01452

CONTRACTOR QUALITY CONTROL – TRACTION POWER EQUIPMENT

PART 1 - GENERAL


A. Traction power equipment required for the contract is unique in terms of rating (frequency, voltage, and single phase) and will be supplied by multiple manufacturers. Quality control by the Contractor is therefore of paramount importance.

B. SEPTA shall monitor Contractor’s quality control of traction power equipment during design, manufacturing, installation, and by conducting reviews of submittals, design review meetings, observing manufacturing process, inspecting installation, and witnessing tests at the factory and site.

C. In case of conflict with other sections, provision that is more stringent shall apply.


A. All Sections of Division 1

B. Section 01612 – Delivery, Storage, and Handling – Traction Power Equipment

C. Section 01752 – Spare Parts and Maintenance Materials

D. Section 01822 – Demonstration and Training – Traction Power Equipment

E. Section 01832 – Operations and Maintenance Manuals – Traction Power Equipment

F. Section 05090 – Metal Fasteners, Joining, and Welding

G. Section 09910 – Paints and Coatings

H. Section 16052 – General Electrical Requirements – Traction Power Equipment

I. Section 16060 – Grounding and Bonding

J. Section 16075 – Electrical Identification

K. Section 16262 – Static Frequency Converter

L. Section 16290 – Protective Devices and Instrument Transformers

M. Section 16310 – Transmission and Distribution

N. Section 16330 – Medium Voltage (2-Pole) Breakers, Switching & Protection

O. Section 16335 – Surge Arresters

P. Section 16791 – Combined Relay and Control Switchboard

Q. Section 16910 – Electrical Systems Control (SCADA)

R. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS

A. Design Documentation

1. Studies and Reports


a) Submit studies and reports for each component design requiring calculations. This is specifically applicable for the components which have not been previously used on similar traction power equipment. As a minimum, include in each report the following sections:

1) General description

2) Design parameters

3) Design procedures

4) Calculation procedures

5) References to standards and technical literature

6) Design of the equipment based on the calculations

7) Statement of compliance with the Contract Documents, specified standards and codes to which each item of equipment is designed

8) Conclusions

9) Seal and signature of a Professional Engineer registered in the Commonwealth of Pennsylvania.

2. Product Data

a) Provide technical product data for all items of equipment used.

b) Identify materials, dimensions, weights, manufacturing and fabrication procedures, factory and field tests, and installation procedures.

c) Make use of standard equipment product data and specifications where practical and describe functional, design, electrical characteristics, and performance requirements. Identify materials, fabrication procedures, factory tests, field tests, and installation procedures.

d) Modify manufacturer’s standard schematics, drawings, brochures, diagrams, details, procedures, instructions, schedules, illustrations, calculations and other descriptive data as follows:

1) Delete information which is not applicable to this Contract

2) Highlight pertinent information related to this project.

3) Show dimensions, clearances, performance characteristics, interfaces, wiring diagrams, inputs, outputs and controls, as appropriate.

e) Submit Certificates of Compliance for those products for which no product samples or tests are specified. Demonstrate that the product complies with the Contract Document requirements. The Certificates of Compliance shall be signed by an authorized representative of the product manufacturer.

3. Design and Shop Drawings

a) The Contract includes design and manufacture of traction power equipment rated at frequency and voltage that are not commonly used in other traction distribution systems. Submit detailed


design drawings including control schematics, and layouts for SEPTA review and approval.

b) Prepare all Design and Shop Drawings using SEPTA approved border and title block. Include in the title block the drawing number, title, date, contract number, reference to next higher assembly, and signature of the Contractor’s responsible engineer.

c) All drawings shall be prepared to SEPTA AutoCAD standards as specified elsewhere.

d) Reserve a blank area, 2 inches x 4 inches in the lower right corner just above the title block, for SEPTA’s review stamp.

e) Include a complete list of materials and parts with Contractor’s part number. Provide room for including SEPTA’s part number.

f) Fully dimension each assembly.

g) Provide weight of each assembly.

h) Identify commercial equivalent of components, where possible.

i) Changes in products for which Drawings have been reviewed and approved will not be permitted, unless those changes have been submitted to and approved in writing by SEPTA.

j) Deviations from the Contract specifications are not encouraged. Highlight the deviations, if any, from the Contract Specifications and Drawings in the letter to SEPTA. Only those deviations which are specifically approved by SEPTA will be considered valid deviations.

k) Include seal and signature of a Professional Engineer registered in the Commonwealth of Pennsylvania on all drawings.

4. Manufacturers Internal Quality Control Tests and Control Points

a) Submit details of the internal factory tests that will be performed by the manufacturer as part of his quality control.

b) Submit list of control points where manufacturer's internal quality department will perform a pass/fail check.

c) SEPTA may elect to witness any or all control point tests at manufacturer’s factory.

5. Bill of Materials

a) Provide a complete list of all equipment and materials used.

b) For each item of equipment on the list include the following information:

1) Item identification

2) Major characteristics

3) Name and address of the manufacturer

4) Catalog number

5) Complete ordering data

6) Alternate manufacturers


B. Product Samples

1. Submit product samples to SEPTA as specified in other Sections of this Specification.

2. Prepay all shipping charges to SEPTA’s offices or construction site.

3. Provide samples and quantity to clearly illustrate full color, range, and functional characteristics of products and materials. Provide complete accessories or attachment devices. After review and written approval by SEPTA, samples may be used in construction, if not damaged and if allowed by SEPTA.

4. Changes in products for which samples have been approved will not be permitted, unless those changes have been reviewed and approved in writing by SEPTA.

C. Software Code and Documentation

1. Provide all software source code and software documentation developed under the Contract, more specifically for the control of the switchgear and protective relays, to insure that should the need arise after expiration of the warranty and the Contractor is unable or unwilling to provide technical support, SEPTA or a software consultant, will have the capability to perform any needed software modifications. At this time, SEPTA has no plans to modify supplied software without the Contractor’s knowledge and consent.

2. Include all application and diagnostic software and any software developed for embedded microprocessors that are integrated into the equipment modules.

3. Software documentation shall include the following:

a) General description and operation

b) Software architecture and program functions

c) Data flow information

d) Annotated source code listing, with comments and descriptions pertaining to each module in sufficient detail to allow an experienced programmer to understand the program

e) Detailed memory map and listing

f) Input/output port map

4. In addition to the software source code and documentation described above, submit the following:

a) A licensed copy of all software tools such as debuggers, assemblers, and compilers, needed to convert the supplied source code into executable form used by the target processors.

b) Hardware devices, such as EPROM programmers, with their accompanying software tools, necessary to transfer the executable programs onto the storage devices used by any embedded microprocessors.

c) Documentation that describes the procedures necessary to convert the supplied source code into an executable format.

D. Photographs


1. Provide professional quality, digital, color photographs to document manufacturing, installation and completed installation of traction power equipment.

2. These photographs are in addition to the requirements included in Section 01380. The photographs shall show the layout of internal equipment in clear detail.

3. Provide at least twenty five (25) views of various stages of installation for each of the following equipment. For all equipment (except the grounding system), include views of crane setting/rigging, unconnected in place on pad, and final installation with all hookups.

a) Relay and Control Switchboards

b) Grounding system

4. Identify each print on back with the following information:

a) Owner’s name: Southeastern Pennsylvania Transportation Authority

b) FTA and SEPTA’s Project Numbers

c) Project name and location

d) Date and time taken

e) Brief description of the photograph view

5. SEPTA reserve the right to photograph, without restriction and at its own expense, all phases of equipment manufacture and construction.

E. Record Documents

1. Maintain one record copy of all Design Documents and change orders at the work site. The Design Documents shall be continuously annotated to indicate the following:

a) All design changes in the field

b) Substitutions of items of equipment as changes occur

c) Additional details not provided on the original Design Documents

d) All other changes, as required, to show a complete “as built” condition

2. Periodically update the drawings electronically. Upon completion of the construction, when the Design Documents include all design and field changes, designate and stamp the documents as Record Documents.

3. At completion of all work ensure the Record Documents are sealed by a Professional Engineer registered in the Commonwealth of Pennsylvania and submit to SEPTA. All Record Documents will become the property of SEPTA.

4. Retain all system Design and Record Documents for a minimum of five (5) years from the Final Acceptance date of each element of work. The documents shall be accessible to SEPTA during this period.


A. Use the following standards for the preparation of drawings:


1. ANSI Y14.38 – Abbreviations and Acronyms for Use on Drawings and Related Documents

2. IEEE 91 – Graphics Symbols for Logic Functions

3. IEEE 315 – Graphics Symbols for Electrical and Electronic Diagrams

4. SEPTA Drawing Standards

PART 2 - PRODUCTS

2.01 SEPTA’S REVIEWS

A. All submissions shall be subject to review and approval by SEPTA in accordance with Section 01300 or as amended herein. Approval does not relieve the Contractor of its obligation to meet the requirements of the Contract.

B. One copy of each submittal will be returned to the Contractor. Submittals bearing exception and submittals not approved will indicate the review comments and instruction relative to correction of the resubmittal.

C. Review and approval of a separate item will not constitute approval of the assembly in which the item functions.

D. Allow twenty-one (21) calendar days for all SEPTA reviews for submittals relating to traction power equipment. SEPTA can potentially cut the review time duration for shorter submittals.

2.02 DESIGN REVIEW MEETINGS

A. Design review meetings shall be conducted to discuss and evaluate design progress, technical adequacy of the design, and the compliance with the performance requirements of the Contract. Each review shall also evaluate compatibility of the functional interfaces between the System Components and between other facilities.

B. Hold design review meetings monthly, and at special design milestones as required by SEPTA. The special design milestones shall include, but not be limited to:

1. In-progress (60%) Design Review Meeting following the In-progress Design Submission.

2. Pre-Final (90%) Design Review Meeting following the Pre-Final Design Submission.

3. Final Design (100%) Review Meeting following the Final Design Submission.

C. The location of the review meetings shall be, at the option of SEPTA, either at the Contractor’s offices or at SEPTA’s office. Prepare written record of each meeting in the form of meeting minutes. The meeting minutes shall be included in the project correspondence and shall be distributed to SEPTA.

D. SEPTA reserves the right to review any and all design drawings, design data, studies, and analyses.

E. SEPTA reserves the right to audio tape all meetings.


2.03 MANUFACTURE OBSERVATION AND CONSTRUCTION INSPECTION

A. SEPTA and its representatives will visit the Contractor’s facilities and the construction site from time to time to monitor manufacturing and construction progress.

B. For this purpose, provide SEPTA thirty (30) days’ notice of upcoming control points in the manufacture of traction power equipment, and arrange for design staff, manufacturing personnel, and construction personnel to be available for formal meetings, shop floor discussions, and site inspections.

2.04 TEST WITNESSING

A. A SEPTA-assigned person will always be at the construction site. SEPTA’s representative will visit the construction site from time-to-time to support the project development. SEPTA and its representatives will be present at important stages of equipment testing.

B. For this purpose, provide SEPTA fifteen (15) days’ notice of all important installation events, such as delivery of major equipment, and arrange for required field staff to be available for meetings and discussions at site.

PART 3 - EXECUTION

3.01 INTERFACE COORDINATION SYSTEM

A. Setup a control system to track all areas requiring interface between the three prime Contractors. Use the control system for the following activities:

1. Tracking of all interface requirements.

2. Any potential conflicts with other prime Contractors.

3. Impact on the contract construction schedule.

3.02 DESIGN SUBMITTALS

A. Submit all traction power design submittals at the following levels of design completion:

1. Within 30 days of the award of the contract, submit the details of the major traction power equipment (switchgear, circuit breakers, current transformers, potential transformers, and disconnect switches) proposed to be used to enable proper interface by other prime Contractors.

2. In-Progress Design Submission at 60% design completion level. Provide essentially completed design, although some special designs may not have been finalized. Include documentation, drawings, data, and calculations necessary to permit full understanding of the design. All studies specified in Section 16052 would have been completed by this time.

3. Pre-Final Design Submission at 90% design completion level. Provide all Design Documentation.

4. Final Design Submission at 100% design completion level. Provide all Design Documentation sealed by a Professional Engineer registered in the Commonwealth of Pennsylvania as an Electrical Engineer.


3.03 DISTRIBUTION OF APPROVED SUBMITTALS

A. Distribute copies of approved submittals bearing SEPTA’s stamp and signature to relevant subcontractors, suppliers and manufacturers and to members of the Contractor’s force.

B. Ensure that all holders of approved submittals receive updated copies to ensure the availability of the latest approved data.

3.04 RESUBMISSION REQUIREMENTS

A. Resubmit all documents to SEPTA in time to avoid delay to the Project Schedule.

B. Indicate any changes other than those required by SEPTA. If the Contractor considers any correction indicated on the submittal to constitute a change in scope of the Contract requirements, notify SEPTA in writing at the time of resubmittal.

3.05 NOTIFICATION

A. Coordinate notification and submittal days with requirements of Section 16262, Static Frequency Converter and associated appendices.

B. Provide advance notification to SEPTA prior to important design, manufacture, testing, and construction events, as shown in Table 01452-2.

Table 01452-2 - Notification Schedule

Event Minimum Advance Notification Requirement(Days)

Design Review Meetings 15

Field Inspections 7

Testing Factory 30

Field 15

Ground Grid Construction and Testing

Construction Commencement

15

Backfilling 7

Equipment Delivery 15

3.06 SUBMISSION SCHEDULE

A. Provide submittals as shown in Table 01452-3.


Table 01452-3 - Submission Schedule

Deliverable Item Level of Submission Submission

Design Documentation

Studies and Reports In-Progress

At least 15 days prior to Preliminary Design meeting

Final At least 15 days prior to In-Progress Design meeting

Product Data In-Progress

At least 15 days prior to Preliminary Design meeting


Design and Shop Drawings In-Progress

At least 15 days prior to In-Progress Design meeting

Pre-Final At least 15 days prior to Pre-Final Design meeting

Final At least 15 days prior to Final Design meeting

Plans and Procedures In-Progress At least 15 days prior to Preliminary Design meeting


Test Documentation Test Plan, In-Progress At least 15 days prior to Preliminary Design meeting

Test Plan, Final At least 15 days prior to In-Progress Design meeting

Test Procedures, In- Progress

At least 15 days prior to In-Progress Design meeting

Test Procedures, Final At least 15 days prior to Pre-Final Design meeting

Test Reports Within 30 days of test completion


Deliverable Item Level of Submission Submission Requirement

Bill of Material In-Progress At least 15 days prior to Pre-Final Design meeting

Final At least 15 days prior to Final Design meeting

Spare Parts, Special Tools, and Test Equipment

Pre-Final List At least 15 days prior to Pre-Final Design meeting

Final List At least 15 days prior to Final Design meeting Parts, Tools and Equipment

With delivery of the last item of equipment

Catalogs With delivery of the last item of equipment

Product Samples In-Progress At least 15 days prior to In-Progress Design meeting

Software Code and Documentation

Final Within 30 day of final system acceptance

Photographs Final Within 30 day of final system acceptance

Operations and Maintenance Manuals

Manuals, Pre-final Include in Pre-final Design Submission

Manuals, Final With delivery of the last item of equipment

Training and Training Manuals

Personnel Resumes At least 120 days prior to commencement of training

Training Plan At least 120 days prior to commencement of training

Training Program At least 90 days prior to commencement of training

Training Manuals, Final At least 30 days prior to commencement of training

Training Materials At least 30 days prior to commencement of training

Program Demonstration At least 30 days prior to commencement of training

Record Documents Final Within 30 day of final system acceptance

END OF SECTION


SECTION 01500

CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

PART 1 - GENERAL


A. The Coordinating Contractor shall provide temporary facilities and controls needed for the performance of its Work, provide for public and employee safety and protect SEPTA property. This may include, but not necessarily limited to:

1. Temporary utilities such as heat, water, electricity, and telephone

2. Field office for the Contractor’s personnel and a separate facility for SEPTA’s personnel use

3. Sanitary facilities

4. Enclosures such as tarpaulins, barricades and canopies

5. First-aid facilities, per OSHA requirements

6. Temporary fencing and other safety devices for pedestrian and vehicular traffic as well as isolating the construction area

7. Entry Control

8. The Electrical Contractor shall provide Personnel Identification

1.02 RELATED WORK

A. Agreement




E. Section 01060 – Regulatory Safety Requirements

F. Section 01505 – Mobilization and Demobilization

G. Section 01580 – Project Identification Signs and Other Construction Signage

H. Section 01590 – SEPTA Field Office

1.03 SUBMITTALS

A. The Contractor shall comply with pertinent provisions of section 01300.

B. If required by the SEPTA PM, the Contractor shall provide shop drawings (including sealed engineering drawings if requested) for any temporary facility.


A. The Contractor shall maintain and protect all temporary facilities and controls in proper and safe condition throughout progress of the Work. For facilities visible to the public, the Contractor will maintain them in an acceptable appearance and repair any vandalism within 24 hours or as requested by the SEPTA PM.


1.05 TEMPORARY UTILITIES AND SERVICES

A. Water:

1. The Contractor shall provide drinking water from an approved source, so piped or transported as to keep it safe and fresh and served from single service containers or satisfactory types of drinking stands or fountains. All such facilities and services shall be furnished in strict accordance with existing governing health regulations.

2. Refer to the Agreement, Paragraph VIII.D. The Contractor shall protect pipes from freezing during inclement weather and repair any vandalism.

B. Sanitary Facilities:

1. Refer to the Agreement Paragraph VIII.D.

2. The Contractor is prohibited from using existing toilet facilities – either those intended for SEPTA personnel or those intended for the public at large.

3. The Contractor shall furnish for the work force on this project, the necessary toilets, secluded from public observation. The toilets shall be kept in a clean, sanitary condition and shall comply with the requirements and regulations of the agencies having jurisdiction. The SEPTA PM must approve all toilet locations and may demand increased maintenance if he finds the level of maintenance unacceptable.

C. Power and Lighting:

1. The Contractor shall provide, maintain and pay for all costs of temporary electrical and lighting services required at the site for the proper performance and inspection of work. The level of lighting shall not be less than the existing. Lighting shall also be provided to all temporary public facilities at levels satisfactory to the SEPTA PM. Remove services and lighting after completion of work and repair of all damages.

2. The Contractor shall provide area distribution boxes so located that the individual trades may furnish and use 100 ft. maximum length extension cords to obtain power and lighting at points where needed for work, inspection, and safety.

3. The Contractor shall provide all necessary items such as breakers, transformers, panel boards, and cable required for the service. The Contractor shall provide a complete distribution system expanded as required during the construction including wiring devices, outlets, distribution panels, transformers, cable and other related work necessary to provide a temporary power system for use during construction.

4. The Contractor shall pay all costs associated with the utility tie-ins, physical plant, maintenance of system throughout construction, removal of same at project completion and any other items necessary in providing temporary power and light.

5. The temporary power and lighting system shall at all times conform to the applicable codes and regulations of OSHA, NFPA, UL, and the local municipality.

D. Telephones: The Contractor shall make necessary arrangements and pay costs for installation, maintenance and operation of direct line (non-pay type) telephone services in SEPTA’s field office at the site. Portable (cellular) may be provided to fulfill this requirement at the SEPTA PM discretion.


E. Heating: The Contractor shall provide and maintain heat necessary for proper conduct of operations.

1.06 ACCESS, STORAGE AND PARKING AREAS

A. The Contractor shall establish a construction compound in which the Coordinating Contractor provided SEPTA office trailer will be located adjacent to the Contractor’s office trailer. The physical location of the compound will require written approval of SEPTA’s Project Manager.

B. The Contractor shall provide a minimum of five (5) parking spaces adjacent to the SEPTA trailers within the compound for SEPTA vehicles.

C. The Contractor shall provide all necessary security for this compound area. The Contractor shall provide all necessary keys to SEPTA’s Project Manager to provide access to the compound at any time.

D. The Contractor shall submit to the Project Manager a plan layout of the Compound within twenty-one (21) days after Notice to Proceed (NTP).

E. The Contractor shall coordinate the provision of utility services for all trailers and be responsible for all installation charges, removal costs at Project completion, and any periodic or other charges incidental to the provision of those utility services.

F. Upon final acceptance of the Work, the Contractor shall clean up the work areas and leave them in a neat and orderly condition. The Contractor shall dismantle and remove all temporary fencing and barricades and other temporary items installed, unless otherwise directed by the Project Manager. Repair damaged areas to their original condition.

1.07 FIELD OFFICES AND SHEDS

A. Contractor’s Field Office:

1. Furnish and maintain a field office with a telephone at the site during the entire period of construction. The Contractor’s superintendent shall be present at said office at all times while its work is in progress. Keep readily accessible, at the field office, copies of both the Contract Documents and the latest approved shop and working drawings.

2. Submit for SEPTA’s written acceptance, working drawings showing proposed locations and size of offices and shops.

B. Field Office Security

1. The Contractor shall Guard against unauthorized or illegal entry and protect the field office against vandalism, theft and mischief. The Contractor shall be responsible for the replacement and/or compensation for any items owned by SEPTA or SEPTA employees, which are related to the subject work, which are removed or damaged as the result of vandalism, theft, mischief or illegal entry to the field office.

C. Upon project completion, the Contractor shall assume ownership of and remove temporary field offices and appurtenances from the job site, except as otherwise noted.

1.08 TEMPORARY BARRICADES, ENCLOSURES AND FENCING

A. The Contractor shall provide all temporary barricades required by the phasing plans or otherwise necessary for the safe execution of the project, including but not limited to


barricades for designated Contractor work areas, Contractor laydown areas, and public access for areas that must remain open during a phase.

1. Where barricades are required outside a designated work area for the exclusive use of a Contractor, the barricades shall be provide by the Contractor.

2. SEPTA reserves the right to require the Contractor to provide all necessary barricades to ensure the safety of SEPTA personnel and passengers as determined by the SEPTA PM, whose decision shall be final.

B. Submit drawings of the proposed temporary barricades for SEPTA’s review. Do not install barricades until the drawings for them have been reviewed by SEPTA.

1. Barricades shall enclose and prevent entry into the work area and shall be full height and dustproof.

2. Barricades shall be constructed of materials suitable for location.

3. At open locations in unconfined spaces - Wood construction shall conform to the AFPA “National Design Specification for Wood Construction”, the latest edition. As a minimum, the barricades shall be constructed of 5/8” thick APA rated exterior grade plywood. Framing members shall be Spruce-Pine-Fir No.2 or better, a minimum of 2” x 4” and larger sizes as necessary, spaced at a maximum 16” on center to provide a rigid temporary structure to resist all applicable loads.

4. All barriers in confined spaces, as determined by the SEPTA PM, must be constructed to not contribute smoke to or support flame spread of a fire. To achieve this, such barriers shall be built of metal studs and Wonderboard style cement board.

5. Barricades shall be painted on all solid surfaces exposed to public view.

6. Traffic cones, tape, stakes with ribbons or other insubstantial items shall not be used to differentiate construction areas in lieu of barricades. At his sole discretion, the SEPTA project manager may make exceptions for work of extremely short duration.

C. Temporary Doors: The temporary barricades shall have a reasonable number of hollow metal doors and frames, with locksets, at locations acceptable to SEPTA. The locksets on the doors requiring SEPTA access for operational and safety reasons shall be keyed to SEPTA’s standard lock system.

D. On a daily basis, the Contractor shall maintain the temporary barricades in a “like new” condition. The Contractor shall remove graffiti and restore surfaces on a continual maintenance basis. Maintenance shall continue until the barricades are removed.

E. The Contractor is required to enclose areas required by SEPTA for access and maintenance. If these areas are in public areas they shall be secured with temporary barricades and doors in accordance to 1.08 C&D above. The Contractor shall take all means to alleviate any or all tripping and falling hazards both within the work site but also in public areas. Areas where the general public or passengers may fall shall be secure and covered.

1.09 TEMPORARY SIGNAGE (CONSTRUCTION)

A. The Contractor must provide and install project identification signs to direct the public around the construction site, as determined by the SEPTA PM. These signs must be professionally fabricated and maintained/replaced to keep an “as new” appearance.


1.10 PROTECTION OF NEW WORK AND AREAS OUTSIDE OF THE PROJECT

A. The Contractor shall take all necessary precautions to protect new work (whether executed by himself or others). All damage which does occur shall be repaired to the satisfaction of the SEPTA PM at no cost to SEPTA.

B. The Contractor must avoid damaging all property and facilities not included in the project scope. All damage which does occur shall be repaired to the satisfaction of the SEPTA PM at no cost to SEPTA. If non-SEPTA property is damaged it must be repaired to the written satisfaction of the owner and at no cost to SEPTA.

1.11 DUST CONTROL

A. The Contractor shall take all necessary precautions to eliminate dust and dirt created during the construction process from entering non-project areas and those areas not owned by SEPTA. The Contractor shall be responsible for cleaning affected areas and restoring then to their preconstruction condition to the satisfaction of the property owner and at no cost to SEPTA.

1.12 SECURITY

A. The Contractor shall provide adequate security measures to protect material, equipment, and work from incidental and intentional damage or theft at project site locations, staging areas and fabrication yards.

B. The use of guard dogs and the possession of firearms on SEPTA property are prohibited.

C. The Contractor shall be responsible for supplying the following security measures:

1. Exterior lighting of 20 – 30 lux within the yard areas.

2. 8’ high chain link fence enclosure with gate(s) so the yard areas may be fully secured during non-work periods. Chain link fence fabric to have openings no greater than 2 1/2”.

D. The Contractor shall submit to the Project Manager a plan layout of the security measures within twenty-one (21) days after Notice to Proceed (NTP).

END OF SECTION




SECTION 01505

MOBILIZATION AND DEMOBILIZATION

PART 1 - GENERAL


A. This Section specifies the general requirements for Mobilization and Demobilization on the Wayne Junction SFC Rehabilitation Project.

B. The work under this section includes all labor, equipment, and materials associated with setting up the project work site and dismantling and removing such items at the end of the Project.

C. The work includes but is not necessarily limited to:

1. Project Work Signs

2. Initial Project Setup

3. Final Cleaning

4. Restoration of surfaces and repairs

5. Disposal of all debris and excess materials

D. SEPTA will allocate an area for equipment storage, laydown areas and office space for use by the Contractor. The availability of laydown areas may be limited. Unless otherwise directed by the Contract Documents, the Contractor shall make off-site arrangements for storage, staging, and deliver material to the site as required to not affect work progress of other Contractors and/or create unsafe conditions. All temporary facilities associated shall be at the Contractor’s expense.

E. Access to the worksite shall be arranged by the Contractor in coordination with SEPTA.

1.02 RELATED WORK

A. Section 01500 – Construction Facilities & Temporary Controls

B. Section 01580 – Project Identification Signs and Other Construction Signage

C. Section 01700 – Project Closeout

D. Section 01710 – Final Cleaning

1.03 SUBMITTALS

A. Submit within twenty-one (21) days after the Notice to Proceed, a layout of the proposed construction site including fences, roads, buildings, trailers and storage areas. If non-SEPTA property is to be utilized, submit a proposal and obtain tentative approval for this arrangement before committing to any lease arrangements or other legal agreements for the use of this land.

PART 2 - PRODUCTS


2.01 PLANT AND EQUIPMENT

A. Construction plant and equipment shall be of the capacity, type, quality, function and in the quantity necessary for the timely prosecution of the Work.

PART 3 - EXECUTION

3.01 GENERAL

A. Construction plant, equipment, materials, supplies, temporary buildings, facilities and other items necessary for mobilization shall be available at the work site at the times they are to be built, used, installed or operated.

B. Construction plant location shall be approved by SEPTA and shall be appropriately close to the portion of the Work for which it will be used. The construction plant, including equipment and personnel, shall have sufficient capacity, in the opinion of the Project Manager, to permit a rate of progress which will ensure completion of the Work within the contract time required by the Agreement and shall also have sufficient excess capacity for emergencies and overloading.

C. The Project Manager shall have the right to reject construction plants and apparatus which, are in its opinion, unsafe, improper, or inadequate. Rejected construction plants and apparatus shall be brought to acceptable condition or shall be removed from the jobsite by the Contractor.

3.02 DEMOBILIZATION

A. Upon completion of the Work. The Contractor shall remove construction plant, equipment, materials, supplies, temporary building, facilities and other items that were necessary for mobilization. The Contractor shall return the area allocated for the construction plant to its condition prior to the start of the Work.

END OF SECTION


SECTION 01600

MATERIAL AND EQUIPMENT

PART 1 - GENERAL


A. Work of this Section includes:

1. Manufacturer’s Recommendations

2. Fulfilling SEPTA sustainability goals and the reuse of materials

3. Transportation and handling

4. Storage and protection

5. Repairs and replacements

6. Product options

1.02 RELATED WORK

A. SEPTA Agreement,



D. Section 01060 – Regulatory Requirements and Safety

E. Section 01300 – Submittals


G. Section 01410 – Testing and Inspection Services

1.03 QUALITY ASSURANCE:

A. The Contractor shall include in its Quality Assurance Program all procedures that are required to assure the proper handling, storage and installation of all materials and equipment.

B. The Contractor must identify the country of origin for all materials subject to source restrictions such as the “Buy America” requirements. Specifically stated relief, including acknowledgement of the country of origin, from these regulations must be obtained in writing before installation of any non-conforming material. Merely obtaining clearance for non-conforming material through the submittal process, even if the country or origin is stated, shall not be interpreted as providing this relief.

C. The Contractor shall turn over copies of all bills of lading, packing slips, labels, quality assurance test results and other information which establishes that materials delivered to the job site are consistent with the requirements of the Contract Documents to the SEPTA PM.

D. The Contractor shall maintain on site a copy of storage and installation instructions and Material Safety Data Sheets for all materials being used in the project.


1.04 MANUFACTURERS’ RECOMMENDATIONS:

A. The Contractor shall comply with manufacturers’ recommendations on product handling, storage, and protection except as noted in the Contract Documents, or otherwise approved by SEPTA.

B. If the Contract Documents deviate from any manufacturer’s recommendations for material utilization and/or installation, the Contractor shall bring this to the attention of the SEPTA Project Manager and obtain clarification before proceeding.

1.05 FULFILLING SEPTA SUSTAINABILITY GOALS AND THE REUSE OF MATERIALS

A. For materials identified elsewhere as required to meet specific sustainability goals, the Contractor will keep all documentation necessary to establish that specific materials were used in a manner which meets these requirements.

B. The Contractor shall not reuse materials and equipment found on the existing premises, except as specifically called for by the Contract Documents, or as approved through the change order process. If materials are called to be reused, their use shall be documented to the satisfaction of the SEPTA Project Manager and in sufficient detail to fulfill all sustainability documentation requirements.

1.06 TRANSPORTATION AND HANDLING

A. The Contractor shall transport and handle products in accordance with manufacturer’s instructions. Excessive damage during transport and unloading, as judged by the SEPTA PM, may be grounds for rejection of that material.

B. The Contractor shall promptly inspect shipments to ensure that products comply with requirements, quantities are correct, and products are undamaged.

C. The Contractor shall provide equipment and personnel to handle products by methods to prevent soiling, disfigurement, or damage.

D. The Contractor shall deliver and have delivered products to the job site in their manufacturer’s original container, with labels intact and legible.

1. The Contractor shall maintain packaged materials with seals unbroken and labels intact until time of installation.

2. The Contractor shall promptly remove damaged material and unsuitable items from the job site, and promptly replace with material meeting the specified requirements, at no additional cost to SEPTA.

E. SEPTA may reject, as non-complying, material and products that do not bear satisfactory identification as to manufacturer, country of origin, grade, quality, and other pertinent information.

1.07 STORAGE AND PROTECTION

A. The Contractor shall store and protect products in accordance with manufacturers’ instructions, with seals and labels intact and legible.

B. The Contractor shall store sensitive products in weather tight, climate controlled enclosures.

C. For exterior storage of fabricated products which are intended for exterior installation; the Contractor shall provide above ground sloped supports as a minimum storage strategy.


Components shall be appropriately protected from the weather. This storage is subject to the approval of the SEPTA PM.

D. SEPTA will allocate an area for equipment storage, laydown areas and office space for use by the Contractor. The availability of laydown areas may be limited. Unless otherwise directed by the Contract Documents, the Contractor shall make off-site arrangements for storage, staging, and deliver material to the site as required to not affect work progress of other Contractors and/or create unsafe conditions. All temporary facilities associated shall be at the Contractor’s expense.

E. The Contractor shall protect all finished surfaces and equipment.

F. The Contractor shall provide protection for finished floor surfaces prior to allowing equipment or materials to be moved over such surfaces.

G. The Contractor shall maintain finished surfaces and equipment clean, unmarred, and suitably protected until final acceptance by SEPTA.

1.08 REPAIRS AND REPLACEMENTS:

A. In event of damage, the Contractor shall promptly make replacements and repairs at no additional cost to SEPTA. Do not install damaged material.

B. Additional time required to secure replacements and to make repairs will not be considered by SEPTA as justification for extension to Contract time.

1.09 PRODUCT OPTIONS & SUBSTITUTIONS

A. If a product becomes unavailable during the construction process, the Contractor must submit an alternative following the normal submittal review process in Section 01300. Under no circumstances may a Contractor install an alternate material from that which was submitted, no matter how closely the substitute resembles the original, without the written permission of the SEPTA PM.

END OF SECTION




SECTION 01612

DELIVERY, STORAGE & HANDLING – TRACTION POWER EQUIPMENT

PART 1 - GENERAL


A. Deliver, store, and handle all equipment from manufacturing plants to the construction site or Contractor provided storage facility. Pack, load, transport and unload all equipment. Access to the site is by public roads.

B. Accept the delivered equipment and check for any damage that may have occurred during shipment. Replace any damaged equipment.

C. Pay all costs associated with equipment shipping including transportation costs, insurance, and custom's fees. Obtain all relevant shipping approvals and permits prior to shipping.



B. Section 01452 – Contractor Quality Control – Traction Power Equipment

C. Section 01752 – Spare Parts and Maintenance Materials





H. Section 16050 – Basic Electrical Materials and Methods

I. Section 16052 – General Electrical Requirements – Traction Power Equipment

J. Section 16060 – Grounding and Bonding

K. Section 16075 – Electrical Identification

L. Section 16262 – Static Frequency Converter

M. Section 16290 – Protective Devices and Instrument Transformers

N. Section 16310 – Transmission and Distribution

O. Section 16330 – Medium Voltage (2-Pole) Breakers, Switching & Protection

P. Section 16335 – Surge Arresters

Q. Section 16791 – Combined Relay and Control Switchboard

R. Section 16910 – Electrical Systems Control (SCADA)

S. Section 16970 – Electrical Testing – Traction Power Equipment

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION


3.01 PREPARATION

A. General

1. Pack all equipment into crates or containers in accordance with manufacturer’s recommendations. Pack in a dry and clean area. Wrap all equipment in weatherproof coverings to protect the equipment from moisture and dust. Pad all equipment for protection against mechanical damage.

2. Provide adequate quantity of desiccants to keep the moisture out of the equipment crates and containers. Provide additional quantity of desiccants for travel over oceans and waterways and provide packing which shall prevent damage from water spray.

3. Brace all crates or containers to protect the equipment against damage due to vibration.

4. Provide recording tilt and impact indicators prior to shipping any SFC equipment, transformers and switchgear assemblies. The indicators shall record tilts of more than 20 degrees and impacts of more than 0.5 g in any direction. The indicators shall not be removed until the equipment is in its permanent installed position.

5. SEPTA shall inspect the indicators before the equipment is unloaded from its carrier and again after it is in its permanent installed position before the indicators are removed.

6. Survey the route to verify no delivery conflicts. Ensure that the all equipment can be delivered to site by road trailers.

7. Ship equipment only upon written approval from SEPTA. Ship only equipment in mint condition. Inspect content of all packages prior to shipping and upon arrival.

8. Deliver all products to the site in the manufacturer's original packing. Upon arrival at site, verify that no damage has been caused in transit.

9. Provide sufficient notice to SEPTA before unloading the SFC equipment and switchgear assemblies to enable witnessing the same.

10. In the event that components are missing, inform the equipment supplier immediately and request advice from SEPTA on how to proceed.

11. In the event of damage, inform the shipper, SEPTA, and the equipment supplier immediately and request advice on how to proceed. Take photographs of the damaged equipment.

12. Ensure the test equipment against damage and loss in shipment or during use.

B. Switchgear and Circuit Breakers

1. Factory wire, adjust, and test switchgear and circuit breakers before shipment to ensure completeness, adequacy and proper functioning of equipment for the application intended. Short the secondaries of the current transformers before dispatch.

2. Determine the size of the lineup during equipment design. Survey the route early and confirm the delivery of each lineup as one unit to SEPTA.

3. Ship the switchgear in the largest factory assembled units that can be handled by shippers and by installation crew on site.


a) Deliver each lineup as a complete factory-wired and factory-tested unit ready to be installed on site.

b) If constrained by transportation limitations, deliver each bus section as a factory wired and factory-tested unit.

3.02 STORAGE AND HANDLING

A. Store all products in an environment recommended by the manufacturer of the product.

B. Immediately upon arrival at the site or the staging area, store the equipment in dry place protected from the elements. Provide temporary power supply to the SFC equipment, switchgear and control cabinet anti-condensation space heaters to prevent damage from condensation.

C. Indoor Equipment

1. Store all indoor equipment, such as the SFC equipment, batteries and chargers, SFC Control Panels and SCADA RTU, indoors until the time when the SFC buildings are ready to accept the equipment.

2. Store the equipment in weatherproof coverings in a dry and ventilated area in accordance with manufacturer’s recommendations.

D. Outdoor Equipment

1. Store all outdoor equipment, such as filter assemblies, transformers, circuit breakers, disconnect switches and surge arresters, duly protected from weather until the time the concrete pads and steel structures are installed and ready to accept the equipment.

E. Ensure that no condensation takes place in any control cabinets.

END OF SECTION




SECTION 01700

CONTRACT CLOSEOUT

PART 1 - GENERAL


A. This Section specifies the requirements for closing out the Contract and supplements requirements specified in Paragraph XII of the Agreement.

B. Contract closeout is the term used to describe the collective requirements that are to be fulfilled at the end of the Contract term in preparation for final acceptance and occupancy of the Work by SEPTA, as well as final payment to the Contractor and the completion of the Contract.

C. Prior to the completion of the whole project, and at the discretion of the SEPTA PM, a Certificate of Substantial Completion may be issued for portions of the Work completed to the full satisfaction of SEPTA in accordance with 1.03 below.

1.02 RELATED DOCUMENTS

A. Agreement

B. Section 01710 – Final Cleaning

C. Section 01720 – Project As-Built Documents

1.03 PREREQUISITES TO SUBSTANTIAL COMPLETION

A. General: The Contractor shall complete the following before requesting the Project Manager’s inspection for certification of substantial completion for the Work of the Contract. The Contractor shall list known exceptions in the request.

1. In the progress payment request that coincides with, or is the first request following the date substantial completion is claimed, activities should be either 100 percent complete for the portion of the Work claimed as “substantially complete,” or provide a list of incomplete items, the value of incomplete Work, and reasons for the Work being incomplete. Include supporting documentation for completion as indicated in the Contract Documents.

2. Submit written certification to the Project Manager that the project, or designated portion thereof, is substantially complete.

3. Submit the list of items to be completed or corrected and material delivery dates of major items, as applicable.

4. Advise SEPTA of pending insurance change-over requirements.

5. All contract record documents, maintenance manuals, warranties, and bonds shall be submitted as defined in the Agreement and Sections 01720 and 01830.

6. Obtain and submit releases enabling SEPTA full, unrestricted use of the Work and access to services and utilities. Where required, include occupancy permits, operating certificates and similar releases.

7. Deliver any access tools and material stock as required and further defined in Section 01830.


8. Start-up testing and demonstration of equipment and systems shall be completed as specified in Section 01822.

9. Discontinue or change over and remove temporary facilities and services from the project site as directed by the Project Manager along with construction tools and facilities, mock-ups, and similar elements.

10. Touch up and otherwise repair and restore marred exposed finishes.

11. All building operations, maintenance and owner education instructions for the SEPTA’s personnel shall be completed as defined in Section 01830.

B. Inspection Procedures: Upon receipt of the Contractor’s request and submittal for inspection, the Project Manager will either proceed with inspection or advise the Contractor of unresolved prerequisites.

1. Following the initial inspection or before (see below), the Project Manager will either prepare the Certificate of Substantial Completion or advise the Contractor of Work which must be performed before the certificate will be issued. The Project Manager will repeat the inspection when requested and when assured that the Work has been completed.

2. SEPTA reserves the right to halt inspections at any time if in the opinion of the SEPTA PM, the incomplete items of work are either too numerous or too complex to qualify the project as substantially complete.

3. Results of the completed inspection will form the initial “punch list” for final acceptance but this list may be modified at the discretion of the SEPTA PM.

4. The “punch list” shall include a reasonable time period to effectuate the work, which is mutually agreed upon by all parties.

1.04 PREREQUISITES TO FINAL ACCEPTANCE

A. General: The Contractor shall complete the following before requesting the Project Manager’s final inspection for certification of final acceptance and final payment as required by the Agreement, specifically sections regarding the Contractor and Payment and Completion. The Contractor shall list known exceptions, if any, in the request.

1. Submit the final payment request with final releases and supporting documentation not previously submitted and accepted. Include certificates of insurance for products and completed operations where required.

2. Submit an updated final statement to account for final additional changes to the Contract sum.

3. Submit a Certified copy of the Project Manager’s final “punch list” which documents all work which has been completed.

4. Submit final meter readings for utilities, a measured record of stored fuel and similar data as of the date of Substantial Completion or as of the date SEPTA took possession of and responsibility for corresponding elements of the Work, if required. The Coordinating Contractor will pay the utility bills and SEPTA will not be involved.

5. Submit Consent of Surety. Affidavit of Payments of Debts and Claims, Affidavit of Release of Liens. General Release by Trade Contractor of Owner, Guarantee against Defects, any Warranties and Maintenance Bonds. Any special


documentation such as copy of Engineer or DER Permits or Certification of Occupancy.

6. Submit evidence of final, continuing insurance coverage, which complies with Contract insurance requirements.

7. Submit any remaining record documents and drawings, maintenance manuals, final project photographs, damage or settlement survey, property survey, and similar final record information.

8. The Contractor shall also issue final project records in an electronic format. Electronic files shall be in a format approved by the SEPTA PM for each specific item. Electronic files shall be organized and named per applicable section or naming protocol as provided by the SEPTA PM.

9. The SEPTA PM may elect progressive submissions of specific listed items during the course of the work. Electronic files shall be created for the following items:

a) Submittals

b) Construction Permits

c) Certificate of Use and Occupancy

d) As-Built Drawings

e) Manufacturer’s OEM manuals.

f) Manufacturers’ Warrantees

g) Construction Photographs

h) Approved Shop Drawings

i) Testing Service Results

j) Concrete Delivery Forms

k) Steel Certifications

l) UL Inspections

m) Survey Log Records

n) Drilling log Records

o) All Engineering, design and calculations

p) Documentation required by regulatory requirements.

q) Soil Management documentation including but not limited to testing results, soil disposal documentation, chain of custody and permissions, & disposal records

r) Accident Reports

B. Re-inspection Procedure: The Project Manager will re-inspect the Work upon receipt of the Contractor’s notice that the Work, including “punch list” items resulting from earlier inspections, has been completed except for those items whose completion has been delayed because of circumstances that are acceptable to the Project Manager.

1. Upon completion of re-inspection, the Project Manager will either prepare a Certificate of Final Acceptance or will advise the Contractor of Work that is


incomplete or of obligations that have not been fulfilled but which are required for final acceptance.

2. SEPTA reserves the right to halt inspections at any time if it becomes apparent that the incomplete items of work are either too numerous or too complex to qualify the project as substantially complete.

3. If necessary, the re-inspection procedure will be repeated.

END OF SECTION


SECTION 01720

PROJECT AS-BUILT DOCUMENTS

PART 1 - GENERAL


A. The Contractor, throughout progress of the Work, shall maintain an accurate record of changes to the Contract Drawings and Specifications.

B. The Contractor shall at the time of substantial completion, but prior to requesting release of retainage, transfer the changes to a set of Final As-Built Documents, which shall include an As-Built set of Construction Drawings and an annotated set of Specifications.

C. The Contractor shall in addition to the defined requirements to provide paper copies, also provide approved Final As-Built Documents in an electronic format for SEPTA’s future use. The format of these electronic files shall be approved by the SEPTA PM prior to submission.

1.02 RELATED WORK

A. Documents affecting work of this Section include, but are not necessarily limited to, the Agreement and Division 1 of these Specifications.

B. Other requirements affecting Project As-Built Documents may appear in other pertinent sections of these Specifications.

1.03 SUBMITTALS

A. The Contractor shall comply with pertinent provisions of Section 01300.


A. Accuracy of Records:

1. The Contractor shall thoroughly coordinate changes within the As-Built Documents, making adequate and proper entries on each page of Specifications and each sheet of Drawings and other documents where such entry is required to show the change properly.

2. Accuracy of records shall be such that investigations to determine actual installed items may rely reasonably on information obtained from the approved Final Record Documents.

B. The Contractor shall make entries on the As-Built Documents on a weekly basis to include all changes to the Work performed during the last week to confirm they are an accurate representation of the As-Built conditions.

C. The Contractor shall transfer “job set” information to a set of Final As-Built Documents in a neat and professional manner.


A. The Contractor shall maintain the “job set” of Record Documents completely protected from deterioration and from loss and damage until completion of the Work and transfer of all recorded data to the Final As-Built Documents.


PART 2 - PRODUCTS

2.01 RECORD DOCUMENTS

A. Job Set:

1. Following receipt of SEPTA’s Notice to Proceed, the Contractor shall secure from SEPTA one complete set of all drawings and specifications comprising the Contract Documents. This “job set” will be maintained at the site to record all As-Built changes.

B. Final As-Built Documents:

1. The Final As-Built Documents are to include:

a) Updated As-Builts of the original Contract Drawings.

b) Additional As-Built Drawings as necessary, to describe changes during the Contract period that could not be included on the original Contract Drawings.

c) Annotated Specifications to include Contract Specifications with all changes made during the Contract period.

d) “As installed” versions of same size drawings of all fabrication, detail and installation drawings.

PART 3 - EXECUTION

3.01 MAINTENANCE OF JOB SET

A. The Contractor shall, immediately upon receipt of the job set described in Paragraph 2.01, A. above, identify each of the Documents with the title “AS-BUILT DOCUMENTS - JOB SET.”

B. Preservation:

1. The Contractor shall devise a suitable method for protecting the As-Built Job Set (job set) in consideration of the Contract duration, the probable number of occasions upon which the job set must be taken out for new entries and for examination; the transfer of information on Final As-Build Documents; and the conditions under which these activities will be performed.

2. The Contractor shall not use the job set for any purpose except entry of new data, for review by SEPTA and for the transfer of data to Final As-Built Documents.

3. Maintain the job set at the site of Work.

C. Making entries on Drawings:

1. The Contractor shall utilize an erasable colored pencil (not ink or indelible pencil) to clearly describe the change by graphic line and note as required.

2. The Contractor shall date all entries.

3. The Contractor shall call attention to the entry by a “cloud” drawn around the area or areas affected.

4. The Contractor shall in the event of overlapping changes, use different colors for the overlapping changes.


D. Revisions:

1. The Contractor shall transfer all changes to respective Specifications and/or Drawings set (if appropriate) immediately, as the change is approved.

2. The Contractor shall make appropriate entries in the drawings as soon as the change is incorporated in the field.

E. Conversion of schematic layouts:

1. The Contract drawings may indicate arrangements of conduits, circuits, piping, ducts, and similar items shown schematically, and is not intended to portray precise physical layout.

2. Final physical arrangement is determined by the Contractor, subject to SEPTA’s written approval. However, design of future modifications of the facility requires accurate information as to the final physical layout of items, which must be schematically shown on the Final As-Built Drawings.

3. Show on the job set of As-Built Drawings, by dimension accurate to within English Dimensioning Standards, the center-line of each run of items such as are described in subparagraph 3.01E.1, above.

a) The Contractor shall clearly identify the item by accurate note such as “cast iron drain”, “galv. conduit,” and the like.

b) The Contractor shall show, by symbol or note, the vertical location of the item (“under slab,” “in ceiling plenum,” “exposed,” and the like).

c) The Contractor shall make all identification sufficiently descriptive that it may be related reliably to the Specifications.

3.02 FINAL PROJECT RECORD INFORMATION

A. The purpose of the Final Project As-Built Documents is to provide factual information regarding all aspects of the Work, both concealed and visible, to enable future modifications of the Work to proceed without lengthy and extensive site measurement, investigation, and examination.

B. Accuracy of Record Data Prior to Transfer:

1. The Contractor is solely responsible for accurate transfer of all field changes and preparing additional reproducible drawings and specification pages.

C. Transfer of Data to Drawings:

1. The Contractor shall carefully transfer change data shown on the job set to the Final As-Built Documents coordinating the changes as required.

2. The Contractor shall clearly indicate at each affected detail and master drawing a full description of changes made during construction, and the actual location of items.

3. The Contractor shall call attention to each entry by drawing a “cloud” around the areas affected.

4. The Contractor shall make changes neatly, consistently, and with the proper media to assure longevity and clear reproduction.


5. The Contractor shall prepare additional reproducible drawings in the same size as the original contract drawings for changes to details (including installation and fabrication drawings) incorporated in the construction that could not be corrected on the As-Built drawings. These drawings shall be adequately identified and cross-referenced with pertinent Drawing(s) to make it part of the Final As-Built Documents.

D. Transfer of Data to Specifications:

1. The Contractor shall accurately and legibly transfer all information from job set to Final Annotated Project Record Specifications Set.

E. Review and Submittal:

1. The Contractor shall submit the completed set of Final As-Built Documents to SEPTA.

2. The Contractor shall participate in review meetings as required.

3. The Contractor shall make required changes and promptly deliver the Final Project As-Built Documents to SEPTA.

4. The Contractor shall sign each sheet of the record drawings, certifying that they are an accurate representation of the As-Built condition.

5. The Final approved set of As-Built Documents shall be delivered to SEPTA at the conclusion of the project. The Record Drawings submission shall include two (2) sets of black-line prints and a duplicate set of CD’s (2 sets). Supporting studies, field surveys, calculations, etc., (one set of each) shall also be delivered to SEPTA with the Record Drawings.

3.03 CHANGES SUBSEQUENT TO ACCEPTANCE

A. The Contractor has no responsibility for recording changes in the Work subsequent to Final Completion, except for changes resulting from work performed under Warranty.

END OF SECTION


SECTION 01752

SPARE PARTS AND MAINTENANCE MATERIALS

PART 1 - GENERAL


A. Furnish all spare parts required for operation and maintenance of the supplied equipment and systems.

B. Furnish complete sets of special tools and test equipment required for maintenance and testing of the systems supplied including thermographic test equipment as specified below.

C. Set up inventory of all spare parts, special tools, and test equipment in SEPTA’s facility.




C. Section 01612 – Delivery, Storage, and Handling – Traction Power Equipment





H. Section 16050 – Basic Electrical Materials and Methods

I. Section 16052 – General Electrical Requirements – Traction Power Equipment

J. Section 16060 – Grounding and Bonding

K. Section 16075 – Electrical Identification

L. Section 16262 – Static Frequency Converter

M. Section 16290 – Protective Devices and Instrument Transformers

N. Section 16310 – Transmission and Distribution

O. Section 16330 – Medium Voltage (2-Pole) Breakers, Switching & Protection

P. Section 16335 – Surge Arresters

Q. Section 16791 – Combined Relay and Control Switchboard

R. Section 16910 – Electrical Systems Control (SCADA)

S. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS

A. Submit the following documents for SEPTA’s review and approval:

1. Preliminary and final list of all recommended spare parts, special tools, and test equipment.

2. Spare parts, special tools, and test equipment catalog including the following:


a) Inventory of all spare parts, special tools, and test equipment.

b) Fixed unit price for all spare parts valid for two (2) years after substation acceptance by SEPTA.

c) Statement that guarantees availability of all spare parts, special tools, and test equipment for a period of twenty (20) years after substation acceptance by SEPTA.

3. Provide computer-based inventory for all spare parts, special tools, and test equipment.

B. Provide the following submittals in hard copy and electronic format:

1. Manufacturer’s descriptive literature

2. Product specifications and performance data

3. Calibration requirements and instructions

4. List of recommended service centers for warranty administration and repair services

5. Operation and Maintenance Manual

6. Spare parts list

7. All required software


A. Comply with applicable provisions of the most recent issues of the following reference:

1. NFPA 70E Electrical Safety Requirements for Employee Workplace

PART 2 - PRODUCTS

2.01 SPARE PARTS

A. Spare Parts for Warranty Repairs

1. Spare parts ordered by SEPTA for support of revenue operations shall not be utilized by the Contractor for warranty repairs and warranty parts replacements.

2. Spare parts required for use by the Contractor to provide warranty support are the responsibility of the Contractor. SEPTA will not be responsible for receiving or storing any parts for warranty support.

3. At the end of the warranty period, SEPTA will consider a negotiated price for purchase of all spare parts stocked by the Contractor for warranty support.

2.02 SPECIAL TOOLS

A. Special tools include crimping tools, jigs, fixtures, equipment, hand tools, power tools, circuit-board testers, and other tools and equipment necessary to maintain, repair, overhaul, assemble, and disassemble the equipment, that are not commonly available from commercial tool suppliers.

B. Any tool that is not found in the catalog or showroom of the following companies is considered a special tool: Sears, AeroQuip, Grainger, Snap-On, AMP, MAC, Williams, Black & Decker, Black Hawk, Starrett, ACE Hardware, Hilti, Home Depot, and Lowe’s.


C. Contractor shall provide fall protection based on the highest standard at the time of construction, with zero fall arrest. Protection shall be suitable for use with the fall protection facilities provided on SEPTA substation transformers. Fall protection system at the transformer shall mount to plates fixed to the equipment and shall have a minimum, individual personnel working load capability of 350 lbs. and rated for 2 users. Tower systems manufactured by Winsafe Corporation or equal will be suitable.

2.03 TEST EQUIPMENT

A. Provide portable high-pot testers, meggers, relay test sets, transducer test and calibration sets, converter test and calibration sets, and printed circuit board testers to test all equipment supplied.

B. Furnish all equipment complete with all cables, connectors, probes, and associated equipment to interface with the test points. Provide carrying case for each item of equipment.

C. Furnish self-contained, solid-state, programmable test and calibration equipment with LCD indicating analog and digital displays of appropriate variables, including, but not limited to, volts, and amperes, phase angle degrees.

D. Supply test units to allow rapid identification of failures on individual assemblies to the lowest level replaceable unit (LLRU). Furnish test equipment using guided-probe technology to the maximum degree possible to test, troubleshoot, and calibrate all electrical, electronic, mechanical, and electro-mechanical components.

E. All test and calibration equipment shall be designed to generate accurate signals for testing of the connected equipment. Adjustment of signals shall be independent of each other.

F. Use hook-up multi-conductor cables with multi-pin connectors, as appropriate, to establish all connections required. No high-voltage connections to the test equipment are allowed.

G. Provide diagnostic laptop computers, complete with all Operations and Maintenance Manuals, diagnostic software, and inventory software loaded. Provide all cables and hard cases.

H. All desktop test equipment shall operate on 120 VAC, 60 Hz. All portable test equipment shall operate on rechargeable batteries. Furnish rechargeable batteries, chargers, and adaptors, as required.

2.04 THERMOGRAPHIC TEST INSTRUMENT

A. General Requirements:

1. Provide a portable, handheld, thermal infrared imager of rugged, durable, compact, and lightweight construction housed in a non-conductive and insulating enclosure.

2. Provide an instrument suitable for specific intended use within electrical preventative maintenance applications to determine electrical equipment hot spots from a safe visual distance away from the equipment and capable of providing images in compliance with NFPA 70E electrical arc-flash hazard access limitations.

3. Imaging procedure must be totally self-contained to a handheld unit, without the use of any additional umbilical connecting cords, battery packs, or remote processing equipment. Provide simple operating controls and adjustments that do not take extensive field manipulations, tools, setups or pre-calibrations.


4. Fully test and calibrate the thermal imager equipment prior to delivery. Demonstrate calibration in the field.

B. Provide the instrument with full complement of accessories, including:

1. Rechargeable battery that can operate the instrument continuously for a minimum period of 3 hours without recharge. Include two (2) additional spare batteries.

2. Removable battery pack capable of accepting standard and rechargeable type cell batteries.

3. Permanent charger station for docking and recharging the instrument when not in use, including:

a) Battery charging indicator lights on the instrument and on the docking station to indicate Charging in Progress and Charging Complete.

b) Standard 120 Vac, 60 Hz line cord.

4. USB 3.0 computer cable port connectors and associated cable, 5 feet minimum, for I/O exchange between the instrument and computer.

5. Impact-resistant, carrying, suitcase type protective hard case, capable of holding the instrument, all its accessories, and spare batteries. Provide the case with case handles, toggle latches, and a padlock.

6. Protective covers to protect the lens, displays, and connection ports when not in use.

7. Vial of any special required lens cleaner that is not otherwise commercially available.

8. All supporting computer software and hardware that is fully compatible with Microsoft Windows XP®, or newer operating systems.

9. Additional Accessories. Provide the following additional accessories:

a) RS-232 to USB 3.0 adapter

b) Wrist strap

c) Neck strap

C. Approved Manufacturers. Supply thermographic test equipment and accessories as manufactured by one of the following approved manufacturers:

1. Raytek Corporation, ThermoviewTM Ti30 Thermal Imager

2. Infrared Solutions, IR-Insight® T Infrared Camera

3. Flir Systems ThermaCam® 25 Infrared Camera

4. Fluke Tix1000 Infrared Camera

PART 3 - EXECUTION

3.01 INVENTORY

A. Provide computer-based inventory for all spare parts, special tools, and test equipment in a format acceptable to SEPTA.


B. Include manufacturer’s catalog number, description, quantity recommended for being stocked as spares, quantity installed in the system, unit production price, subcontractor markup, and price based on the recommended quantities.

3.02 AVAILABILITY OF SPARE PARTS, SPECIAL TOOLS, AND TEST EQUIPMENT

A. Guarantee availability of all spare parts, special tools, and test equipment for a period of twenty (20) years after substation acceptance by SEPTA.

3.03 QUANTITIES

A. Provide as a part of the equipment to be delivered adequate spare parts in sufficient quantities to enable system maintenance for a period of two (2) years after final acceptance by SEPTA. The spare parts shall include, as a minimum, the following:

1. Two-Pole, Live-Tank Circuit Breakers:

a) One each of all types of protective relays

b) One each of the bay modules

c) One each of the indicating instruments

d) Three sets of fuses used in the switchgear lineup

e) Three set of indicating lamps good for replacement of all lamps three times

f) One set of all types of auxiliary relays used in the switchgear

g) One set of auxiliary contacts of one cubicle

h) One pound of the recommended lubricant, if required, to be used for periodical maintenance of the switchgear

i) One set of spare anti-condensation heaters

j) One spare humidistat

k) One hundred feet of each type of control cable used

2. Transformers:

a) One each of each type of protective relays

b) One each of each type of meter or gauge or indicating instruments

c) One set of spare anti-condensation heaters

d) One spare humidistat

e) One set of fuses

f) One set of indicating lamps

g) One set of all types of auxiliary relays used in the transformer

h) One each of the indicating instruments

B. Major Spare Parts

1. Special tools required to enable system maintenance: Two (2) sets

2. Test equipment sets for the systems supplied: Two (2) sets

3. Diagnostic laptop computers: Two (2)


4. Thermographic test instrument: One (1)

a) Rechargeable battery packs: two (2) spare packs in addition to the rechargeable battery pack provided within the test instrument.

C. Flash memory: two (2) spare flash memory packs in addition to memory pack provided with instrument.

END OF SECTION


SECTION 01822

DEMONSTRATION AND TRAINING

PART 1 - GENERAL


A. Conduct demonstration of the installed equipment and systems to SEPTA staff and their representatives.

B. Provide technical support for the delivered equipment. Ensure availability of expert services from various equipment suppliers on short notice to assist SEPTA on-site personnel in investigation and resolution of equipment malfunctions during commissioning and warranty period.

C. Provide training for SEPTA personnel to enable SEPTA staff to operate, service, and maintain the equipment and systems furnished. Commence training only at direction of SEPTA, after approval of training related submittals and delivery of sufficient amount of equipment spare parts and special tools.





D. Section 01752 – Spare Parts and Maintenance Materials


F. Section 09910 – Paints and Coatings

G. Section 16050 – Basic Electrical Materials and Methods




K. Section 16262 – Static Frequency Converter

L. Section 16290 – Protective Devices and Instrument Transformers

M. Section 16310 – Transmission and Distribution

N. Section 16330 – Medium Voltage (2-Pole) Breakers, Switching & Protection

O. Section 16335 – Surge Arresters

P. Section 16791 – Combined Relay and Control Switchboard

Q. Section 16910 – Electrical Systems Control (SCADA)

R. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS



1. Detailed resumes of all technical support and training personnel

2. Training plan

3. Training program

4. Training manuals

5. Training materials

PART 2 - PRODUCTS

2.01 TECHNICAL SUPPORT AND TRAINING PERSONNEL

A. Provide experienced and competent technical support and training personnel who have direct and complete knowledge of the equipment and systems supplied and are capable of providing detailed explanations of the operation and maintenance of all equipment and systems.

B. Provide technical support and training personnel with minimum of 10 years of experience in the design, manufacture, installation, and maintenance of the equipment.

C. All technical support and training personnel shall be fluent in oral and written English, with a complete understanding of the English language.

D. The technical support and training personnel shall be subject to approval by SEPTA. SEPTA reserves the right to request personnel replacement for any reason and have the technical support activity or training subject repeated.

E. Technical support personnel shall be under direction of SEPTA’s management staff, shall be integrated with SEPTA’s staff, and shall participate in activities of SEPTA personnel. The technical support personnel shall be available by phone 24 hours a day, 7 days a week and available for site work within 24 hours, or as may be required by the nature of the problem to be resolved and SEPTA’s working schedule.

F. Ensure that all instructors teaching the training courses are familiar with all technical information and are able to utilize proper methods of instruction, training aids, and audiovisual materials to insure effective presentations.

G. Coordinate with SEPTA to determine the student qualifications, number of students in the class, and the level of training required before preparing the training plan, program, manuals, and materials.

H. Utilization of equipment supplier presenters is encouraged and supported by SEPTA. The Contractor is responsible for scheduling and cost of supplier presenters.

I. Provide Training CD that includes all items indicated in Sections 2.02 & 2.03 of this specification Section 01822 for future training of new employees.

2.02 TRAINING PLAN

A. Develop a training plan. Include in the plan the following:

1. Training course outline, including:

a) Program introduction and overview.

b) Statement of overall program goals.


c) Learning objectives specifically describing the desired knowledge to be gained.

2. Lesson schedule

3. List of printed materials, audio aids, and visual aids to be used during lessons

4. Schedule for written and practical tests

B. As a minimum, include the following topics in the plan:

1. Reliability program support

2. Warranty program support

3. Trouble shooting support

4. Training and continuing education support

5. Technical support for maintenance activities in the field

6. Developing alternative sources of spare parts and maintaining contact with spare part suppliers.

C. The Contractor is responsible for providing any special equipment needed to make the presentations, such as audio visual equipment, blackboards, wipe boards, flip charts, and overhead or slide projectors.

D. SEPTA will assist the Contractor in the set up and tear down of training aids and models used in presentations.

2.03 TRAINING PROGRAM

A. Based on the training plan, develop a comprehensive training program for SEPTA’s personnel to include both classroom and practical hand-on exercise sessions for all equipment, systems and subsystems supplied under the Contract.

B. Arrange the training program in three classes of six participants each. Each class would have personnel of similar technical background.

C. Design the course to cover all necessary details for performance of:

1. Equipment operations and its place in the system

2. Preventive, corrective, and overhaul maintenance

3. Test procedures

4. Equipment safety procedures

D. Conduct the program at SEPTA-provided facilities.

E. Demonstrate the training program to SEPTA’s management. Ultimately, SEPTA will approve the training program.

F. Classes will be held only during daytime. Develop class schedules in coordination with SEPTA.

G. Personnel attending each class will be designated by SEPTA and a list of attending individuals will be provided to the Contractor.


H. Design and give written and practical tests at suitable points of the course to determine the extent to which employees have learned and can apply the information presented. All attendance records and test scores will be kept by SEPTA.

I. Update lesson plans as required during the course of design and construction.

2.04 TRAINING MANUALS

A. Provide separate Training Manuals for operations and for maintenance personnel. SEPTA staff will use the manuals as text books for the training and for future reference.

B. Provide Training Manuals containing the following:

1. A discussion of staff prerequisites

2. Program overview and goals

3. Individual lessons, containing the following:

a) Overview of each lesson and student learning objectives

b) Instructional methods and learning activities

c) Required equipment and resources

d) A fully developed content of each lesson

e) Illustrations, charts, and graphics, as needed, to enhance content of the lessons

C. As a minimum, include the following training topics:

1. Step-by-step introduction to each equipment and system function and operation, including terminology and identification of components.

2. Detailed theory of operation. Explain theoretical background of operation of all equipment being furnished.

3. Routine care including frequency of inspection, cleaning, lubrication, and adjustments. Include manpower and time requirement.

4. Identification of problem symptoms, troubleshooting procedures, and repair procedures. Demonstration of taking out of service, repairing, maintaining, testing, and placing into service all components of the system.

5. Demonstration of shutdown and re-starting procedures.

6. Demonstration of disassembly and reassembly of systems and components.

7. Instruction in the use and maintenance of all special tools and techniques to perform complex maintenance functions in the field and in the shop.

8. Safety instruction for all maintenance activities.

9. Emergency and permanent repair procedures.

D. Provide all illustrations with high resolution presentation suitable for producing a high-quality images when projected on a typical classroom presentation screen.

E. Maintain, upgrade, and update the Training Manuals to include the latest data and information. Such maintenance of the Training Manuals may be performed remotely with notice to SEPTA. With each notice include a list of changes and the location of each change within the Manuals.


F. SEPTA reserves the right to video tape and/or audio tape any or all training presentations and activities by Contractor for its sole use, without costs, obligation, or liability to SEPTA.

G. Prepare the Training Manuals in hard copies and electronic format as specified in Section 01832.

2.05 TRAINING MATERIALS

A. Provide all training aids, audiovisual equipment and visual aids for the courses.

B. Submit all Training Materials for approval. Provide one set of Training Materials per student. The Training Materials shall include all materials for the students to interact in the learning situations.

C. Provide an adequate supply of high quality, professionally prepared authoritative and up-to-date reference materials as well as other training aids necessary to impart the essential knowledge to SEPTA staff.

D. Work closely with SEPTA during development of training materials to ensure that the course organization, content, and overall quality of all training materials meet SEPTA expectations.

E. Use spare parts already supplied to SEPTA to facilitate hands-on training for educational purposes.

F. Restore all equipment utilized for training purposes to as new condition.

G. Illustrate operation of significant components using diagrams or cutaway views.

H. Demonstrate component locations by component cutaways, schematics, and wiring diagrams.

I. All training materials shall become the property of SEPTA at the completion of the training program. SEPTA reserves the right to duplicate, at its expense, all films, slides, view graphs, tapes, and handouts for its sole use.

J. Replace all training damaged materials unless the damage resulted from neglect by SEPTA.

PART 3 - EXECUTION

3.01 DURATION OF TECHNICAL SUPPORT

A. Begin technical support starting on the day of the equipment acceptance.

B. Provide technical support for the period of one (1) year from substantial completion.

Table 01822-1 - Training Requirements

Equipment Length of Training (Hours) Circuit Breakers 72 Transformers 16 Protective Relaying 64 SCADA System 24


3.02 TRAINING REQUIREMENTS

A. Minimum hour of training for each class for each major item of equipment is shown in Table 01822-1.

END OF SECTION



SECTION 01830

OPERATION AND MAINTENANCE DATA

PART 1 - GENERAL


A. Format and Content of Manuals

B. Instruction of SEPTA Personnel

C. Schedule of Submittal

1.02 RELATED WORK

A. Section 01300 – Submittals


C. Section 01410 – Testing and Inspection Services

D. Section 01600 – Material & Equipment

E. Section 01700 – Contract Close Out

F. Section 01720 – Project As-Built Documents

1.03 SUBMITTALS

A. Submit operations and maintenance manuals for each machinery and equipment item as follows:

1. One (1) copy of sample format and outline of contents in draft form with the equipment shop drawings.

2. One (1) copy of complete manual in final form on equipment delivery date for review and comment by SEPTA.

3. Five (5) copies of approved manual after the equipment is installed and ready to test.

4. In addition to the paper copies required elsewhere in this section, all documents, after final approval, will be submitted in an electronic format as approved by the SEPTA PM.

B. Schedule of Submittals


A. Prepare instructions and data by personnel experienced in maintenance and operation of described products.

B. General Requirements for Manuals:

1. Prepare manuals written in clear grammatical English.

2. Manuals furnished may be manufacturer’s standard publications in regard to size and binding provided they comply with specified requirements relative to quantity and quality of information data.


3. Bind manuals within hard or flexible covers. Make illustrations clear, and printed matter, including dimensions and lettering on drawings, easily legible. If reduced drawings are incorporated into manuals, heavy-up original lines and letters as necessary to retain their legibility after reduction. Larger drawings may be folded into manuals to page size.

C. Prepare manuals using the following materials:

1. Loose leaf, on 60-pound, three-hole punched paper.

2. Holes reinforced with plastic cloth.

3. Page size, 11” x 8 ½” (if available) or 280 mm x 215 mm.

4. Foldout diagrams and illustrations.

5. Reproducible by dry-copy xerography method.

6. Oil, moisture and wear-resistant plastic covers.

1.05 FORMAT

A. The Contractor shall prepare data in the form of an instructional manual which conforms to the requirements as outlined below:

(Specify type, number, volume, and quality of manuals and contents, e.g.)

Clearly identify each manual through the front cover with at least the following information: (Description of manual) (Description of equipment or systems) SOUTHEASTERN PENNSYLVANIA TRANSPORTATION AUTHORITY CONTRACT (NAME & PO #) (Name of Contractor) Date:

B. The Contractor shall prepare a Table of Contents for each volume, with each product or system description identified, in three parts as follows:

1. Part 1: Directory, listing names, addresses, and telephone numbers of Architect/Engineer, Contractor, subcontractors, and SEPTA Personnel (including Operations).

a) Title page: Include the name and function of the equipment and manufacturers

b) Table of Contents, in numerical order listing all sections and subsection titles of included diagrams and drawings.

c) Index, in alphabetical order.

d) Front piece: Recognition illustration of the equipment described in the O&M Manual.


2. Part 2: Operation and maintenance instructions, arranged by system and subdivided by specification section. For each category, identify names, addresses, and telephone numbers of subcontractors and suppliers. Identify the following:

a) Significant design criteria

b) List of equipment, including manufacturer’s literature describing each piece of equipment, including major assemblies and subassemblies, and giving manufacturer’s model number drawing number.

c) Parts list for each component (if available):

1) Manufacturer’s literature describing each piece of equipment including major assemblies and subassemblies, and giving manufacturer’s model number and drawing number.

2) “Long-Lead-Time” spare parts list for all spare parts not readily available on the open market or for which it is anticipated ordering and delivery time will exceed ten (10) days.

3) Complete list of parts and supplies, with current unit prices and sources of supply.

4) List of parts and supplies that are either normally furnished at no extra cost with purchase of equipment, or specified herein to be furnished as part of Contract.

5) List of nearest local suppliers for all equipment parts.

d) Operating Instructions:

1) Operation instructions including step-by-step preparation for starting, operation, shutdown and draining, and emergency requirements.

2) Control diagrams, as installed by the manufacturer.

3) Sequence of operation by the control manufacturer.

4) Wiring diagrams, as installed by the manufacturer.

5) Diagrammatic location, functions and tag numbers of each valve.

e) Maintenance instructions for equipment and systems:

1) Maintenance instruction: Include step-by-step procedures for inspection, operation checks, cleaning, lubrication, adjustments, repair, overhaul, disassembly, and reassemble of the equipment for proper operation of the equipment. Include list of special tools, which are required for maintenance with the maintenance information.

2) Possible breakdowns and repairs.

3) Lubrication schedule indicating type and frequency of lubrication.

f) Maintenance instructions for provided equipment finishes, including recommended cleaning methods and materials, and special precautions identifying detrimental agents.


3. Project documents and certificates, including the following:

a) Shop drawings and product data

b) Air and water balance reports

c) Certificates

d) Photocopies of warranties (and bonds).

e) Appendix: Include safety precautions, a glossary, and, if available at time of submittal, copies of test reports, and other relevant material not specified to be submitted.

1.06 CONTENTS, EACH VOLUME

A. Table of Contents: Provide title of Project; names, addresses, and telephone numbers of Architect/Engineer, Sub-consultants, and Contractor with name of responsible parties; schedule of products and systems, indexed to content of the volume.

B. For Each Product or System: List names, addresses and telephone numbers of Sub-contractors and suppliers, including local source of supplies and replacement parts.

C. Product Data: Mark each sheet to clearly identify specific products and component parts, and data applicable to installation. Delete inapplicable information.

D. Drawings: Supplement product data to illustrate relations of component parts of equipment and systems, to show control and flow diagrams. Project As-Built Documents shall not be used as maintenance drawings.

E. Typed Text: As required to supplement product data. Provide logical sequence of instructions for each procedure, incorporating manufacturer’s instructions specified in Section 01400.

1.07 MANUAL FOR MATERIALS AND FINISHES

A. Building Products, Applied Materials, and Finishes: Include product data, with catalog number, size, composition, and color and texture designations. Provide information for re-ordering custom manufactured products.

B. Instructions for Care and Maintenance: Include manufacturer’s recommendations for cleaning agents and methods, precautions against detrimental agents and methods, and recommended schedule for cleaning and maintenance.

C. Moisture Protection and Weather Exposed Products: Include product data listing applicable reference standards, chemical composition, and details of installation. Provide recommendations for inspections, maintenance, and repair.

D. Additional Requirements: As specified in individual Product specification sections.

E. Provide a listing in Table of Contents for design data, with tabbed fly sheet and space for insertion of data.

1.08 MANUAL FOR EQUIPMENT AND SYSTEMS

A. Each item of Equipment and each system: Include description of unit or system, and component parts. Identify function, normal operating characteristics, and limiting conditions. Include performance curves, with engineering data and tests, and complete nomenclature and model number of replaceable parts.


B. Panelboard Circuit Directories: Provide electrical service characteristics, controls, and communications. Directories shall be typed by label machine.

C. Include color-coded wiring diagrams as installed.

D. Operating Procedures: Include start-up, break-in, and routine normal operating instructions and sequences. Include regulation, control, stopping, shutdown, and emergency instructions. Include summer, winter, and any special operating instructions.

E. Maintenance Requirements: Include routine procedures and guide for trouble-shooting, disassembly, repair, and reassembly instructions; and alignment, adjusting, balancing, and checking instructions.

F. Provide servicing and lubrication schedule, and list of lubricants required.

G. Include manufacturer’s printed operation and maintenance instructions.

H. Include sequence of operation by controls manufacturer.

I. Provide original manufacturer’s parts list, illustrations, assembly drawings, and diagrams required for maintenance.

J. Provide control diagrams by controls manufacturer as installed.

K. Provide Contractor’s coordination drawings, with color-coded piping diagrams as installed.

L. Provide charts of valve tag numbers, with location and function of each valve, keyed to flow and control diagrams.

M. Provide list of original manufacturer’s spare parts, current prices, and recommended quantities to be maintained in storage.

N. Include test and balancing reports as specified in Section 01400.

O. Additional Requirements: As specified in individual Product specification sections.

P. Provide a listing in Table of Contents for design data, tabbed, and space for insertion of data.

1.09 INSTRUCTION OF SEPTA PERSONNEL

A. Before final inspection, instruct SEPTA designated personnel in operation, adjustment, and maintenance of products, equipment, and systems, at agreed upon time.

B. Use operation and maintenance manuals as basis for instruction. Review contents of manual with personnel in detail to explain all aspects of operation and maintenance.

C. Prepare and insert additional data in Operation and Maintenance Manual when need for such data becomes apparent during instruction.

END OF SECTION




SECTION 01832

OPERATIONS AND MAINTENANCE MANUALS – TRACTION POWER EQUIPMENT

PART 1 - GENERAL


A. Furnish SEPTA with comprehensive Operations and Maintenance Manuals of all equipment and systems furnished.

B. Prepare manuals uniform in presentation showing all interfaces between equipment and subsystems in sufficient detail to present a complete and clear picture of the equipment and subsystems.

C. Ensure that the nomenclature, functional designations of components and their interconnections are consistent with the As-built Drawings.

D. Provide all information needed for optimum and safe maintenance and repair of the equipment.






E. Section 01822 – Demonstration and Training – Traction Power Equipment





J. Section 16075 – Equipment Identification

K. Section 16290 – Protective Devices and Instrument Transformers

L. Section 16310 – Transmission and Distribution

M. Section 16330 – Medium Voltage (2-Pole) Breakers, Switching & Protection

N. Section 16335 – Surge Arresters

O. Section 16791 – Combined Relay and Control Switchboard

P. Section 16910 – Electrical Systems Control (SCADA)

Q. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS

A. Submit the following Manuals for SEPTA’s review and approval:

1. Operations Manual

2. Preventive Maintenance Manual


3. Corrective Maintenance Manual

4. Heavy Repair Manual

5. Spare Parts Manual

6. Special Tools, and Test Equipment Manual

PART 2 - PRODUCTS

2.01 OPERATIONS MANUAL

A. Provide all information needed for the optimum and safe operation of the equipment, including:

1. General system descriptions and its division into subsystems. General system and subsystems operation. Use block diagrams, as appropriate, to illustrate basic functions of equipment and interfaces between equipment.

2. General systems familiarization material, such as location, function, and operation of controls, gauges, indicators and switches. Use photos, sketches, and cut-section views for explanation.

3. Procedures to enable maintenance staff to operate the individual system components and the system as a whole in its normal and various contingency and emergency modes.

4. Explain, in detail, the operation of switchgear from SCADA, local area network controller (desktop computer), and via local control. Explain various safety interlockings between switchgear and disconnect switches. Explain function of all protective relays in detail.

5. Include step-by-step instructions for equipment energization, operation, normal shutdown, and emergency shutdown. Emphasize the safety precautions to be observed during normal operation, inspection, and before energization after a maintenance shutdown.

2.02 PREVENTIVE MAINTENANCE MANUAL

A. Provide all information needed to enable maintenance staff to perform periodic inspection tasks to keep the system in satisfactory working order.

B. Include all information needed for preventive maintenance, adjustments, and on-line trouble diagnosis of each equipment and system.

C. Include step-by-step procedures for inspection, operation checks, cleaning, lubrication, and adjustments of the equipment.

D. Include maintenance standards, including specifications, wear limits, settings, and tolerances.

E. Provide recommended preventive maintenance schedule for all system components.

F. Provide procedures for equipment removal and re-installation.


2.03 CORRECTIVE MAINTENANCE MANUAL

A. Provide all information needed to enable on-the-line and off-the-line troubleshooting. Include troubleshooting flow charts for diagnosis of breakdowns of all equipment and systems.

B. Include description of trouble symptoms, methods for diagnosing causes of trouble symptoms, and corrective actions.

C. Provide all information needed to enable maintenance staff to troubleshoot, adjust and completely repair all equipment and systems.

D. Include detailed description and operation of each system, using block diagrams, flow diagrams, detailed schematics and functional wiring diagrams.

E. Provide test and repair evaluation procedures.

F. Include safety precautions and procedures, glossary of terms, and other relevant material.

2.04 HEAVY REPAIR MANUAL

A. Provide all information needed to enable maintenance staff to service, maintain, repair, replace, disassemble, reassemble, rebuild, and overhaul the equipment and the system.

B. Include detailed description of procedures for long-term periodic maintenance requirements of all components. Include detailed description of mid-life rehabilitation or replacement of any component, as required.

2.05 SPARE PARTS MANUAL

A. Enumerate and describe every component with its related spare parts.

B. Provide detail drawings of all spare parts. Use drawings showing cutaway isometric and exploded views of subassemblies and components to identify all parts down to the lowest level replaceable unit (LLRU).

C. Include the supplier's number, the commercial equivalents, and SEPTA stock number. The inclusion of SEPTA stock number will require prior submission of the spare parts catalogs to SEPTA for coding.

D. Parts common to different assemblies, such as bolts and nuts, shall bear the same Contractor's number in all assemblies, with an index reference to the other assemblies in which they are found. Each part or subassembly shall be identified as part of a next higher assembly.

E. Commercially available items such as common fastenings, fuses, lamps, fittings, and relays shall be identified in a separate list in the parts catalog by the Contractor’s part number and standard hardware nomenclature, sufficient for ordering these items commercially.

F. Itemize all consumable parts and servicing materials, such as, oils, paints, special compounds, and greases.

G. Provide, at least three supply sources (other than the Contractor) for all required consumables and servicing materials. Of the three required sources, at least two shall be in the United States.

H. Provide complete list of parts and supplies, with current unit prices and sources of supply.

I. Provide a list of all functional components, with manufacturer's model number and manufacturer's part number.


J. Provide long-lead-time spare parts list for spare parts not readily available on the open market or for which it is anticipated ordering and deliver time will exceed 10 days.

K. Provide the last date of manufacturer's warranty and guarantee date.

2.06 SPECIAL TOOLS AND TEST EQUIPMENT MANUAL

A. Provide list of special tools and test equipment for general upkeep, inspection and maintenance of the equipment.

B. Provide instructions and directions on how to use special tools and test equipment.

C. Include setup and testing procedures for all special tools and test equipment and procedures needed for periodic inspection and servicing requirements including lubrication, inspection, and adjustment of all apparatus.

D. Provide instructional manuals and user guides for all special tools and test equipment, including parts lists, diagrams, specifications, schematics, as well as maintenance, calibration instructions, and trouble-shooting procedures.

PART 3 - EXECUTION

3.01 MANUAL FORMAT AND CONTENT

A. Prepare hard copies of the Manuals in the following format:

1. Use loose leaf, 60-pound, punched 8½” x 11” paper with holes reinforced with plastic cloth.

2. Provide pocket folders for foldout diagrams and illustrations. All diagrams and illustrations shall be reproducible by dry-copy xerography method.

3. Bind Manuals in heavy duty, 3-ring vinyl-covered binders, oil-, moisture-, and wear-resistant covers identified on both the front and spine.

B. Include the following in each Manual:

1. Use covers resistant to oil, moisture, and wear.

2. Title Page. Include the Manual title, name and function of the equipment, and illustration of the equipment described in the Manual.

3. Table of Contents. Provide listing of each section and subsection with page numbers. Provide list of included diagrams and drawings.

4. Index. Provide index in alphabetical order.

5. Provide manufacturer’s literature describing each piece of equipment, including major assemblies and subassemblies, and giving manufacturer’s model number and drawing number.

6. Provide control diagrams, sequence of operation diagrams, wiring diagrams, and interlocking diagrams. Reproduce diagrams by photographic process to a size not to exceed 11 inches by 17 inches.

a) Provide only complete, clear, and legible diagrams on white paper. Vacuum-seal the diagrams in transparent plastic material impervious to moisture and oil, and resistant to abrasion.


b) Other formats which are equal in clarity, sharpness, durability and permanence may be considered.

c) Dimensions and lettering on drawings shall be easily legible. If reduced drawings are incorporated into manuals, the original lines shall retain their legibility after reduction. Larger drawings may be folded into manuals to page size. Any reproduction shall be of near perfect quality.

C. Format all data contained in the Manuals consistently from section to section.

D. Manuals consisting of catalog cuts shall not be acceptable.

E. Supply hard copies of all Manuals in approved format and on CD-ROM.

3.02 INTERACTIVE WEB-COMPATIBLE MANUALS SYSTEM

A. Provide all Manuals in Interactive Web-Compatible Manual (IWCM) system based on SGML or HTML in combination with a Web Browser.

B. The IWCM shall contain all functional descriptions, repair procedures, overhaul procedures, and support information for equipment and components in a browsable format. Provide cross references by “hot links”.

C. Users of each Manual in electronic format shall be able to read and scroll through text and illustrations just as if reading a hard copy Manual. The user shall be able to search text and illustrations based on key words, text strings, and part numbers.

D. The IWCM shall be usable on conventional laptop computers, on Internet and Intranet. The system shall be compatible with commonly-available browsers, such as those developed by Microsoft and Google. Provide to SEPTA any other necessary specialized software and hardware required for the system not currently supported by SEPTA.

E. Provide SEPTA Information Technology staff with instructions on development and continued maintenance of the IWCM system.

END OF SECTION




SECTION 05120

STRUCTURAL STEEL

PART 1 - GENERAL


A. This Section covers the design, manufacture, and installation of structural steel framing.



B. Section 01305 – Request(s) for Information

C. Section 01400 – Quality Requirements

D. Section 03600 – Grout

E. Section 05310 – Steel Deck

F. Section 05500 – Metal Fabrications

G. Section 09910 – Paintings and Coatings

H. Section 09960 – High-Performance Coatings

1.03 REFERENCES

A. American Institute of Steel Construction:

1. 2005 Specification for Structural Steel Buildings

2. 2005 Code of Standard Practice for Steel Buildings and Bridges

3. 2004 RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

B. American National Standards Institute:

1. ANSI B18.22.1, Plain Washers

C. American Society for Testing and Materials:

1. ASTM A36, Specification for Carbon Structural Steel

2. ASTM A53, Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless

3. ASTM A123, Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

4. ASTM A153, Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

5. ASTM A276, Stainless and Heat-Resisting Steel Bars and Shapes

6. ASTM A320, Alloy-Steel Bolting Materials for Low Temperatures Service

7. ASTM A325, Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi minimum Tensile Strength

8. ASTM A500, Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes


9. ASTM A563, Specification for Carbon and Alloy Steel Nuts

10. ASTM A572, Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

11. ASTM A780, Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

12. ASTM A992, Specifications for Structural Steel Shapes

13. ASTM B633, Specification for Electro deposited Coatings of Zinc on Iron and Steel

14. ASTM E164, Practice for Ultrasonic Contact Examination of Weldments

15. ASTM E709, Guide for Magnetic Particle Examination

16. ASTM F436, Specification for Hardened Steel Washers

17. ASTM F959, Specification for Compressible-Washer-Type Direct Tension Indicators for use with Structural Fasteners

18. ASTM F1 554, Specification for Anchor Bolts, Steel, 36, 55, and 105 ksi Yield Strength

19. ASTM F1 852, Specification for “Twist Off” Type Tension Control Structural Bolt/Nut/Washer Assemblies, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

D. American Welding Society (AWS): D1.1, Structural Welding Code - Steel

E. The Society for Protective Coatings:

1. Steel Structures Painting Manual (SSPC)

1.04 SUBMITTALS

A. Shop Drawings and Product Data:

1. Submit shop drawings, prepared under the supervision of and sealed by a Structural Engineer licensed in the Commonwealth of Pennsylvania, identifying the details as indicated on Drawings, indicating completely its location in the project, the size and weights of members, the methods of joining various components, the quantity, finish, the location and type of anchors and necessary measurements.

2. For shop assemblies which require markings for erection identification, provide easy-to-read markings on shop and erection drawings.

3. Note on shop drawings variations in tolerances or clearances between various products.

4. Use standard welding symbols of the American Welding Society on shop drawings; show size, length, and type of each weld.

5. Indicate type, size, and length of bolts, distinguish between shop and field bolts. Identify pretension and slip critical, high strength bolted connections

B. Working Drawings:

1. Furnish setting diagrams, templates, and directions for the installation of structural framing anchor bolts, bearing plates, and other embedded items.


C. Job Standards:

1. Submit job standards for typical beam, girder, column splices, and moment connection details prior to submitting detail drawings; standards shall be prepared under the supervision of and sealed by a Structural Engineer licensed in the Commonwealth of Pennsylvania.

D. Connection Calculations: for structural steel connections indicated to comply with design loads, include analysis data signed and sealed by the qualified professional engineer responsible for their preparation.

1. Design all connections in accordance with AISC “Specifications for Structural Steel Buildings.

2. Calculations shall be prepared and sealed by a Structural Engineer licensed in the Commonwealth of Pennsylvania.

3. Use type of shop and field connections shown or, in absence of such indication, use the most appropriate type. Connections shall safely withstand the combined effects of shears, direct forces, moments, and torques at applicable design stresses.

4. Connection details shown on the drawings are illustrative only. Design and detail connections so interference does not occur with architectural clearance lines and finishes. One-sided or other eccentric connections are not permitted unless detailed on the Contract Drawings.

E. Welding Records and Data:

1. Prior to commencing work requiring welding, submit the procedure which will be used for prequalifying welders and welding procedures. For all procedures other than those set forth in AWS D1 .1, submit a copy of procedure qualification test records.

2. Submit certified copy of qualification test record that each welder, welding operator, and tacker who will be employed in the work has satisfactorily passed AWS qualification tests for welding procedures.

3. Submit certified copy of reports for all analyses and tests required by referenced ASTM Specifications, including test reports for filler metals for welding, and mechanical tests for high-strength threaded fasteners.

F. Mill Test Results

1. Submit reports signed by the manufacturer certifying their products comply with requirements specified.

2. Submit test reports certifying material conforms to ASTM or AASHTO specifications.

3. Submit guarantee that all steel used for this project is American-made.

4. Submit written affidavits from steel manufacturer indicating the percentage of post-industrial recycled content (90% min.) and post-consumer recycled content (75% min.)

G. Product Test Reports:

1. Bolts, nuts, and washers including mechanical properties and chemical analysis.

2. Direct-tension indicators.


3. Tension-control, high-strength, bolt-nut-washer assemblies.

4. Shear stud connectors.

5. Shop primers.

6. Non-shrink grout.

H. An Independent Testing Agency shall submit inspection and testing reports required by this Section.

1.05 QUALITY CONTROL

A. Qualifications:

1. Fabricator: Company experienced in fabricating structural steel similar to that indicated for the project who has a successful in- service performance for a minimum of 5 continuous years and sufficient production capacity.

a) Fabricator must participate in the AISC Quality Certification Program and be certified using the criteria of the AISC Certification Standard for Steel Building Structures.

2. Erector: Company experienced in erecting structural steel work similar to that indicated for the project who has a successful in- service performance with a minimum of 5 continuous years of experience.

a) Installer must participate in the AISC Quality Certification Program and is designated an ASIC– Certified Erector, Category CSE.

3. Welder, Tacker, and Welding Operator Qualifications: Use welders, tackers, and welding operators who have been previously qualified by tests as prescribed in the Structural Welding Code, AWS D1.1 of the American Welding Society, to perform type of work required.

B. Comply with applicable provisions listed in those references stated in Article 1.03 of this specification unless otherwise indicated.

C. Materials and fabrication procedures are subject to inspection and tests in mill, shop and field by a qualified inspection agency. Such inspections and tests will not relieve the Contractor of responsibility for providing materials and fabrication procedures in compliance with specified requirements.

1. Promptly remove and replace materials or fabricated components that do not comply.

1.06 DELIVERY, STORAGE, AND HANDLING

A. Deliver materials to site at such times and intervals to ensure continuity of installation and uninterrupted progress of work.

B. Store steel on platforms, skids, blocking or other supports to prevent dirt and debris contact. Protect from exposure to conditions that produce rust.

C. Handle steel so no parts are bent, broken or otherwise damaged and avoid damage to other material and work. Store beams with webs vertical. Exercise care to avoid scraping and over stressing the steelwork.

D. Mark weight on all members. Match-mark all shop pre-fitted members.


E. Ship small parts, such as bolts, nuts, washers, pins, fillers, and small connecting plates and anchors, in boxes, crates, or barrels. Pack separately each length and diameter of bolt and each size of nut and washer. Plainly mark an itemized list and description of the contents on the outside of each container.

F. Replace pieces bent or damaged unless repairs are authorized by the Engineer.

1.07 JOB CONDITIONS

A. Provide anchor rods and other anchorage items to be embedded in or attached to concrete, masonry, or other materials in ample time to not delay work.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Steel:

1. Structural Steel: ASTM A992,

2. Structural Steel Rectangular (Square) HSS Tubing: ASTM A500, Grade C.

3. Structural Steel Round HSS: ASTM A500, Grade C.

4. Structural Steel Pipe: ASTM A53, Grade B.

B. Fasteners:

1. High-Strength Bolted Connections:

a) High Strength Bolts: ASTM A325.

b) Carbon and Alloy Steel Nuts: ASTM A563.

c) Hardened Steel Washers: ASTM F436, Type 1.

d) Direct Tension Indicators (for use in slip-critical connections): ASTM F959, Type 325.

e) Twist – Off – Type Tension Control Bolt Assemblies: ASTM F1852.

2. Unheaded Anchor Rods: ASTM F 1554, Grade 36 or ASTM F 1554, Grade 55, weldable.

a). Configuration: Straight.

b). Nuts: ASTM A 563 heavy-hex carbon steel.

c) Plate Washers: ASTM A 36/A 36M carbon steel.

d). Washers: ASTM F 436, Type 1, hardened carbon steel.

e). Finish: Plain or Hot-dip zinc coating, ASTM A 153/A 153M, Class C.

3. Headed Anchor Rods: ASTM F 1554, Grade 36 or ASTM F 1554, Grade 55, weldable, straight.

a). Nuts: ASTM A 563 heavy-hex carbon steel.

b). Plate Washers: ASTM A 36/A 36M carbon steel.

c). Washers: ASTM F 436, Type 1, hardened carbon steel.

d) Finish: Plain or Hot-dip zinc coating, ASTM A 153/A 153M, Class C.


4. Threaded Rods: ASTM A 36.

a). Nuts: ASTM A 563 heavy-hex carbon steel.

b). Washers: ASTM F 436, Type 1, hardened carbon steel.

c). Finish: Plain or Hot-dip zinc coating, ASTM A 153/A 153M, Class C.

5. Bolt Lubricant: Molybdenum disulfide base.

6. Steel Expansion Anchors and Stainless Steel Expansion Anchors: Conforming to Fed. Spec. FF-S-325 Group II, Type 4, Class 1, such as Hilti Kwik-Bolt, Phillips Red Head Wedge- Anchor, Molly Parabolt or Equal.

7. Adhesive Anchors: Composed of an anchor rod assembly and injection cartridge.

a) Anchor Rod Assembly: Chamfered and threaded rod of ASTM A36 steel with nut and washer. Rod size as indicated on Contract Drawings. Type 316 stainless steel shall be used for locations exposed to cleaning or de-icing chemicals.

b) Injection Adhesive: A mixture of resin, hardener, cement and water to provide optimal curing speed and high strength, furnished in side by side refill packs that keep two components separate until use; alternately, product may be furnished in large rigid cartridges.

c) Acceptable Manufacturers:

1. Hilti Fastening Systems; HIT HY200 SAFE SET.

2. Or Equal.

C. Hardware and Miscellaneous Items:

1. Guard Chain: Individually welded straight link AISC Type 316 stainless steel with stainless steel hook and eyes.

D. Welding Electrodes:

1. AWS D1, Table 3.1, E70XX.

2. Use low-hydrogen electrodes.

E. Paints and Coatings:

1. Painting: Shop prime all steel surfaces with Primer conforming to Section 09910 Paints and Coatings, except for the following:

a) Surfaces embedded in concrete or mortar. Extend priming of partially embedded members to a depth of 2 inches. b) Surfaces to be field welded.

c) Surfaces of high-strength bolted, slip-critical connections.

d) Surfaces to receive sprayed fire-resistive materials (applied

fireproofing).

2. Galvanizing: Steel indicated to be galvanized shall be hot dip galvanized (unless stainless) in accordance with ASTM A123 and subsequently painted in accordance with specification 09960.


a) Coating Weight: Conform to paragraph 6.1 of ASTM A123.

b) Repair areas damaged by welding, flame cutting or during handling, transport and erection by an approved method in accordance with ASTM A780.

c) Galvanizing Repair Paint: ASTM A780.

3. All fasteners and hardware items shall be hot dip galvanized (unless stainless) in accordance with ASTM A1 53, except for high-strength fasteners as noted below.

a) Mechanically galvanize A325 bolts and nuts in accordance with ASTM B695.

F. Headed Stud Type Shear Connectors (Studs): ASTM A 108. Weld in accordance with AWS D1 .1, Section 7, and meet the mechanical properties of Type B studs (Table 7.1).

G. Non-Shrink, Non-Metallic Grout: As specified in Section 03600.

2.02 FABRICATION

A. Fabricate structural steel in accordance with Drawings and referenced AISC standards. Properly mark and match-mark materials for field assembly.

1. Mill ends of columns and other members transmitting loads in bearing.

B. Perform shearing, flame cutting, and chipping carefully and accurately so as not to induce residual stress in the metal being cut. Cut flame-cut edges of members subjected to dynamic loading by a mechanically guided torch or by hand, and remove all nicks. The radii of re-entrant gas-cut fillets shall be not less than 3/4 inch and as much larger as practicable. Perform flame cuttings in such manner that metal being cut is not carrying stress. Exposed edges, flame-cut by hand, shall be finished by grinding.

1. Add additional reinforcing as required where members are cut or coped to meet framing conditions.

C. Arrange bolts as indicated on the drawings, or if not indicated, arrange so that heads (not nuts) show in areas exposed to view. Clearly indicate bolt arrangements on shop drawing submittals.

1. Use special care in handling and shipping members.

2. Weld tabs for temporary bracing and safety cabling at points concealed from view in the completed structure.

D. Connections: Except where welded connections are shown, use ASTM A325 bolts for connections.

E. Bolt Holes: Punch, drill, subpunch, subdrill, and ream holes for bolts as required in accordance with AISC Specifications.

F. Welding: Perform all welding in accordance with AWS D1 .1 except as modified herein.

1. Perform procedure and sequence of welding so as to avoid needless distortion and minimize stresses. Straighten transverse warpage of flanges if necessary by controlled heating along outside face.

2. Make allowance in shop for expected weld shrinkage in laying out and assembling members. Trim members to size only when most or all of welding has been completed.


G. Holes for Other Work: Provide holes required for securing other work to structural steel framing and for passage of other work through members as shown on final approved shop drawings.

1. Ream, drill, or punch holes perpendicular to metal surface. Do not flame cut holes or enlarge by burning.

2. Additional openings in members not shown on final approved shop drawings shall not be performed, approval of the Engineer is required.

H. Unpainted structural steel surfaces shall be cleaned of heavy deposits of oil and grease by applicable AISC standards after fabrication.

I. Hot-Dip Galvanized Finish: Apply zinc coating by the hot-dip process to structural steel according to ASTM A 123.

1. Fill vent and drain holes that are exposed in the finished Work unless they function as weep holes, by plugging with zinc solder and filing off smooth.

2. Galvanize all exterior structural-steel framing, lintels and shelf angles and welded door frames attached to structural-steel frame and located in exterior walls.

PART 3 - EXECUTION

3.01 EXAMINATION

A. Before erection proceeds, verify elevations of concrete and masonry bearing surfaces and locations of anchorage for compliance.

1. Prepare a certified survey of existing conditions. Including bearing surfaces. Anchor rods bearing plates and other embedment’s showing dimensions locations angles and elevations

B. Do not proceed with erection until unsatisfactory conditions have been corrected.

3.02 PREPARATION

A. Provide temporary shores, guys, braces, and other supports during erection to keep structural steel secure, plumb, and in alignment against temporary construction loads and loads equal in intensity to design loads. Remove temporary supports when structural steel, connections, and bracing are in place, unless otherwise indicated.

3.03 ERECTION

A. Erect steel structures true and plumb following the match marks and in accordance with the Drawings, pertinent regulations, and referenced AISC standards.

1. If anchor rods are cast in substructure when it is being constructed, ensure that they are firmly held in their correct position and elevation by suitable templates.

2. Allow concrete foundations to reach a minimum of 14-days curing time before torquing anchor rods.

3. The variation in location of anchor rods and other embedded items from the dimensions shown on the Contract Drawings shall meet the tolerances listed in the AISC “Code of Standard Practice for Steel Buildings and Bridges.”

B. Thoroughly clean surfaces to be joined.


C. Align column bases and bearing plates for beams and similar structural members with steel wedges or shims. After the supported members have been aligned and properly positioned and the anchor nuts have been tightened, dry-pack the entire area under bearing plates with non-shrink non-metallic grout.

1. Apply coal tar epoxy coating to steel below grade.

D. Use temporary bracing to resist loads to which the structures may be subjected, including erection equipment or the operations of same. Leave bracing in place as long as may be required for safety.

E. Report immediately errors in shop fabrication or deformation resulting from handling or transportation, which prevent the proper erection and fitting of parts.

1. Do not field cut or alter structural members without the approval of the Engineer.

F. Bolting:

1. For connections using high-strength steel bolts, conform to requirements of AISC Specifications.

2. Assemble high-strength bolted parts so that they fit solidly together when assembled. Do not use gaskets or any other interposed compressible materials.

3. Remove scale, dirt, burrs, and other defects liable to prevent proper seating when assembling joint surfaces, including those adjacent to washers.

4. Clean oil, paint, or lacquer from contact surfaces of slip-critical joints.

5. Enlarge holes to admit bolts for connections only if approved by the Engineer. Make the enlargement by reaming and not by burning. Avoid hand reaming.

6. For bearing-type connections (snug-tighten), the A 325 bolts should be tightened to a snug tight condition achieved by a few impacts of an impact wrench or the full effort of a man using an ordinary spud wrench to the extent that all plies of the connected material have been brought into snug contact.

7. For slip-critical and pretension connections, tighten the A325 bolts, nuts and direct tension indicators or twist-off-type tension control bolt per AISC specifications.

a) A representative from the direct tension indicator supplier shall be on site during initial tightening to witness and approve degree of tightening to ensure proper tensioning is achieved.

b) Place direct tension indicators under either the bolt head or the hardened washer.

c) If direct tension indicators are placed under the turned element, place a hardened round steel washer between the direct tension indicator and the turned element.

8. Arrange bolts so that heads show in areas exposed to view.

9. Ensure that holes are not enlarged and that the metal in the vicinity of the holes is not disturbed by the drifting occurring during assembly.

10. As erection progresses, perform sufficient bolting of the work to resist dead load and wind and erection loads. Perform permanent bolting when sufficient alignment has been completed to ensure as much of the structure as possible will be supported by such fastening work.


11. Erection bolts used in welded construction shall be tightened securely and left in place.

G. Expansion and Adhesive Anchor Installation:

1. Expansion Anchor Installation:

a) General: Install expansion anchors in strict accordance with manufacturer’s instructions and in accordance with the following.

b) Drilling Holes: Use rotary hammer type drill and make drill holes to the required diameter and depth as consistent with anchor manufacturer’s instructions for such anchors being installed.

c) Minimum Embedment: Embed expansion anchors to four and one-half bolt diameters, unless otherwise indicated on the Drawings.

2. Adhesive Anchor Installation:

a) General: Install adhesive anchors in strict accordance with manufacturer’s instructions and accordance with the following.

b) Drilling Holes: Use rotary hammer type drill and make drill holes to the required diameter and depth as consistent with anchor manufacturer’s instructions for size of anchors being installed.

1. Prior to setting anchor, clean drilled holes free of loose material by vacuum process, finishing with a blast of compressed air, and cover hole until actual use. Holes for adhesive anchors shall be dry at the time of installation.

c) Minimum Embedment: Embed Anchor Rod to four and one- half rod diameters unless noted otherwise on Drawings.

d) For installation of horizontal and upward inclined adhesive anchors, the installer shall be certified by and ACI/CRSI adhesive anchor installation program.

e) Adhesive anchors shall not be used in structural elements required to be fire resistant.

H. Field welding only permitted where approved by the Engineer or as indicated in the drawings.

I. Prior to installation of metal decking, clean unpainted top flanges of beams of all heavy rust, mill scale, dirt or other material.

3.04 SHEAR CONNECTORS

A. General: Installation shall be in accordance with AWS Code using automatic welding equipment. Clean welding surface before installing studs.

B. Location: See the Drawings for spacing and arrangement.

C. Weld shear connectors to support framing according to AWS D1 .1 and manufacturer’s instructions.

D. Replace studs which fail inspection by Independent Testing Agency at no expense to SEPTA.

E. Break ferrules away from all studs.


F. Do not weld when base metal temperature is below -18 degrees C, nor when welding surface is wet.

3.05 QUALITY ASSURANCE TESTING

A. Special Inspections: SEPTA will engage a qualified special inspector to perform the required special inspections indicated on the drawings.

B. An Independent Testing Agency shall be engaged to inspect high- strength bolted connections and welded connections, to perform tests, and prepare test reports.

1. The Independent Testing Agency shall conduct and interpret test results.

2. Written reports on all tests and inspections shall be provided immediately after work is performed. The reports shall state whether test specimens comply with requirements or deviate from them.

C. Provide access for the Independent Testing Agency to places where structural steel work is being fabricated or produced so required inspection and testing can be accompanied. The Agency may inspect structural steel at plant before shipment.

D. Shop-Bolted Connections: The Independent Testing Agency will inspect or test in accordance with AISC specifications, and the RCSC’s “Specification for Structural Joints Using ASTM A325 or A490 Bolts.”

1. Verify proper fastening components were used and the connected elements were fabricated properly.

2. Slip-critical and pretension connections: Test 2 bolts per connection.

E. Shop Welding: The Independent Testing Agency will inspect and test during fabrication of structural steel assemblies, as follows:

1. Certify welders and conduct inspections and tests as required. Record types and locations of defects found in work. Record work required and performed to correct deficiencies.

2. Perform visual inspection of full length of all welds.

3. In addition to visual inspection of shop-welded connections, welds will be inspected and tested according to AWS D1.1 and the inspection procedures listed below:

a) Complete penetration welds: Ultrasonic Inspection; ASTM E1 64.

b) Fillet welds: Magnetic Particle Method; ASTM E709.

4. Perform ultrasonic testing of the entire length of full penetration welds for the following:

a) Rigid (moment) frame flange connection plates on columns; test fifty (50%) percent of tension plates and twenty (20%) of compression plates.

b) Tube member to end connection plate; test twenty (20%) percent of welds.

c) 10% (minimum) of all other groove and full-penetration welds.

5. Perform magnetic particle testing on the entire length of fillet welds as follows:

a) Gusset Plate for bracing to Steel Member: 20% of fillet weld locations.

b) Other locations: 5% (minimum) of fillet welds.


F. Field-Bolted Connections: The Independent Testing Agency will inspect and test field-bolted connections in accordance with AISC specifications and RCSC’s “Specification for Structural Joints Using ASTM A25 or A 490 Bolts” and the following:

1. Verify proper fastening components were used and the connected elements were fabricated properly.

2. Slip-critical and pretension connections: Test 2 bolts per connection.

G. Field Welding: The Independent Testing Agency will inspect and test during erection of structural steel as follows:

1. Certify welders and conduct inspections and tests as required. Record types and locations of defects found in work. Record work required and performed to correct deficiencies.

2. Perform visual inspection of full length of all welds.

3. In addition to visual inspection of field-welded connections, welds will be inspected and tested according to AWS D1.1 and the inspection procedures listed below:

a) Complete penetration welds: Ultrasonic Inspection; ASTM E1 64.

b) Fillet welds: Magnetic Particle Method; ASTM E709.

4. Perform ultrasonic testing of the entire length of complete penetration welds for the following:

a) Rigid (moment) frame flange connection plates on columns; test all welds.

b) 20% (minimum) of all other groove and full-penetration welds.

5. Perform magnetic particle testing on the entire length of fillet welds as follows:

a) Beam connection plate (angles) to embedded plate in concrete: test all welds.

b) Diagonal bracing member to gusset: 40% of fillet weld locations.

c) Gusset plate for bracing to steel member: 40% of fillet weld locations.

d) 10% (minimum) of all other fillet welds.

6. Welding of rigid frame flange connection plates on columns shall be done in the field only if required for ease of erection. This field welding, if required, shall be clearly indicated on the shop drawings and approved by the Engineer.

H. The Independent Testing Agency will confirm that the structure is square, plumb, and level in accordance with AISC tolerances.

I. Remove and replace work that does not comply with specified requirements.

J. The Contractor shall correct deficiencies in structural steel work that inspections and test reports have indicated to be not in compliance with requirements. The Independent Testing Agency will perform additional tests, at the Contractor’s expense, as necessary to reconfirm any noncompliance of original work and to show compliance of corrected work.

END OF SECTION


SECTION 05400

COLD-FORMED METAL FRAMING

PART 1 - GENERAL


This Section includes the following:

1. Interior framing

RELATED WORK

Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 General Requirements apply to this Section.

Section 05120 – Structural Steel

Section 09260 – Gypsum Board Assemblies

SUBMITTALS

Product Data: For each type of cold-formed metal framing product and accessory indicated.

Shop Drawings: Show layout, spacings, sizes, thicknesses, and types of cold-formed metal framing; fabrication; and fastening and anchorage details, including mechanical fasteners. Show reinforcing channels, opening framing, supplemental framing, strapping, bracing, bridging, splices, accessories, connection details, and attachment to adjoining work.

Delegated Design: Provide structural analysis data signed and sealed by the qualified professional engineer responsible for their preparation.

1. Perform the design calculations required to size members, and prepare details of connections and other structural data including specifications for fasteners, anchors, and other structural items required.

2. Submit the Professional Engineer’s (licensed in the Commonwealth of Pennsylvania) calculations to the SEPTA Project Manager for approval.

Welding certificates.

Qualification Data: For installer, professional engineer and testing agency.

Product Test Reports: From a qualified testing agency, unless otherwise stated, indicating that each of the following complies with requirements, based on evaluation of comprehensive tests for current products:

1. Steel sheet.

2. Expansion anchors.

3. Power-actuated anchors.

4. Mechanical fasteners.

5. Vertical deflection clips.

6. Horizontal drift deflection clips


7. Miscellaneous structural clips and accessories.

QUALITY ASSURANCE

Installer Qualifications: Installer of cold-formed metal framing is a certified installer with experience installing manufacturer’s products according to manufacturer’s specifications

Engineering Responsibility: Preparation of Shop Drawings, design calculations, and other structural data by a qualified professional engineer.

Professional Engineer Qualifications: A professional engineer who is legally qualified to practice in the Commonwealth of Pennsylvania and who is experienced in providing engineering services of the kind indicated. Engineering services are defined as those performed for installations of cold-formed metal framing that are similar to those indicated for this Project in material, design, and extent.

Testing Agency Qualifications: An independent testing agency, acceptable to authorities having jurisdiction, qualified according to ASTM E 329 to conduct the testing indicated.

Product Tests: Mill certificates or data from a qualified independent testing agency, indicating steel sheet complies with requirements, including base-metal thickness, yield strength, tensile strength, total elongation, chemical requirements, ductility, and metallic-coating thickness.

Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, “Structural Welding Code--Steel,” and AWS D1.3, “Structural Welding Code--Sheet Steel.”

Fire-Test-Response Characteristics: Where indicated, provide cold-formed metal framing identical to that of assemblies tested for fire resistance per ASTM E 119 by a testing and inspecting agency acceptable to authorities having jurisdiction.

AISI Specifications and Standards: Comply with AISI's “North American Specification for the Design of Cold-Formed Steel Structural Members” and its “Standard for Cold-Formed Steel Framing - General Provisions.”

1. Comply with AISI's “Standard for Cold-Formed Steel Framing - Header Design.”

Pre-installation Conference: Conduct conference at Project site to comply with requirements in Division 01.

PERFORMANCE REQUIREMENTS

Structural Performance: Design, fabricate and install cold-formed metal framing capable of withstanding design loads within limits and under conditions indicated.

Design Loads: Applicable code specific minimums unless otherwise indicated on structural drawings

Deflection Limits: Design framing systems to withstand design loads without deflections greater than required by applicable codes.

Design framing systems to provide for movement of framing members without damage or overstressing, sheathing failure, connection failure, undue strain on fasteners and anchors, or other detrimental effects when subject to a maximum ambient temperature change of 120 deg F (67 deg C).

Design framing system to maintain clearances at openings, to allow for construction tolerances, and to accommodate live load deflection of primary building structure as stated in the structural drawings but no less than ½”.


Cold-Formed Steel Framing, General: Design according to AISI's “Standard for Cold-Formed Steel Framing - General Provisions.”

Headers: Design according to AISI's “Standard for Cold-Formed Steel Framing - Header Design.”

Design exterior non-load-bearing wall framing to accommodate horizontal deflection without regard for contribution of sheathing materials. Framing shall have a maximum depth of 3-5/8” as shown on construction drawings.

DELIVERY, STORAGE, AND HANDLING

Protect cold-formed metal framing from corrosion, deformation, and other damage during delivery, storage, and handling.

Store cold-formed metal framing, protect with a waterproof covering, and ventilate to avoid condensation.

PRODUCTS

MANUFACTURERS

Available Manufacturers: Subject to compliance with requirements, manufacturers offering cold-formed metal framing that may be incorporated into the Work include, but are not limited to, the following:

1. MarinoWare; a division of Ware Industries.

2. Super Stud Building Products, Inc.

3. United Metal Products, Inc.

4. Or Approved equal

MATERIALS

Steel Sheet: ASTM A 1003/A 1003M, Structural Grade, Type H, metallic coated, of grade and coating weight as follows:

1. Grade: As required by structural performance.

2. Coating: G60.

Steel Sheet for Vertical Deflection Clips: ASTM A 653/A 653M, structural steel, zinc coated, of grade and coating as follows:

1. Grade: As required by structural performance

2. Coating: G90 (Z275)

JOIST FRAMING

Steel Ceiling Joists: Manufacturer's standard C-shaped steel sections, of web depths indicated, unpunched, with stiffened flanges, and as follows:

1. Minimum Base-Metal Thickness: 0.0538 inch (1.37 mm)

2. Flange Width: 1-5/8 inches (41 mm)

FRAMING ACCESSORIES


Fabricate steel-framing accessories from steel sheet, ASTM A 1003/A 1003M, Structural Grade, Type H, metallic coated, of same grade and coating weight used for framing members.

Provide accessories of manufacturer's standard thickness and configuration, unless otherwise indicated, as follows:

1. Supplementary framing.

2. Bracing, bridging, and solid blocking.

3. Web stiffeners.

4. Anchor clips.

5. End clips.

6. Foundation clips.

7. Gusset plates.

8. Stud kickers, knee braces, and girts.

9. Joist hangers and end closures.

10. Hole reinforcing plates.

11. Backer plates.

ANCHORS, CLIPS, AND FASTENERS

Steel Shapes and Clips: ASTM A 36/A 36M, zinc coated by hot-dip process according to ASTM A 123/A 123M.

Anchor Bolts: ASTM F 1554, Grade 55, threaded carbon-steel hex-headed bolts and carbon-steel nuts; and flat, hardened-steel washers; zinc coated by hot-dip process according to ASTM A 153/A 153M, Class C.

Expansion Anchors: Fabricated from corrosion-resistant materials, with capability to sustain, without failure, a load equal to 5 times design load, as determined by testing per ASTM E 488 conducted by a qualified independent testing agency.

Power-Actuated Anchors: Fastener system of type suitable for application indicated, fabricated from corrosion-resistant materials, with capability to sustain, without failure, a load equal to 10 times design load, as determined by testing per ASTM E 1190 conducted by a qualified independent testing agency.

Mechanical Fasteners: ASTM C 1513, corrosion-resistant-coated, self-drilling, self-tapping steel drill screws.

1. Head Type: Low-profile head beneath sheathing, manufacturer's standard elsewhere.

Welding Electrodes: Comply with AWS standards.

MISCELLANEOUS MATERIALS

Galvanizing Repair Paint: ASTM A 780.

Cement Grout: Portland cement, ASTM C 150, Type I; and clean, natural sand, ASTM C 404. Mix at ratio of 1 part cement to 2-1/2 parts sand, by volume, with minimum water required for placement and hydration.


Nonmetallic, Non-shrink Grout: Premixed, nonmetallic, noncorrosive, nonstaining grout containing selected silica sands, Portland cement, shrinkage-compensating agents, and plasticizing and water-reducing agents, complying with ASTM C 1107, with fluid consistency and 30-minute working time.

Shims: Load bearing, high-density multimonomer plastic, nonleaching.

Sealer Gaskets: Closed-cell neoprene foam, 1/4 inch (6.4 mm) thick, selected from manufacturer's standard widths to match width of bottom track or rim track members.

FABRICATION

Fabricate cold-formed metal framing and accessories plumb, square, and true to line, and with connections securely fastened, according to referenced AISI's specifications and standards, manufacturer's written instructions, and requirements in this Section.

1. Fabricate framing assemblies using jigs or templates.

2. Cut framing members by sawing or shearing; do not torch cut.

3. Fasten cold-formed metal framing members by welding, screw fastening, clinch fastening, or riveting as standard with fabricator. Wire tying of framing members is not permitted.

a) Comply with AWS D1.3 requirements and procedures for welding, appearance and quality of welds, and methods used in correcting welding work.

b) Locate mechanical fasteners and install according to Shop Drawings, with screw penetrating joined members by not less than three exposed screw threads.

Fasten other materials to cold-formed metal framing by welding, bolting, or screw fastening, according to Shop Drawings.

1. Fabrication Tolerances: Fabricate assemblies level, plumb, and true to line to a maximum allowable tolerance variation of 1/8 inch in 10 feet (1:960)

2. Spacing: Space individual framing members no more than plus or minus 1/8 inch (3 mm) from plan location. Cumulative error shall not exceed minimum fastening requirements of sheathing or other finishing materials.

Squareness: Fabricate each cold-formed metal framing assembly to a maximum out-of-square tolerance of 1/8 inch (3 mm).

EXECUTION

EXAMINATION

Examine supporting substrates and abutting structural framing for compliance with requirements for installation tolerances and other conditions affecting performance.

Proceed with installation only after unsatisfactory conditions have been corrected.

PREPARATION

Install sealer gaskets to isolate the underside of wall bottom track or rim track and the top of foundation wall or slab at stud or joist locations.


INSTALLATION, GENERAL

Cold-formed metal framing may be shop or field fabricated for installation, or it may be field assembled.

Install cold-formed metal framing according to AISI's “Standard for Cold-Formed Steel Framing - General Provisions” and to manufacturer's written instructions unless more stringent requirements are indicated.

Install cold-formed metal framing and accessories plumb, square, and true to line, and with connections securely fastened.

1. Cut framing members by sawing or shearing; do not torch cut.

2. Fasten cold-formed metal framing members by welding, screw fastening, clinch fastening, or riveting. Wire tying of framing members is not permitted.

a) Comply with AWS D1.3 requirements and procedures for welding, appearance and quality of welds, and methods used in correcting welding work. Retain subparagraph above and subparagraph below if using mechanical fasteners.

b) Locate mechanical fasteners and install according to Shop Drawings, and complying with requirements for spacing, edge distances, and screw penetration.

Install framing members in one-piece lengths unless splice connections are indicated for track or tension members.

Install temporary bracing and supports to secure framing and support loads comparable in intensity to those for which structure was designed. Maintain braces and supports in place, undisturbed, until entire integrated supporting structure has been completed and permanent connections to framing are secured.

Do not bridge building expansion and control joints with cold-formed metal framing. Independently frame both sides of joints.

Install insulation, specified in Division 07 Section 07200 “Thermal Protection,” in built-up exterior framing members, such as headers, sills, boxed joists, and multiple studs at openings, that are inaccessible on completion of framing work.

Fasten hole reinforcing plate over web penetrations that exceed size of manufacturer's standard punched openings.

Erection Tolerances: Install cold-formed metal framing level, plumb, and true to line to a maximum allowable tolerance variation of 1/8 inch in 10 feet (1:960) and as follows:

1. Space individual framing members no more than plus or minus 1/8 inch (3 mm) from plan location. Cumulative error shall not exceed minimum fastening requirements of sheathing or other finishing materials.

JOIST INSTALLATION

Install perimeter joist track sized to match joists. Align and securely anchor or fasten track to supporting structure at corners, ends, and spacings indicated on Shop Drawings.

Install joists bearing on supporting frame, level, straight, and plumb; adjust to final position, brace, and reinforce. Fasten joists to both flanges of joist track.


1. Install joists over supporting frame with a minimum end bearing of 1-1/2 inches (38 mm).

2. Reinforce ends and bearing points of joists with web stiffeners, end clips, joist hangers, steel clip angles, or steel-stud sections as indicated on Shop Drawings.

Space joists not more than 2 inches (51 mm) from abutting walls

Joist Spacing: minimum 16 inches

Frame openings with built-up joist headers consisting of joist and joist track, nesting joists, or another combination of connected joists if indicated.

Install joist reinforcement at interior supports with single, short length of joist section located directly over interior support, with lapped joists of equal length to joist reinforcement, or as indicated on Shop Drawings.

Install web stiffeners to transfer axial loads of walls above.

Install bridging at intervals indicated on Shop Drawings. Fasten bridging at each joist intersection as follows:

1. Bridging: Combination of flat, taut, steel sheet straps of width and thickness indicated and joist-track solid blocking of width and thickness indicated. Fasten flat straps to bottom flange of joists and secure solid blocking to joist webs.

Secure joists to load-bearing interior walls to prevent lateral movement of bottom flange.

Install miscellaneous joist framing and connections, including web stiffeners, closure pieces, clip angles, continuous angles, hold-down angles, anchors, and fasteners, to provide a complete and stable joist-framing assembly.

FIELD QUALITY CONTROL

Testing: Contractor will engage a qualified independent testing and inspecting agency to perform field tests and inspections and prepare test reports.

Field and shop welds will be subject to testing and inspecting.

Testing agency will report test results promptly and in writing to the SEPTA Project Manager, Contractor and Architect.

Remove and replace work where test results indicate that it does not comply with specified requirements.

Additional testing and inspecting, at Contractor's expense, will be performed to determine compliance of replaced or additional work with specified requirements.

REPAIRS AND PROTECTION

Galvanizing Repairs: Prepare and repair damaged galvanized coatings on fabricated and installed cold-formed metal framing with galvanized repair paint according to ASTM A 780 and manufacturer's written instructions.

Provide final protection and maintain conditions, in a manner acceptable to manufacturer and Installer that ensure that cold-formed metal framing is without damage or deterioration at time of Final Acceptance.

END OF SECTION




SECTION 05500

METAL FABRICATIONS

PART 1 - GENERAL


A. This section specifies items and assemblies fabricated from structural steel shapes and other materials, as shown and specified.

B. Items specified:

1. Support for Wall Mounted Items

2. Shelf Angles

3. Painted cast iron rain water leaders

4. Fixed ladders


A. Section 04200 – Unit Masonry

B. Section 05120 – Structural Steel

C. Section 09910 – Paints and Coatings

1.03 REFERENCES

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

B. American Society of Mechanical Engineers (ASME):

1. B18.2.2-87(R2005): Square and Hex Nuts

C. American Society for Testing and Materials (ASTM):

1. A 36/A 36M-05: Structural Steel

2. A 47-99 (R2004): Malleable Iron Castings

3. A 48-03: Gray Iron Castings

4. A 53-06: Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless

5. A 123-02: Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

6. A 167-99 (R2004): Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet and Strip

7. A 269-07: Seamless and Welded Austenitic Stainless Steel Tubing for General Service

8. A 307-07: Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength

9. A 312/A 312M-06: Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

10. A-380: Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems


11. A 391/A 391M-01: Grade 80 Alloy Steel Chain

12. A480/480M: General Requirements for Flat-Rolled Stainless and Heat Resisting Steel Plate, Sheet, and Strip

13. A484/484M: General Requirements of Stainless Steel Bars

14. A555/555M: General Requirements for Stainless Steel and Heat Resistant Steel Wire and Wire Rods

15. F593: Standard Specification for Stainless Steel Bolts, Hex Cap Screws and Studs

16. A 653/A 653M-07: Steel Sheet, Zinc Coated (Galvanized) or Zinc-Iron Alloy Coated (Galvannealed) by the Hot-Dip Process

17. A666: Austenitic Stainless Steel Sheet, Strip, Plate and Flat Bar for Structural and Architectural Applications

18. A 786/A 786M-05: Rolled Steel Floor Plate

19. B 209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

20. B 221-06: Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes

21. B 456-03: Electrodeposited Coatings of Copper plus Nickel plus Chromium and Nickel plus Chromium

22. B 632-02: Aluminum-Alloy Rolled Tread Plate

23. C 1107-07: Packaged Dry, Hydraulic-Cement Grout (Non-shrink)

24. D 3656-04: Insect Screening and Louver Cloth Woven from Vinyl-Coated Glass Yarns

25. F 436-07: Hardened Steel Washers

26. F 468-06: Nonferrous Bolts, Hex Cap Screws, and Studs for General Use

27. F 593-02: Stainless Steel Bolts, Hex Cap Screws, and Studs

28. F 1667-05: Driven Fasteners: Nails, Spikes, and Staples

D. American Welding Society (AWS):

1. D1.1-04: Structural Welding Code Steel

2. D1.2-03: Structural Welding Code Aluminum

3. D1.3-98: Structural Welding Code Sheet Steel

E. National Association of Architectural Metal Manufacturers (NAAMM)

1. AMP521-01: Pipe Railing Manual

2. AMP 500-505-1988: Metal Finishes Manual

3. MBG 531-00: Metal Bar Grating Manual

4. MBG 532-00: Heavy Duty Metal Bar Grating Manual

F. Structural Steel Painting Council (SSPC):

1. SP 1-05 : No. 1, Solvent Cleaning

2. SP 2-05 : No. 2, Hand Tool Cleaning


3. SP 3-05 : No. 3, Power Tool Cleaning

G. Federal Specifications (Fed. Spec):

1. RR-T-650E: Treads, Metallic and Nonmetallic, Nonskid

H. Occupational Safety and Health Administration (OSHA):

1. 1910.27: Fixed Ladders

1.04 SUBMITTALS

A. Submit in accordance with Section 01300 – Submittals.

B. Shop Drawings:

1. Each item specified, showing complete detail, location in the project, material, and size of components, method of joining various components and assemblies, finish, and location, size, and type of anchors.

2. Mark items requiring field assembly for erection identification and furnish erection drawings and instructions.

3. Provide templates and rough-in measurements as required.

C. Manufacturer’s Certificates:

1. Live load designs as specified.

D. Welding certificates.

E. Design Calculations for specified live loads including dead loads.

F. Qualification Data: For professional engineer.

G. Furnish setting drawings and instructions for installation of anchors to be preset into concrete and masonry work, and for the positioning of items having anchors to be built into concrete or masonry construction.

H. Delegated-Design Submittal: For ladders, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.


A. Field welding is not permitted.

B. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, “Structural Welding Code - Steel.”

C. Field Measurements: Verify actual locations of walls and other construction contiguous with metal fabrications by field measurements before fabrication

D. Each manufactured product shall meet, as a minimum, the requirements specified, and shall be a standard commercial product of a manufacturer regularly presently manufacturing items of type specified.

E. Assemble products to the greatest extent possible before delivery to the site. No field welding will be permitted without the permission of the SEPTA PM.

F. Include additional features, which are not specifically prohibited by this specification, but which are a part of the manufacturer’s standard commercial product.


G. Employ a professional engineer licensed to practice in the Commonwealth of Pennsylvania competent in design and structural analysis to fabricate ladders and other metal fabrications in compliance with industry standards and local codes.

H. SEPTA reserves the right to shop inspect at any time during the fabrication and finishing processes.

I. SEPTA reserves the right to require NDE inspection from an independent testing agency, at no cost to SEPTA.

J. The Contractor must notify SEPTA (5) days prior to beginning fabrication and finishing, to determine if SEPTA shall require a shop inspection prior to allowing the product to move forward to the next phase.

K. Field Visit and Measurements:

1. Any discrepancies between the drawings and what is in the field shall be brought to the attention of the project manager. It is assumed that slight variation may exist and this is to be expected. Extras associated with discrepancies shall only be granted where these discrepancies can be proved to be a major consequence on the design and fabrication.

2. It is recommended that the fabricator visit the site prior to bidding on any fabrication in which the size of the project may require special on-site handling requirements, or where the fabrication must fit into existing conditions.


A. Deliver materials in protective wrappings with each item labeled with installation location.

B. Deliver, store and handle all materials to prevent damage by breaking, water or moisture and contamination by foreign materials.

C. Store materials on a clean, dry surface or platform, off ground, covered, separate from each other and protected from deterioration and the elements. Bear fully along all supported edges on level and true structural supports. Ventilate to avoid condensation.

D. Handle all materials in a manner which will prevent undue stress on component parts, sealants and structural members. Do not rack, torque, or cause load forces in an inappropriate manner. Lift panels from top only unless specifically instructed by the manufacturer.

1.07 WARRANTY

A. Ladder:

1. Manufacturer has responsibility for an extended Corrective Period for work of this Section for a period of 5 years from date of Substantial Completion against all the conditions indicated below, and when notified in writing from Owner, manufacturer shall promptly and without inconvenience and cost to Owner correct said deficiencies.

a) Defects in materials and workmanship.

b) Deterioration of material and surface performance below minimum OSHA standards as certified by independent third party testing laboratory. Ordinary wear and tear, unusual abuse or neglect excepted.


c) Within the warranty period, the manufacturer shall, at its option, repair, replace, or refund the purchase price of defective ladder.

2. Manufacturer shall be notified immediately of defective products, and be given a reasonable opportunity to inspect the goods prior to return. Manufacturer will not assume responsibility, or compensation, for unauthorized repairs or labor. Manufacturer makes no other warranty, expressed or implied, to the merchantability, fitness for a particular purpose, design, sale, installation, or use, of the ladder; and shall not be liable for incidental or consequential damages, losses of or expenses, resulting from the use of ladder products.

PART 2 - PRODUCTS

2.01 DESIGN CRITERIA

A. Delegated Design: Engage a qualified professional engineer licensed in the Commonwealth of Pennsylvania, as defined in Section 01400 “Quality Requirements,” to design ladders, including attachment to building construction.

B. Structural Performance: Decorative formed metal items, including anchors and connections, shall withstand the effects of gravity loads and the following loads and stresses without exceeding the allowable design working stress of materials involved and without exhibiting permanent deformation in any components:

1. Wind Loads on Exterior Items: As indicated on Drawings

C. Seismic Performance: Exterior decorative formed metal items, including anchors and connections, shall withstand the effects of earthquake motions determined according to ASCE/SEI 7.

1. Component Importance Factor: 1.0.

D. Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects.

1. Temperature Change: 120 deg F ambient; 180 deg F material surfaces.

2.02 METALS

A. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes.

B. Steel Plates, Shapes, and Bars: ASTM A 36.

1. Rolled Steel Floor Plate: ASTM A 36

C. Steel Tubing: ASTM A 500, cold-formed steel tubing.

D. Steel Pipe: ASTM A 53.standard weight (schedule 40) unless otherwise indicated

1. Galvanized for exterior locations.

2. Type S, Grade A unless specified otherwise.

3. NPS (inside diameter) as shown.

E. Cast Iron: Either gray iron, ASTM A 48, or malleable iron, ASTM A 47, unless otherwise indicated.


2.03 HARDWARE

A. Rough Hardware:

1. Furnish rough hardware with a standard plating, applied after punching, forming and assembly of parts; galvanized, cadmium plated, or zinc-coated by electro-galvanizing process. Galvanized G-90 where specified.

2. Use G90 galvanized coating on ferrous metal for exterior work unless non-ferrous metal or stainless is used.

2.04 FASTENERS

A. General: Unless otherwise indicated, provide Type 304 stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, at exterior walls. Select fasteners for type, grade, and class required.

1. Provide stainless-steel fasteners for fastening aluminum.

2. Provide stainless-steel fasteners for fastening stainless steel.

3. Provide stainless-steel fasteners for fastening nickel silver.

4. Provide bronze fasteners for fastening bronze.

B. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 307, Grade A; with hex nuts, ASTM A 563; and, where indicated, flat washers.

C. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 325, Type 3; with hex nuts, ASTM A 563, Grade C3; and, where indicated, flat washers.

D. Stainless-Steel Bolts and Nuts: Regular hexagon-head annealed stainless-steel bolts, ASTM F 593; with hex nuts, ASTM F 594; and, where indicated, flat washers; Alloy Group 1 (A1).

E. Anchor Bolts: ASTM F 1554, Grade 36, of dimensions indicated; with nuts, ASTM A 563; and, where indicated, flat washers.

1. Hot-dip galvanize or provide mechanically deposited, zinc coating where item being fastened is indicated to be galvanized.

F. Anchors, General: Anchors capable of sustaining, without failure, a load equal to six times the load imposed when installed in unit masonry and four times the load imposed when installed in concrete, as determined by testing according to ASTM E 488/E 488M, conducted by a qualified independent testing agency.

G. Cast-in-Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47 malleable iron or ASTM A 27 cast steel. Provide bolts, washers, and shims as needed, all hot-dip galvanized per ASTM F 2329.

H. Post-Installed Anchors: chemical anchors.

1. Material for Interior Locations: Carbon-steel components zinc plated to comply with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, unless otherwise indicated.

2. Material for Exterior Locations and Where Stainless Steel Is Indicated: Alloy Group 1 (A1) stainless-steel bolts, ASTM F 593, and nuts, ASTM F 594.

3. Blind Bolts: Type HB – Hollo Bolt, or approved equal


2.05 MISCELLANEOUS MATERIALS

A. Shop Primers: Provide primers that comply with Section 09910 “Paints and Coatings”

B. Shop Primer for Galvanized Steel: Primer formulated for exterior use over zinc-coated metal and compatible with finish paint systems indicated.

C. Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.

D. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.

E. Non-shrink, Nonmetallic Grout: Factory-packaged, non-staining, noncorrosive, nongaseous grout complying with ASTM C 1107 Provide grout specifically recommended by manufacturer for interior and exterior applications.

2.06 FABRICATION GENERAL

A. Material

1. Use material as specified. Use material of commercial quality and suitable for intended purpose for material that is not named or its standard of quality not specified.

2. Use material free of defects which could affect the appearance or service ability of the finished product.

B. Shop Assembly: Preassemble items in the shop to greatest extent possible. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Clearly mark units for reassembly and coordinated installation.

C. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1/32 inch unless otherwise indicated. Remove sharp or rough areas on exposed surfaces.

D. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

E. Form exposed work with accurate angles and surfaces and straight edges.

F. Weld corners and seams continuously to comply with the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing. Weld in accordance with AWS.

5. Welds shall show good fusion, be free from cracks and porosity, and accomplish secure and rigid joints in proper alignment.

6. Where exposed in the finished work, continuous weld for the full length of the members joined and have depressed areas filled and protruding welds finished smooth and flush with adjacent surfaces.

7. Finish welded joints to match finish of adjacent surface.


G. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Where exposed fasteners are required, use Phillips flat-head (countersunk) fasteners unless otherwise indicated. Locate joints where least conspicuous.

1. Miter or butt members at corners.

2. Where frames members are butted at corners, cut leg of frame member perpendicular to surface, as required for clearance.

H. Fabricate seams and other connections that are exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate.

I. Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items.

1. Accurately cut, machine, and fit joints, corners, copes, and miters.

2. Fit removable members to be easily removed.

3. Design and construct field connections in the most practical place for appearance and ease of installation.

4. Fit pieces together as required.

5. Fabricate connections for ease of assembly and disassembly without use of special tools.

6. Joints firm when assembled.

7. Conceal joining, fitting, and welding on exposed work as far as practical.

8. Do not show rivets and screws prominently on the exposed face.

9. The fit of components and the alignment of holes shall eliminate the need to modify component or to use exceptional force in the assembly of item and eliminate the need to use other than common tools.

J. Provide for anchorage of type indicated; coordinate with supporting structure. Space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads.

1. Use methods for fastening or anchoring metal fabrications to building construction as shown or specified.

2. Where fasteners and anchors are not shown, design the type, size, location and spacing to resist the loads imposed without deformation of the members or causing failure of the anchor or fastener, and suit the sequence of installation.

3. Use material and finish of the fasteners compatible with the kinds of materials which are fastened together and their location in the finished work.

4. Fasteners for securing metal fabrications to new construction only, may be by use of threaded or wedge type inserts or by anchors for welding to the metal fabrication for installation before the concrete is placed or as masonry is laid.

5. Fasteners for securing metal fabrication to existing construction or new construction may be expansion bolts, toggle bolts, power actuated drive pins, welding, self-drilling and tapping screws or bolts, except where otherwise specified.


K. Where units are indicated to be cast into concrete or built into masonry, equip with integrally welded steel strap anchors, 1/8 by 1-1/2 inches, with a minimum 6-inch embedment and 2-inch hook, not less than 8 inches from ends and corners of units and 24 inches o.c., unless otherwise indicated.

L. Size:

1. Size and thickness of members as shown.

2. When size and thickness is not specified or shown for an individual part, use size and thickness not less than that used for the same component on similar standard commercial items or in accordance with established shop methods.

M. Connections

1. Except as otherwise specified, connections may be made by welding, riveting or bolting.

2. Field riveting will not be approved.

3. Design size, number, and placement of fasteners, to develop a joint strength of not less than the design value.

4. Size and shape welds to develop the full design strength of the parts connected by welds and to transmit imposed stresses without permanent deformation or failure when subject to service loadings.

5. Use Rivets and bolts of material selected to prevent corrosion (electrolysis) at bimetallic contacts. Plated or coated material will not be approved.

6. Use stainless steel connectors for removable members - machine screws or bolts.

N. Workmanship

1. General:

a) Fabricate items to design shown.

b) Furnish members in longest lengths commercially available within the limits shown and specified.

c) Fabricate straight, true, free from warp and twist, and where applicable square and in same plane.

d) Provide holes, sinkages, and reinforcement shown and required for fasteners and anchorage items.

e) Provide openings, cut-outs, and tapped holes for attachment and clearances required for work of other trades.

f) Prepare members for the installation and fitting of hardware.

g) Cut openings in gratings and floor plates for the passage of ducts, sumps, pipes, conduits and similar items. Provide reinforcement to support cut edges.

h) Fabricate surfaces and edges free from sharp edges, burrs, and projections which may cause injury.

O. Finish:

1. Finish exposed surfaces in accordance with NAAMM Metal Finishes Manual.


2. Steel and Iron: NAAMM AMP 504.

a) Zinc coated (Galvanized): ASTM A 123, G90 unless noted otherwise.

b) Surfaces exposed in the finished work:

1) Finish smooth rough surfaces and remove projections.

2) Fill holes, dents and similar voids and depressions with epoxy type patching compound.

c) Shop Prime Painting:

1) Surfaces of Ferrous metal:

Items not specified to have other coatings.

Galvanized surfaces specified to have prime paint.

Remove all loose mill scale, rust, and paint, by hand or power tool cleaning as defined in SSPC-SP2 and SP3.

Clean of oil, grease, soil and other detrimental matter by use of solvents or cleaning compounds as defined in SSPC-SP1.

After cleaning and finishing apply one coat of primer as specified in Section 09910 – Paints and Coatings.

2) Non ferrous metals: Comply with NAAMM-500 series.

P. Protection:

1. Spot prime all abraded and damaged areas of zinc coating which expose the bare metal, using zinc rich paint on hot-dip zinc coat items and zinc dust primer on all other zinc coated items.

2.07 MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work.

B. Fabricate units from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction.

1. Fabricate units from slotted channel framing where indicated.

2. Furnish inserts for units installed after concrete is placed.

C. Galvanize miscellaneous framing and supports where indicated.

D. Prime miscellaneous framing and supports with primer specified in Section 09910 Paints and Coatings.

2.08 SHELF ANGLES

A. Fabricate shelf angles from steel angles of sizes indicated and for attachment to concrete framing. Provide horizontally slotted holes to receive 3/4-inch bolts, spaced not more than 6 inches from ends and 24 inches o.c., unless otherwise indicated.

1. Provide mitered and welded units at corners.


2. Provide open joints in shelf angles at expansion and control joints. Make open joint approximately 2 inches larger than expansion or control joint.

B. For cavity walls, provide vertical channel brackets to support angles from backup masonry and concrete.

C. Galvanize and prime all shelf angles located in exterior walls.

D. Prime shelf angles located in exterior walls with primer specified in Section 09910 “Paints and Coatings.”

2.09 LOOSE BEARING AND LEVELING PLATES

A. Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Drill plates to receive anchor bolts and for grouting.

B. Galvanize plates.

C. Prime plates with zinc-rich primer. Refer to Section 09910 “Paints and Coatings”.

2.10 STEEL WELD PLATES AND ANGLES

A. Provide steel weld plates and angles not specified in other Sections, for items supported from concrete construction as needed to complete the Work. Provide each unit with no fewer than two integrally welded steel strap anchors for embedding in concrete.

2.11 METAL LADDERS

A. General:

1. Comply with ANSI A14.3

B. Manufacturers

1. Basis of Design - O’Keeffe’s, Inc.; 325 Newhall St. San Francisco, CA 94124. Tel: (888) 653-3333. http://www.okeeffes.com.

2. ACL Industries, Inc.

3. ALACO Ladder Co.

4. Or approved equal.

C. Fixed Access Ladder:

1. Heavy Duty Tubular Rail Access Ladder.

a) Model 501 as manufactured by O’Keeffe’s Inc or approved equal

b) Security door

D. Finish: Clear Anodic Finish: AA-M10C22A41 Mechanical finish as fabricated. Architectural Class I, clear coating 0.018 mm or thicker.

E. Material:

1. Aluminum Sheet: Alloy 5005-H34 to comply with ASTM B209.

2. Aluminum Extrusions: Alloy 6063-T6 to comply with ASTM B221.

F. Fabrication


1. Rungs: Not less than 1-1/4 inches in section and 18–3/8 inches long, formed from tubular aluminum extrusions. Squared and deeply serrated on all sides.

a) Rungs shall withstand a 1,500 pound load without deformation or failure.

2. Channel Side Rails: Not less than 1/8 inch wall thickness by 3 inches wide.

3. Heavy Duty Tubular Side Rails: Assembled from two interlocking aluminum extrusions no less than 1/8 inch wall thickness by 3 inches wide. Construction shall be self-locking stainless steel fasteners, full penetration TIG welds and clean, smooth and burr free surfaces.

4. Ladder Safety Post: Retractable hand hold and tie off.

2.12 RAIN LEADER

A. Rain Leader: Plain round complete with mitered elbows, manufactured from the following exposed metal. Furnish with metal hangers, from same material as downspouts, and anchors.

B. Material: Cast iron

C. Prime cast iron downspouts with zinc-rich primer

D. Finish: As specified on Architectural Drawings

2.13 FINISHES, GENERAL

A. Finish metal fabrications after assembly.

B. Finish exposed surfaces to remove tool and die marks and stretch lines, and to blend into surrounding surface.

2.14 STEEL AND IRON FINISHES

A. Galvanizing: Hot-dip galvanize items as indicated to comply with ASTM A 153 for steel and iron hardware and with ASTM A 123 for other steel and iron products.

1. Do not quench or apply post galvanizing treatments that might interfere with paint adhesion.

B. Preparation for Shop Priming Galvanized Items: After galvanizing, thoroughly clean railings of grease, dirt, oil, flux, and other foreign matter, and treat with metallic phosphate process.

C. Shop prime iron and steel items not indicated to be galvanized unless they are to be embedded in concrete, sprayed-on fireproofing, or masonry, or unless otherwise indicated.

1. Shop prime with primers specified in Section 09910 “Paints and Coatings”

D. Preparation for Shop Priming: Prepare surfaces to comply with requirements indicated below:

1. Exterior Items: SSPC-SP 6/NACE No. 3, “Commercial Blast Cleaning.”

2. Items Indicated to Receive Zinc-Rich Primer: SSPC-SP 6/NACE No. 3, “Commercial Blast Cleaning.”

3. Items Indicated to Receive Primers Specified in Section 099600 “High-Performance Coatings”: SSPC-SP 6/NACE No. 3, “Commercial Blast Cleaning.”


4. Other Items: SSPC-SP 3, “Power Tool Cleaning.”

E. Shop Priming: Apply shop primer to comply with SSPC-PA 1, “Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel,” for shop painting.

PART 3 - EXECUTION

3.01 EXAMINATION AND INSPECTION

A. SEPTA reserves the right to shop inspect at any time during the fabrication and finishing process.

B. The contractor must notify SEPTA five (5) days prior to beginning fabrication, galvanizing and painting, to determine if SEPTA shall require a shop inspection prior to allowing the product to move forward to the next phase.

3.02 INSTALLATION, GENERAL

A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack & twist, set parallel or perpendicular as required to line and plane of surface and measured from established lines and levels.

B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections.

C. Fastening to In-Place Construction: Provide anchorage devices and fasteners where metal fabrications are required to be fastened to in-place construction. Provide threaded fasteners for use with concrete and masonry inserts, toggle bolts, through bolts, lag screws, wood screws, and other connectors.

1. Provide temporary bracing for such items until concrete or masonry is set.

2. Place in accordance with setting drawings and instructions.

3. Build strap anchors into masonry as work progresses.

D. Set frames of gratings, covers, corner guards, trap doors and similar items flush with finish floor or wall surface and, where applicable, flush with side of opening.

E. Field weld in accordance with AWS.

1. Design and finish as specified for shop welding.

2. Use continuous weld unless specified otherwise.

F. Install anchoring devices and fasteners as shown and as necessary for securing metal fabrications to building construction as specified. Expansion Anchors should be used where shown on the drawings and elsewhere except where shown otherwise. Power actuated drive pins may be used except for removable items and where members would be deformed or substrate damaged by their use.

G. Spot prime all abraded and damaged areas of zinc coating as specified and all abraded and damaged areas of shop prime coat with same kind of paint used for shop priming.


H. Isolate aluminum from dissimilar metals and from contact with concrete and masonry materials as required to prevent electrolysis and corrosion.

3.03 INSTALLATION OF MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Install framing and supports to comply with requirements of items being supported, including manufacturers’ written instructions and requirements indicated on Shop Drawings.

B. Anchorage to structure.

1. Secure angles and clips to structure as shown or as required.

2. Secure supports to mid height of concrete beams when inserts do not exist with expansion anchors and to slabs, with expansion anchors unless shown otherwise.

3. Secure steel plate and steel angles to slabs or masonry walls, with expansion anchors unless shown or specified otherwise.

3.04 INSTALLING BEARING AND LEVELING PLATES

A. Clean concrete and masonry bearing surfaces of bond-reducing materials, and roughen to improve bond to surfaces. Clean bottom surface of plates.

B. Set bearing and leveling plates on wedges, shims, or leveling nuts. After bearing members have been positioned and plumbed, tighten anchor bolts. Do not remove wedges or shims but, if protruding, cut off flush with edge of bearing plate before packing with nonshrink grout. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

3.05 CLEAN AND ADJUSTING

A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas. Paint uncoated and abraded areas with the same material as used for shop painting to comply with SSPC-PA 1 for touching up shop-painted surfaces.

1. Apply by brush to provide a minimum 2.0-mil dry film thickness.

B. Touchup Painting: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint are specified in Section 09910 “Paints and Coatings”

C. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780/A 780M.

D. Clean after installation exposed pre-finished and plated items and items fabricated from stainless steel, aluminum and copper alloys, as recommended by the metal manufacture and protected from damage until completion of the project.

E. Stainless Steel: Clean after installation exposed pre-finished and plated items and items fabricated from stainless steel, as recommended by the metal manufacture and protect from damage until completion of the project.

F. If any surface staining becomes apparent, stainless steel must be cleaned and repassivated by experienced personnel. If this action is deemed necessary by SEPTA PM or Architect/Engineer, Contractor shall submit their proposed process and a mock-up to SEPTA for approval prior to start of work.

G. Only approved stainless steel cleaners shall be used. Strong unapproved acids such as muriatic or cleaners containing chlorine shall not be used.


END OF SECTION




SECTION 05610

MISCELLANEOUS METALS

PART 1 - GENERAL


A. This Section specifies furnishing and installing all miscellaneous metal works.


A. Section 05120 – Structural Steel

B. Section 09910 – Paints and Coatings


A. Materials and workmanship to be furnished under this Specification, including all accessories, shall conform to the Commonwealth of Pennsylvania building code (IBC 2009).

B. Welding processes and welding operators shall be qualified in accordance with AWS Standard Qualification Procedure.

C. Field measurement shall be taken prior to preparation of shop drawings and fabrication, where possible, to ensure proper fitting of the work. Allowance for fitting and trimming shall be made wherever the taking of field measurements before fabrication might delay the work.

D. Items shall be pre-assembled in the shop to the greatest extent possible. Units shall be field-assembled or re-assembled only to the extent necessary. Units shall be clearly marked for reassembly and installation coordinated.

1.04 SUBMITTALS

A. Shop drawings of metal fabrications proposed to be used shall be submitted in accordance with Section 01300, Submittals.

B. Shop drawings shall be submitted for the fabrication and assembly of all items and assemblies. They shall show anchorage, accessory items, and adjacent materials and conditions.

PART 2 - PRODUCTS

2.01 GENERAL

A. Only materials which are smooth and free of surface blemishes shall be used for the fabrication of miscellaneous metal work which will be exposed to view.

B. Blemishes shall be removed by grinding, or by welding and grinding, prior to cleaning, treating and application of surface finishes.

2.02 MATERIALS

A. Steel Plate, Shapes and Bars shall comply with ASTM A36, Structural Steel.


B. Steel Plates to be Bent or Cold-Formed shall Comply with ASTM A283/A, Grade C, Low and Intermediate Tensile Strength Steel Plate of Structural Quality.

C. Hot-Rolled Carbon Steel Bars shall comply with ASTM A575, Merchant Quality Hot-Rolled Carbon Steel Bars.

D. Cold-Finished Steel Bars shall comply with ASTM Ai 08, Cold-Finished Carbon Steel Bars and Shafting.

E. Hot-Rolled Carbon Steel Sheets and Strips shall comply with ASTM A568/A, General Requirements for Carbon and High Strength, Low Alloy, Hot-Rolled Sheets and Cold-Rolled Sheets; and ASTM A569/A, Steel Carbon (0.15 maximum Percent) Hot-Rolled Sheet and Strip, Commercial Quality.

F. Cold-Rolled Carbon Steel Sheets shall comply with ASTM A366/A, Steel Sheet, Carbon Cold-Rolled, Commercial Quality.

G. Galvanized Carbon Steel Sheets shall comply with ASTM A526/A -Steel Sheet, Zinc-Coating (Galvanized) by the Hot-Dip Process, Commercial Quality; with 1.25-ounce commercial zinc coat complying with. ASTM A525 Steel Sheet, Zinc-Coating (Galvanized) by the Hot-Dip Process, General Requirements.

H. Steel bar grating shall comply with the requirements of the NAMM “Metal Bar Grating Manual.”

I. Extruded Aluminum Pipe and Tube of Schedule 40 size shall, comply with ASTM B429, 6064-T6.

J. Aluminum Plate Bar and Sheet shall comply with ASTM B209, 6061-T6 or ASTM B221, 6063-T6.

K. Aluminum casting shall comply with ASTM B26/B, ANSI 356-Tb.

L. Metal Separation: Two coats of bituminous paint shall be applied on one or both surfaces wherever dissimilar metals, or metal and masonry, would otherwise be in contact. Gasketed fasteners shall be used where required to eliminate the possibility of corrosive or electrolytic action.

2.03 FASTENERS

A. For securing aluminum plate cover placed across brick opening for roof drain leaders, use 1 inch by 1/4 inch raw plugs (nail-in type) with one piece drive anchors or approved equal. All other masonry anchorage devices shall be expansion shield type with threaded fasteners.

B. Toggle bolts shall be tumble-wing type; type, class and style as required.

C. Zinc-coated fasteners, with ASTM A153; zinc coating (hot-dip) on iron and steel hardware shall be used for exterior use or where built into exterior walls. Fasteners shall be selected for the type, grade and class required for the installation of miscellaneous metal items.

D. Standard bolts and nuts shall be ASTM A307; carbon steel, externally and internally threaded standard fasteners, grade A, regular hexagon head.

E. Lag bolts shall be square-head type.

F. Machine screws shall be cadmium-plated steel.

G. Plain washers, screws (machine, slotted or cross-recessed and round) shall be general assembly grade carbon steel. .


H. Lock washers shall be helical spring type carbon steel.

I. Clip angles, brackets, and flanges shall be of same material to be fastened.

J. Grout shall be that specifically recommended by manufacturer for interior and exterior applications of type specified and shall comply with ASTM C588.

2.04 MISCELLANEOUS FRAMING, SUPPORTS AND LINTELS

A. Miscellaneous units shall be fabricated to the size, shapes and profiles shown or, if not shown, of the required dimensions to receive other work to be retained by the framing.

B. Items shall be fabricated from structural steel shapes, plates and steel bars, of all welded construction using mitered corners, welded brackets and splice plates and a minimum number of joints for field connection. Unit shall be cut, drilled, and tapped to receive hardware and similar items to be anchored to the work.

C. Units shall be equipped with integrally welded anchor straps, for casting into poured concrete or building into masonry wherever required.

D. Miscellaneous framing, supports and lintels shall include, but are not limited to:

1. Miscellaneous clips and angles

2. Frames for gratings

3. Closure and support angles

4. Loose lintels and lintels assemblies

5. Loose bearing and leveling plates

2.05 CAST ABRASIVE NOSINGS

A. Nosings for concrete steps shall be Aluminum, with non-slip abrasive finish of size and configuration shown on Contract Drawings, with cast-on bolt anchor, 1/4-inch diameter x i-inch deep.

B. Pattern of abrasive surface shall be checkered.

2.06 MISCELLANEOUS METAL FABRICATIONS

A. Miscellaneous metal fabrications shall be fabricated to the sizes, shapes, and profile shown.

B. Except as otherwise shown, items shall be fabricated from carbon steel sheets, be of all welded construction using mitered corners, with a minimum number of joints for field connection.

C. Units shall be equipped with integrally welded anchor straps for building into masonry wherever required.

D. Miscellaneous metal fabrications shall include, but are not limited to:

1. Closure trims

2.07 STEEL BAR GRATINGS

A. Steel bar gratings shall be Irving Grating, type CM-2, galvanized, or equal as approved by the Engineer, with bearing bars, 1-1/4 inch x 3/16 inch o.c.

B. Steel bar gratings shall be welded to steel support beams.


2.08 SHOP PAINTING

A. Miscellaneous metal work surfaces and edges, except those members or portions of members to be embedded in masonry, are to be field painted unless otherwise indicated.

B. Rust, scale and other deleterious materials shall be removed before the shop coat of Paint is applied. Heavy rust and loose mill scale shall be cleaned in accordance with SSPC SP-2, Hand Tool Cleaning, or SSPC SP3, Power Tool Cleaning, or SSPC SP-7, Brush-Off Blast Cleaning. Oil, grease and similar contaminants shall be removed in accordance with SSPC SP-1, Solvent Cleaning.

C. One shop coat of metal primer paint shall be applied to fabricated metal items, and two coats of paint to surfaces which are inaccessible after assembly or erection. Color of second coat shall be changed to distinguish it from the first coat.

D. Metal primer paint shall be applied by brush, in accordance with the manufacturer’s instructions, at a rate to provide a uniform dry film thickness of 4.0 mils for each coat immediately .after surface preparation. Methods which will result in full coverage of joints, comers, edges and all exposed surfaces shall be used for applying paint.

PART 3 - EXECUTION

3.01 GENERAL

A. Contractor shall furnish and coordinate anchorage setting drawings, diagrams, templates, instructions, and other directions for installation of anchorages, such as sleeves, anchor bolts and miscellaneous items having integral anchors which are to be imbedded in masonry construction.

B. Delivery of items to the project site shall be coordinated with work of other trades to avoid delays.

C. Work shall be accurately set in location, alignment, and elevation; plumb, level, true and free or rack; measured from established lines and levels.

D. Exposed connections shall fit accurately together to form tight, hairline joints. Weld connections, which are not to be left as exposed joints, but cannot be shop-welded because of shipping limitations, shall be welded in the field.

E. Field welding, where approved by Engineer, shall comply with AWS Code for procedures for Manual Shielded Metal Arc Welding, appearance and quality of welds made, and methods used in correcting welding work.

F. Exposed joints shall be ground smooth and cleaned and painted in accordance with Section 09910, Paints and Coatings.

3.02 SETTING FABRICATIONS

A. Bottom surfaces of units shall be cleaned, set, positioned, and plumbed.

B. Grout shall be packed solidly between units and masonry to ensure that no voids remain.

C. Non-removable units shall be welded to supporting members of frameworks.


3.03 ADJUST AND CLEAN

A. Field welds, bolted connections, and abraded areas of shop paint shall be cleaned, and exposed areas shall be painted with same paint used for shop painting. Paint shall be applied by brush to provide a minimum thickness of 4.0 mils.

END OF SECTION




SECTION 09902

HOT DIP GALVANIZED AND PAINTED STEEL

PART 1 - GENERAL


A. The Contractor shall fabricate, galvanize and paint the steel components and assemblies as shown on the Drawings and described herein.

B. The Contractor shall be responsible for all materials, labor, and shipping costs as required for a complete finished system.


A. Section 05120 – Structural Steel

B. Section 05500 – Metal Fabrications

C. Section 05511 – Metal Grating Stairs

D. Section 05520 – Handrails and Railings

1.03 SUBMITTALS

A. The Contractor shall supply all manufacturer’s technical data and MSDS (Material Safety Data Sheets) sheets on all galvanizing and paint products used. Submissions shall be complete and include all required items for the galvanizing and paint finishes.

B. The Contractor shall include, in steel fabrication shop drawings, vent hole layout which indicates vent hole spacing and sizes required for a complete galvanized product both inside and out. Vent holes shall be placed so as not to be visible on the finished product; typically on a surface that faces downwards or is covered or set tight against another object once assembled. Vent holes shall be closed off after the galvanizing process has been completed and prior to painting. Vent holes shall be capped with nylon plugs.

C. The Contractor shall supply (4) color samples of each color specified.

D. The Contractor shall supply (2) steel tube samples that includes (1) 6” long leg welded at 90 degrees to a 3” long leg. The ends of both legs shall be welded closed. (1) Sample shall be galvanized to show the quality of paint ready galvanized steel and proper vent hole locations. The other sample shall be galvanized, vent holes plugged, and painted per the paint specification. These samples shall be used as a quality acceptance baseline for the finished product.

E. The Contractor shall submit a letter of certification which outlines and identifies the process and standards to which the fabrication was galvanized to. It shall be the Contractor’s responsibility to assure that Subcontractors (fabricator, galvanizer, and painter) satisfy the specification requirements.

F. Product List: Cross-reference to coating system and locations of application areas. Use same designations indicated on Drawings and in schedules. Include color designations.


A. The Contractor shall coordinate fabrication along with all component finishes, and shall assure that the components / fabrications are packaged and shipped properly to assure that


the finish is not damaged while in storage and / or in transit. Damage shall be repaired by the Contractor at no additional cost to SEPTA.

B. The Contractor shall assure that painting shall not be permitted on contaminated and / or blemished surfaces. In particular the Contractor shall assure that all galvanized steel to be painted shall not be quenched. All galvanized metal shall be free of drips, runs and splatters.

C. The galvanizing finish shall meet ASTM D6386 standards to the satisfaction of SEPTA or be rejected and replaced at no additional cost to the SEPTA.

D. During the drying process the painted steel shall be protected from damage by individually hanging, bracing, laying, and / or standing the steel to assure that the surfaces are not marred and that surfaces do not stick to adjacent surfaces. All items shall be dried for a period long enough to assure that the surface can withstand stacking prior to bundling. All items shall be individually wrapped and have spacers placed between adjacent components to assure damage does not occur during storage and / or shipping. If items must be strapped, the use of protective pads must be utilized where the strapping may mar the finish.

E. See 3.01G for additional Quality Assurance requirements.


A. Deliver materials in protective wrappings with each item labeled with installation location.

B. Store all items inside in dry location.

PART 2 - PRODUCTS

2.01 HOT DIP GALVANIZING SYSTEM

A. Galvanizing system shall be suitable for paint finish work and shall meet ASTM A123 and ASTM D6386 standards. Visible drips, splatters, and runs shall not be acceptable. The galvanizer shall provide a smooth consistent surface to receive paint. All galvanized steel to receive a shop paint system shall not be quenched.

B. Thickness – Provide a 2.0 oz/sq ft zinc coating.

C. The galvanizing process shall not warp, twist, or deform material/ assemblies/ fabrications/ members. Adequate measures shall be taken to prevent warping, twisting, or deformations such as, providing adequate vent holes, controlling temperatures, and providing reinforcing. If the Contractor has concerns that the material may deform during the galvanizing process the concern shall be brought to the attention of SEPTA prior to fabrication. The Contractor assumes sole responsibility of the process by proceeding with fabrication and galvanizing process without notification.

D. The Contractor shall be responsible for proper handling of the material / fabrication throughout the entire fabrication process until final delivery and acceptance of finished product by SEPTA.

E. Certification of galvanization shall be provided to SEPTA prior to delivery, see Submittals Section 01300.

2.02 PAINT SYSTEM

A. The steel / metal fabrication paint system shall be a duplex system. The prep, prime and finish of the paint system shall be in accordance with the written specification of the manufacturer, Sherwin Williams. SEPTA draw down colors can be obtained by contacting


the Sherwin Williams Philadelphia Store located at 2301-07 E. Venango Street, Philadelphia, PA 19134.

B. Quenched galvanized steel shall be rejected. Newly galvanized steel must be prepped using Clean and Etch as manufactured by Sherwin Williams. Galvanized steel that has light scaling shall be lightly brush blasted to clean off light scaling. After prepping the galvanized steel for painting the contractor shall verify that the galvanized film thickness meets or exceeds specification. If small areas do not meet the specified film thickness then these section must be primed with Corothane I Galvapac Zinc Primer (B65G11). If large or numerous areas do not meet specification then the painting contractor shall notify the Prime Contractor and these units shall be rejected and re-galvanized so they meet specification.

C. The following paint systems shall be used:

1. General Steel Shapes (framing members)

a) (1) shop-applied wash coat

b) (1) coat Recoatable Epoxy Primer, B65A5H5, R5/B65V5

c) (1) coat Corothane I – MIO Aluminum Primer B65S14 (3 mils dft)

d) (2) coats High Solids Polyurethane B65-100 (3 mils dft)

2. Galvanized Railings, Frames, and Underside of Structural Roof Deck

a) (1) coat Corothane I – MIO Aluminum Primer B65S14 (3 mils dft)

b) (2) coats High Solids Polyurethane B65-100 (3 mils dft)

3. Railings – Spot Primed Areas and Finish

a) (1) coat Corothane I - MIO Aluminum Primer B65S14

b) (2) coats High Solids Polyurethane B65-100

c) Dry Film Thickness:

1) Prime - 2.0 to 3.0 mils DFT

2) 1st and 2nd coats - 3.0 to 4.0 mils DFT per coat

3) Total system thickness = 8.0 to 11.0 mils DFT

4. Railing Base Plate - Spot Prime Soldered Areas

a) (1) coat Corothane I Galvapac Zinc Primer B65G11

b) (1) coat Corothane I - MIO Aluminum Primer B65S14

c) (2) coats High Solids Polyurethane B65-100

d) Dry Film Thickness:

1) 1st Prime - 3.0 to 4.0 mils DFT

2) 2nd Prime - 2.0 to 3.0 mils DFT per coat

3) 1st and 2nd coats - 3.0 to 4.0 mils DFT per coat

4) Total system thickness = 11.0 to 15.0 mils DFT

PART 3 - EXECUTION


3.01 HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH

A. Hot-Dip Galvanizing: Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing or approved equal. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware. Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B. Galvanizing shall exhibit a rugosity (smoothness) not greater than 4 rug (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of architectural and structural elements that are less than 24 pounds per running foot. Profilometer shall be capable of operating in 1 micron increments.

1. Surface blasting prior to application of factory-applied post galvanizing wet coatings will produce a high rugosity and not be acceptable.

C. Galvanize all components after all welding has been completed, to the maximum extent possible. Provide holes throughout fabrication to permit galvanizing fluids to flow inside and out for complete galvanization. Drain holes in horizontal members shall be placed along the bottom of the tube. After the galvanization process close-up all holes not required to be weep holes. Holes shall be plugged with plastic or rubber, cut flush with metal surface prior to painting.

D. Architectural Finish: Provide factory-applied architectural coating over hot-dip galvanized steel.

1. Primer coat shall be factory-applied prime coat. Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.

2. Finish coat shall be factory-applied color-pigmented architectural finish. Apply finish coating at the galvanizer’s plant, in a controlled environment meeting applicable environmental regulations and as recommended by the finish coating manufacturer.

3. Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards.

4. Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.

5. Blast cleaning of the galvanized surface is not acceptable.

E. Performance Criteria: Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

1. Primer:

a) ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).

b) ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).

c) HUMIDITY - Method: ASTM D 4585

d) SALT SPRAY (FOG) - Method: ASTM B 117

e) PENCIL HARDNESS

f) FLEXIBILITY


2. Topcoat:



c) GRAFFITI RESISTANCE - Method: The following graffiti materials applied to coating and allowed to dry for seven days: acrylic, epoxy-ester and alkyd spray paints, ballpoint ink, crayon, Markett marker, black shoe polish and lipstick.

d) EXTERIOR EXPOSURE - Method: Exposed at 45 degrees facing south

e) SURFACE BURNING CHARACTERISTICS: - Method: ASTM E-84

f) QUV - Method: ASTM G 53 (ES-40 bulbs, 4 hours light, 4 hours dark)

g) SALT SPRAY (FOG) - Method: ASTM B 117

h) PENCIL HARDNESS

i) FLEXIBILITY

F. Clearcoat: Provide factory-applied clear coating over primed and color-coated galvanized steel.

1. Performance Criteria: Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:



c) GRAFFITI RESISTANCE - Method: The following graffiti materials applied to coating and allowed to dry for seven days: acrylic, epoxy-ester and alkyd spray paints, ballpoint ink, crayon, Markett marker, black shoe polish and lipstick.

d) WEATHERING: - Method: ASTM D 1014, 45 degrees south; Method: ASTM D 4141C EMMAQUA-NTW

e) QUV - Method: ASTM G 53 (FS-40 bulbs, 4 hours light, 4 hours dark)

f) SALT SPRAY (FOG) - Method: ASTM B 117

g) FLEXIBILITY – Method: ASTM D 522 (Method B, Cylindrical Mandrel)

h) HARDNESS: Method: ASTM D 3363 (Pencil)

G. Quality Assurance for Hot-Dip Galvanizing and Factory-Applied Metal Coatings:

1. Galvanizing shall be performed by a company with documented experience in the successful application of hot-dip galvanizing utilizing the dry kettle process.

2. Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

3. Submit two 3 inch by 6 inch samples of factory-applied coatings and colors proposed for use for approval prior to coating application.

4. Engage the services of a galvanizer who has demonstrated experience in the successful performance of the processes outlined in this specification in within the same facility as outlined herein. The Architect has the right to inspect the facility


where the work is to be done and who will apply the galvanizing and coatings, and approve or reject the galvanizer/galvanizing facility.

5. Handle and install materials with factory-applied coatings as recommended by galvanizer and coating manufacturer to prevent damage to coatings prior to and after installation.

6. Touch-up factory-applied metal coatings as recommended by galvanizer and coating manufacturer.

7. Coatings not matching approved submittals shall be removed and replaced at no additional expense to the Owner.

8. Certificate of compliance that the galvanizer has certified weighers on premises with a certification from the local municipality, and a certified scale or municipal scale has been utilized by the galvanizer.

9. Fabricator shall provide a notarized statement from the galvanizer, along with a description of the material processed, indicating that all work has been done in conformance with this specification prior to receiving payment.

10. Certificate of Compliance for Shop Drawing Review by Galvanizer: Submit galvanizer's certification that shop drawings for metal fabrications to receive metal coatings have been reviewed and that fabrications are acceptable to galvanizer for proper application of galvanizing and metal coatings. All drawings should be stamped by the galvanizer to indicate approval of design for galvanizing.

11. Substitutions shall not be considered unless approved by Architect, Owner/Owner's Representative and Contractor. Substitution requests shall be accompanied by proof that the substitution meets or exceeds the performance, aesthetic and durability requirements of the specified Duncan process. Coatings not matching approved submittals shall be removed and replaced at no additional expense to the Owner

H. Galvanizer/coater shall supply a certificate of compliance that all coatings have been performed in accordance with QP-3 standards and procedures.

END OF SECTION


SECTION 09910

PAINTS AND COATINGS

PART 1 - GENERAL


A. Provide painting, as shown and scheduled per Contract Drawings; including, but not limited to:

1. Painting and surface preparation for interior and exterior finished surfaces.

2. Priming of substrates.

3. Refer to Section 09902 Hot Dip Galvanized and Painted Steel for galvanized and painted steel.

4. Refer to Section 09960 High Performance Coatings for sealing/painting of concrete floor surfaces for Overpass flooring.


A. Section 15932 – Air Outlets and Inlets.

1.03 REFERENCES

A. American Society of Testing Materials (ASTM): Conform to ASTM D16 for interpretation of terms used in this Section.

B. National Paint and Coatings Association (NPCA): Guide to U.S. Government Paint Specifications.

C. Painting and Decorating Contractors of America (PDCA): Painting - Architectural Specifications Manual.

D. Steel Structures Painting Council (SSPC): Steel Structures Painting Manual.

1.04 SUBMITTALS

A. Product Data: Submit manufacturer’s specifications, data, and installation instructions for review.

B. Product List: Cross-reference to coating system and locations of application areas. Use same designations indicated on Drawings and in schedules. Include color designations.

C. Samples:

1. General: Submit specified colors for each surface-finishing product.

2. Field Samples:

a) General: In place, on material scheduled to be finished, illustrating coating color, texture and finish. Locate where directed; accepted sample may remain as part of the Work.

b) Size: One (1) entire unit as scheduled to be finished

D. Certificates: Submit statement of VOC compliance with local regulations.



A. General: Refer To Section 01400 - Contractor’s Quality Assurance System.

B. Qualifications:

1. Applicator: Specializing in performing the work of this Section with documented experience.

2. Volatile Organic Compounds (VOC): Use only products in compliance with VOC content limits required by state and local regulations.


A. Delivery:

1. Schedule delivery of materials at the site at such time as required for proper coordination of the work. Receive materials in manufacturer’s unopened packages and bearing manufacturer’s label.

B. Storage:

1. General: Store materials in a dry and properly ventilated separate structure not less than 50’-0” from any other structure on the site. Adequately protect from damage and exposure to the elements.

2. Temperature: Maintain minimum of 45 degrees F and a maximum of 90 degrees F.

3. Fire Prevention: Take necessary precautions to prevent fire; remove paint-soiled rags and waste from building each day or store in metal containers with covers in the paint storage structure.

1.07 WARRANTY

A. Manufacturer’s Standard Warranty:

1. General: Provide, in required form, for a period of five (5) years from date of final acceptance.

2. Criteria: Color and finish appearance shall remain unchanged throughout entire guarantee period.

1.08 EXTRA MATERIAL

A. Deliver one percent (1%) or a minimum of two (2) gallons of each color, type, and surface texture of paint installed. Label each container with color, type, texture, and room locations.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Manufacturer:

1. Acceptable Manufacturers:

a) Basis of Design: Sherwin Williams.

b) Carboline Co.

c) Benjamin Moore.


d) Or approved equal.

2. Container Label: Identify with manufacturer’s name, and include description of type of paint, brand name, lot number, and brand code and color designation.

B. General: Provide ready mixed products, except field catalyzed coatings. Provide accessory materials such as linseed oil, shellac, thinners, cleaners, and other materials not specifically indicated but required to achieve finishes specified.

1. Use only one lot of paint for any individual element to be painted. Do not mix lots of paint.

C. Galvanized Steel Material (Interior or Exterior):

1. All Galvanized Steel, Galvanized Steel Deck, Galvanized Steel Framing, Galvanized Steel Railings and Frames, and Galvanized Metal Stairs – Refer to Section Hot Dip Galvanized and Painted Steel Section 09902.

D. Exterior:

1. Composite Trim:

a) (1) coat Pro Industrial Pro-Cryl Universal Gray Primer B66-310

b) (2) coats Pro Industrial HP Acrylic, Semi-Gloss B66-650

2. Miscellaneous Metal Trim:

a) (1) coat Macropoxy 646-100 Fast Cure Epoxy, B58-620

b) (2) coats High Solids 100 Polyurethane B65-600

3. Various Slightly Rusted Substrates – Interior or Exterior:

a) (1) coat Kem Bond HS Universal Metal Primer B50AZ8

b) (2) coats Industrial Enamel High Solids Gloss B54 series

or

c) (1) coat Macropoxy 646-100, Fast Cure Epoxy B58-620

d) (2) coats High Solids Polyurethane 100 B65-600

4. Walls:

a) Standard CMU or Concrete Block. Ground face block shall not be painted.

1) (1) coat PrepRite Block Filler B25W25

2) (2) coats A-100 Exterior Latex Satin A82 Series

b) Concrete Walls or Curbs:

1) (1) coat Loxon Concrete & Masonry Primer, A24

2) (2) coats A-100 Exterior Latex Satin A82 Series

E. Interior:

1. Walls

a) Standard CMU or Concrete Block. Ground face block shall not be painted.

1) (1) coat PrepRite Block Filler B25W25


2) (2) coats ProMar 200 Zero VOC Latex Semi Gloss B31W200

b) Concrete Walls or Curbs:

1) (1) coat Loxon Concrete & Masonry Primer, A24

2) (2) coats ProMar 200 Zero VOC Latex Semi-Gloss B31W200

c) Gypsum Board:

1) (1) coat ProMar 200 Zero VOC Interior Latex Primer, B28W2600

2) (2) coats ProMar 200 Zero VOC B-20 Series. Sheen to match existing

d) Fire Rated Plywood:

1) (1) coat ProMar 200 Zero VOC Interior Latex Primer, B28W2600

2) (2) coats Pro Industrial Acrylic, B66-650

e) Cast Iron

1) Primer: refer to specification 05500 – Metal Fabrications

2) (1) coat Pro Industrial HP Acrylic, B66-650

F. Miscellaneous Cleaning and Refinishing Materials:

1. Fine grade Scotch-Brite pads (white and/or green type,) manufactured by 3M Co, St Paul MN, or approved equal.

2. Very fine steel wool, clean and free of contaminants and corrosion.

3. Clean, soft, lintless, cotton rags.

4. Cotton pads and swabs.

G. Solvent Cleaners And Thinners:

1. Xylene: Commercial manufacture.

2. White Spirit: Commercial manufacture.

3. Odorless Lacquer Thinner: Commercial manufacture.

4. Denatured Alcohol: Commercial manufacture.

5. Or approved equal.

2.02 MIXING

A. General: Mix paints at the factory; do not alter or reduce materials except as directed by manufacturer.

B. Colors: See finish schedule on drawings.

C. Mildew Resistance: Add fungicidal agent to paint per manufacturer’s recommendations. Add agent at the factory; clearly indicate on label that paint is mildew resistant.

PART 3 - EXECUTION

3.01 PREPARATION

A. Environmental Requirements:


1. General: Do not apply exterior coatings during rain or snow, or when relative humidity is outside the humidity ranges required by the manufacturer.

2. Temperature:

a) General: Do not apply materials when surface and ambient temperatures are outside the temperature ranges required by the manufacturer.

b) Exterior Paints: 40 degrees F minimum during and for 48 hours after application; do not apply when temperature is over 90 degrees F, except in protected or shaded areas.

c) Interior Paints: 50 degrees F for minimum of 48 hours before, during, and for 48 hours after application.

3. Ventilation: Provide adequate ventilation of all interior spaces during application and curing of all painting products.

4. Lighting Level: Provide minimum 80 foot candles measured at mid-height of room. At exterior, measured at mid height of element to be painted.

B. Examination:

1. General: Examine conditions of surfaces in place before beginning work; report defects.

2. Shop Applied Primer: Test for compatibility with subsequent cover materials

3. Moisture Content: Measure moisture content of surfaces using an electronic moisture meter. Do not apply finishes unless moisture content of surfaces is below the following maximums:

4. Acceptance: Application of first coat of painting process constitutes acceptance of surface

C. Protection: Protect adjacent surfaces not scheduled for paint finish from damage resulting from painting operations.

D. Steel/Metals Surface Preparation:

1. Blast cleaning of faying surfaces shall be performed in accordance with SSPC-SP10, Near-white Blast Cleaning.

2. Blast cleaning all other steel shall be performed in accordance with SSPC-SP6, Commercial Blast Cleaning.

3. Oil, grease, salts, or other surface contaminations must first be removed by the methods outlined in SSPC SP 1.

4. Dust conditions at the station site shall be anticipated, and such dust as may collect shall be removed before touch-up paint is applied.

5. All flux, spatter, slag, or laminations from welding or other sharp projections shall be ground smooth prior to blast cleaning.

6. All areas blast cleaned on any day shall be coated on the same day. Any such areas not coated that are exposed overnight shall be lightly “whip-blasted” to remove any visible or invisible rust that may have formed.

7. Remove or mask electrical plates, hardware, light fixture trim, escutcheons, and fittings prior to preparing surfaces or finishing. Correct defects and clean surfaces


that affect work of this section. Remove existing coatings that exhibit loose surface conditions. Use Shellac to seal marks, which may bleed through surface finishes.

8. Impervious Surfaces: Remove mildew by scrubbing with solution of trisodium phosphate and bleach. Rinse with clean water and allow surface to dry.

9. Shop Primed Steel Surfaces: Sand and scrape to remove loose primer and rust. Feather edges to make touch-up patches inconspicuous. Clean surfaces with solvent to remove all oil, grease and other foreign matter. Prime bare steel surfaces.

3.02 APPLICATION

A. General: Install in conformance with referenced standards, manufacturer’s written directions, as shown, and as specified.

B. Performance:

1. General: Apply each coat to uniform finish, slightly darker than preceding coat unless otherwise approved. Sand surfaces lightly between coats to achieve required finish. Vacuum clean surfaces free of loose particles; use tack cloth just prior to applying next coat. Allow applied coat to dry before next coat is applied.

3.03 CLEANING

A. General: Upon completion, remove masking materials, reinstall electrical cover plates, hardware, light fixture trim, escutcheons, and fittings removed prior to finishing, and thoroughly clean all exposed surfaces per manufacturer’s instructions. Keep premises free from accumulation of waste and rubbish. At the completion of work remove surplus materials, rubbish, and debris.

B. Touch-Up: After detailed inspection of paint work, touch up or refinish abraded, stained, or otherwise disfigured work, as required by the Engineer.

C. Cleaning: Remove containers, rags, and debris from the site; observe special care in control or disposal of flammable materials.

END OF SECTION


SECTION 10400

IDENTIFYING DEVICES

PART 1 - GENERAL


Provide and install all identifying devices as indicated on the Contract Drawings and as specified herein, including, but not limited to, the following:

1. Aluminum Signs

2. Acrylic Signs

3. Tactile and Braille Signs

4. Free Standing Signage

RELATED SECTIONS

Section 05120 – Structural Steel

Section 05500 – Metal Fabrications

Section 07900 – Joint Sealers

REFERENCES

All signage shall comply with the current version of the SEPTA Standard Manual; the messages indicated on the Contract Drawings are illustrative in nature. The Contractor shall become familiar with full range of messages provided. Signage messages for each sign will be provided by SEPTA.

American National Standards Institute (ANSI) A117.1: Providing Accessibility and Usability for Physically Handicap People, Current Edition.

National Association of Architectural Metal Manufactures (NAAMM).

Americans with Disabilities Act Architectural Guidelines (ADAAG).

Department of Justice, Office of the Attorney General, "Americans with Disabilities Act", Public Law 101-336 (ADA).

Federal Register Part II, Architectural and Transportation Barriers Compliance Board, 36 CFR Part 1191: Americans with Disabilities Act (ADA) Accessibility Guidelines for Buildings and Facilities; Amendment to Final Guidelines, September 6, 1991.

American Society for Testing and Materials (ASTM).

1. B209-86 Aluminum and Aluminum-Alloy Sheet and Plate.

2. B211-85 Aluminum-Alloy Bars, Rods, and Wire.

3. B221-85 Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes.

Aluminum Welding Society (AWS).

1. D1.2-83 Structural Welding Code-Aluminum.

Aluminum Association (AA).

1. ASD-1 Aluminum Standards and Data, 1979.


DAF-45 Design System for Aluminum Finishes, 1976.

Federal Specification (FS).

1. FF-92B(1) Screw, Machine, Slotted, Cross Recessed or Hexagon Head.

2. TT-645a Primer, Paint , Zinc-Chromatic, Alkyd-Type.

SUBMITTALS

Refer to Section 01300 – Submittals.

Product Data: For each type of product.

Submit a complete list of all materials proposed to be furnished and installed under this Section.

Shop Drawings:

1. Provide detailed Shop Drawings including message layouts, fabrications, mounting, bracketing details, installation details, installation heights, attachments to other work, and key plans for installation.

2. Submit Braille Certification per this Specification.

3. Sign Schedule including message copy for every sign, by sign number.

a) Sign messages shall be cross-referenced to the appropriate typical layout and the mounting details.

b) Sign number, quantity, panel dimension, copy height, graphics, artwork, copy color, background color, and mounting condition shall be noted for each sign.

4. Provide a colored line for each sign, after approval of shop drawings and prior to fabrication.

a) Colored line shall be ½” size showing actual typography and actual colors.

b) Colored line shall be exact replicas of sign layouts.

c) Colored line shall be keyed to the approved sign schedule.

d) Secure SEPTA approval prior to fabrication.

Samples:

1. Accompanying the material list, submit a sample of each sign material illustrating the actual finish obtained with complete graphics.

2. Submit sample basketry design for typical mounting surfaces wall, pendent, column, etc. (see signage schedule for complete listing.) Also submit a panel sample with frame on two sides for each proposed thickness combination.

3. Prototype: Provide a production prototype for approval at the place of fabrication. The unit will be reviewed by the Engineer and corrections made. This unit will be used as a model for the line production and will be considered an actual unit to be placed on a site, not a mock up, if acceptable to the Engineer

Qualification Data: For installer and manufacturer.

Sample Warranty: for special warranty.


QUALITY ASSURANCE

General: Refer to Section 01400 - Quality Requirements.

Pre-Installation Conference: Closely coordinate tolerances required in this Section for completely coordinated and smooth installation.

For the fabrication of the Signage, use only mechanics that are thoroughly trained and experience in skills required for the manufacture and fabrication of the units.

1. In acceptance or rejection of the manufactured units, no allowance will be made for lack of skill on the part of the fabricator / manufacturer.

2. The materials must be in full compliance with Contract Documents and approved Shop Drawings.

ADA Design Requirements:

1. Signage requiring tactile graphics:

a) Wall mounted signs designating permanent rooms and spaces, such as room numbers, restrooms, electrical closets, and mechanical rooms.

b) Individually applied characters are prohibited.

2. Signage not requiring tactile graphics but requiring compliance to other ADA requirements: All other signs providing direction to or information about function of space, such as directional signs (signs with arrow), informational signs (operating hours, policies, etc.), regulatory signs (no smoking, do not enter) and ceiling and projected wall mounted signs.

ADA Performance Requirements:

1. Tactile Graphics Sign Mounting Requirements:

a) Single doors: Mount 60" to sign centerline above finished floor and on wall adjacent to latch side of door, as shown on drawings.

b) Openings: Mount 60" to sign centerline above finished floor adjacent to opening.

c) No wall space adjacent to latch side of door, opening or double doors: Mount 60" to centerline above finished floor on nearest adjacent wall.

An interior sign plaque shall be installed adjacent to each new door. The final room description on each sign shall be determined by the Owner. A list generated from room names noted on drawings shall be submitted to the Owner for review and comment.

Tolerances:

1. Sign Panels and Extrusions:

a) The Contractor shall note on the shop drawings all fabrication tolerances including, but not limited to: plumb, thickness, length, width, squareness, camber, and flatness.

b) Signs shall be free of defects including, but not limited to: buckles, dents, wraps, wrinkles, and burrs.

c) All extrusions for a given shape shall be fabricated from dies of identical cross section dimensions.


2. Messages:

a) Messages Location: +/-1/16 inch from the location shown.

b) Line to Line: +/-1/32 inch between each line and +/-1/16 inch over the entire message. Letter to Letter or Symbol (horizontally and vertically) +/-1/32 inch between each letter of symbol and +/-1/16 inch over and entire line.

3. Where multiple panels adjoin, the face and edges shall be milled to a tolerance of a +1/32 inch or –1/32 inch from a straight plane, so that when two adjoining panels are assembled, no gap over 1/16 inch shall be visible between panels.

4. Design components to allow for expansion and contraction for temperatures ranging between –20 degrees F and +100 degrees F, without causing bucking, opening of joints other than control joints, or overstressing of welds and fasteners.

5. Comply with AWS D1.2 for recommended practices in shop welding. Provide welds behind finished surfaces without distortion or discoloration of exposed side. Clean exposed welded joints of all welding flux and dress on all exposed and contact surfaces.

6. Mill joints to a tight, hairline fit. Cope or miter corner joints.

Loading: The unit must withstand a wind load of 20#/SF and horizontal/vertical loads of 250# at top center of the sign with a maximum deflection of 1/360 of sign length. Calculations are to be submitted for SEPTA review.

Mounting: The Contractor shall have all mounting and fabrication details and calculations designed and stamped as approved by a Professional Engineer (PE) licensed in the State of Pennsylvania.

FIELD CONDITIONS

Field Measurements: Verify locations of anchorage devices and electrical service embedded in permanent construction by other installers by field measurements before fabrication, and indicate measurements on Shop Drawings.

DELIVERY, STORAGE, AND HANDLING

Protection: Use all means necessary to protect the signs prior to delivery. The pre-assembled units are to be shipped in protective crating and palletized. Each sign package is to bear the identification as noted on the sign schedule.

Packaging: Each sign will come individually shrink-wrapped complete with its own bracketry and attachment hardware.

Replacements: The Engineer’s sole discretion as to whether replacement or repair will be the procedure for damaged units.

WARRANTY

Special Warranty: Manufacturer agrees to repair or replace components of signs that fail in materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a) Deterioration of finishes beyond normal weathering.


b) Deterioration of embedded graphic image.

c) Separation or delamination of sheet materials and components.

2. Warranty Period: Five years from date of Substantial Completion.

PRODUCTS

MANUFACTURERS

Aluminum Signage:

1. Philadelphia Sign Company, Palmyra, New Jersey, Telephone 609-829-1460.

2. Sweet Sign Systems, Doylestown, Pennsylvania, Telephone 215-340-1600.

3. G.P. Dunphy Co., Ashford CT. (860) 429-2550.

4. Or Engineer's approved equal.

Acrylic Signage:

1. East Coast Sign & Supply Inc., Bethel CT, Telephone 203-791-8326.

2. United Sign System, Staten Island, NY, Telephone 718-980-7097.

3. G.P. Dunphy Co., Ashford CT. (860) 429-2550.

4. Or Engineer’s approved equal.

FABRICATION, ALUMINUM SIGNAGE

Face and Back Sheets:

1. Double sided graphic signs.

a) Face sheets and back sheet to be fabricated in one piece from minimum .040” thickness aluminum sheets, 3003 H14 alloy.

2. Single sided graphic signs: Face sheets to be fabricated in one piece .040” thickness. The back sheet shall be .040” minimum thickness, aluminum alloy sheet 3003-H-14 with an alloy 1230 cladding of approximately 5% on both sides.

Panel Frame: Each Panel section shall be provided with an extruded internal perimeter framing shall be aluminum alloy 6063-T6 with a minimum thickness of .080 inches. The perimeter frame shall have mitered corners, reinforced, welded and ground smooth. Intermediate supports shall be included as required.

Core Materials: Core Material shall be 1” thick phenolic impregnated paper honeycomb. Core materials shall meet specification MIL-D-5272 for resistance to fungus. The cell size shall be ½”, weight of Kraft Paper 80lb; impregnation 18 percent by weight minimum.

Lamination: Lamination shall be achieved by use of 3M Scotch-Grip High Performance Contact Adhesive- 1357, meeting specification requirements of MMM-A-1211 and MIL-A2-1366.

Space Bars: Space Bars shall be solid aluminum ¾” x 2” length as required. All exposed surfaces to be primed with zinc chromate alkyd base primer. Provide two (2) finishes coats of epoxy oil base paint. Color: 100% black with low sheen finish.

Hardware:


1. All bolts and screws shall be made of stainless steel unless otherwise indicated.

2. Exposed fasteners on sign faces shall be not be permitted.

3. Exposed Fasteners shall be made tamper-proof by an approved method.

4. Hangers, studs, clip angles and filler plates shall be aluminum, mill finish. 6063 T6, unless otherwise indicated.

5. All welds shall be continuous, and ground smooth, unless otherwise indicated.

Finish:

1. Pre-Treatment:

a) The aluminum sheets are to be especially prepared for application by pretreatment meeting ASTM D1730-67, Type B, Method 5 or 7. Processing shall conform to ASTM B-449-67 (1972) Section 5. Conversation coating weight shall be between 30-100 mgms per square foot.

2. Four (4) Coat System Equal to Kynar 500:

a) Coating application shall be performed under specifications issued by manufacturer and an applicator specifically approved by manufacturer. Said applicator shall provide written notification of approval by manufacturer to application of finish.

b) Coating System shall include (1) primer coat; (2) background color coat; (3) graphic coat; (4) clear coat; with the total minimum dry film thickness to be 1.7 mils. Exposed cap extension shall be aluminum 6063 alloy and coated with System.

Mounting: As specified on Signage Type Detail drawings and per reviewed shop drawings for all signs.

1. Holes shall be pre-drilled in each corner of each sign by the manufacturer. Screws shall be tamper-proof.

2. Sign mounting will be in accordance with ADA Accessibility Guidelines height and clearance requirements.

3. The Contractor shall verify that the Braille message matches the text message.

4. Each sign shall include a complete installation kit with stainless steel, non-removable /clutch head screws.

FABRICATION, ACRYLIC SIGNAGE

Face Sheet: Provide cast methyl methacrylate monomer plastic sheet in sizes and thicknesses indicated on Signage Schedule.

1. Sheet material to be opaque and of the color indicated on Signage Schedule.

2. Colors:

a) Standard colors such as “white,” “blue,” and “black,” shall be selected from the manufacturer’s standard colors.

b) Where specific Pantone Matching System (PMS) color is specified on the Signage Schedule, manufacturer will provide the custom matched color


specified.

3. Sheet material to be 0.120” injection molded, high impact, UV resistant and surface textured with an eggshell matte finish of less than 15 degrees gloss.

4. Acrylic sheet material to have a minimum flexural strength of 16000 psi when tested in accordance with ASTM D790, a minimum allowable continuous service temperature of 176 degrees F.

5. All graphics, text, and Braille characters shall be centered on sign material. Graphics shall be separated from text and Braille with a visible graphic line.

6. Refer to Contract Drawings for signage message information.

Hardware:

1. All bolts and screws shall be made of stainless steel unless otherwise indicated.

2. Exposed fasteners on sign faces shall be not be permitted.

3. Exposed Fasteners shall be made tamper-proof by an approved method.

Mounting: As specified on Signage Type Detail drawings and per reviewed shop drawings for all signs.



3. The Contractor shall verify that the Braille message matches the text message.


TACTILE AND BRAILLE SIGNS

Tactile and Braille signs of type, text and in locations as scheduled on the Contract Drawings.

1. Finished thickness of signs, including raised areas, shall be 0.156”. Finished thickness of signs, exclusive of raised areas, shall be 0.125”.

2. Material: All signage with tactile and braille to be fabricated from Zinc Sheet Metal, 1/8” thick. Copy shall be photo-etched .039 inches from the surface.

3. Letters/Pictograms/Header Line:

a) All shall be raised 1/32” Integral with the sign face by means of die-stamping. Letters, pictograms, header lines shall have well defined, but not sharp edges.

4. Vandal Resistance Level:

a) All raised characters, as well as the sign base shall be scratchproof. Sign finish shall not deteriorate upon application of graffiti removal products.

5. Tactile Characters: As specified on Signage Schedule

a) Unless otherwise noted, 5/8 “-1” Helvetica Medium uppercase letters; die-raised; tactile text, depending on expected size/message of sign.


Contractor to be instructed which size to use on a per sign basis. Glue-on letters or etched backgrounds are not acceptable.

6. Pictograms: As specified on Signage Schedule .

a) 4” tactile pictograms, unless otherwise noted on drawings.

7. Braille characters: Grade 2 Braille to be used, with translation to be provided by signage manufacturer, and certified by an independent organization or agency specializing in services for the blind, to be selected by the manufacturer.

8. Signs to have corners rounded with a ½” radius, and have no borders.

9. Holes for mounting screws/anchors shall be pre-drilled in each corner of each sign.

10. Color: As specified on Signage Schedule.

a) Positive / Relief: Brushed satin silver finish integral with the metal. No applied graphics.

b) Negative / Background: Baked enamel finish with clear coat in eggshell finish

c) Copy: Tactile characters, pictograms and header line.

d) Entire sign shall be coated with clear urethane protective coating after finishing.

11. Mounting: As specified on Signage Type Detail drawings and per reviewed shop drawings for all signs.

a) Holes shall be pre-drilled in each corner of each sign by the manufacturer. Screws shall be tamper-proof.

b) Sign mounting will be in accordance with ADA Accessibility Guidelines height and clearance requirements.

c) The Contractor shall verify that the Braille message matches the text message.

d) Each sign shall include a complete installation kit with stainless steel, non-removable /clutch head screws.

INFORMATIONAL AND DIRECTIONAL SIGNAGE

Reference Standard: SEPTA Signage Manual (latest edition) for specific guidelines on sign layout basic sizes.

Sign Sizes: As specified on Signage Schedule:

1. Length: Dependent on sign message.

2. Depth: .125 inch.

3. Height: Dependent on number of lines.

Character Size: As specified on Signage Schedule.

Character Typeface: Helvetica Bold.

Mounting: As specified on Signage Type Detail drawings and per reviewed shop drawings for all signs:




3. The Contractor shall verify that the Braille message matches the text message


FABRICATION, FREE STANDING SIGNAGE

Reference Standard: SEPTA Signage Manual (latest edition) for specific guidelines on sign layout basic sizes.

See Sign Schedule on Drawings for sign specific information.

Refer to Section 05500 – Metal Fabrications for construction requirements.

EXECUTION

PREINSTALLATION MEETING

A meeting with SEPTA’s Project Manager is required prior any installation.

INSPECTION:

Inspection: Install no work until surfaces on which signage and other Work of this Section are to be placed and attached are free of defects and are in a completed conditions.

Examine substrates, areas, and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of signage work.

Verify that sign-support surfaces are within tolerances to accommodate signs without gaps or irregularities between backs of signs and support surfaces unless otherwise indicated.

Verify that anchor inserts are correctly sized and located to accommodate signs.

Proceed with installation only after unsatisfactory conditions have been corrected.

PREPARATION

General: All surfaces to receive placement of Work of this Section shall be clean and dry.

INSTALLATION

General: Install all signage, and other Work of this Section level, and plumb: secure to substrate in the manner as detailed on the Drawings and as recommended by the Manufacturer.

1. Install signs level, plumb, true to line, and at locations and heights indicated, with sign surfaces free of distortion and other defects in appearance.

2. Install signs so they do not protrude or obstruct according to the accessibility standard.

3. Before installation, verify that sign surfaces are clean and free of materials or debris that would impair installation.


4. Corrosion Protection: Coat concealed surfaces of exterior aluminum in contact with grout, concrete, masonry, wood, or dissimilar metals, with a heavy coat of bituminous paint.

Room-Identification Signs and Other Accessible Signage: Install in locations on walls as indicated and according to accessibility standard

Mounting Methods:

1. Concealed Studs: Using a template, drill holes in substrate aligning with studs on back of sign. Remove loose debris from hole and substrate surface.

a) Masonry Substrates: Fill holes with adhesive. Leave recess space in hole for displaced adhesive. Place sign in position and push until flush to surface, embedding studs in holes. Temporarily support sign in position until adhesive fully sets.

b) Thin or Hollow Surfaces: Place sign in position and flush to surface, install washers and nuts on studs projecting through opposite side of surface, and tighten.

2. Projecting Studs: Using a template, drill holes in substrate aligning with studs on back of sign. Remove loose debris from hole and substrate surface.

a) Masonry Substrates: Fill holes with adhesive. Leave recess space in hole for displaced adhesive. Place spacers on studs, place sign in position, and push until spacers are pinched between sign and substrate, embedding the stud ends in holes. Temporarily support sign in position until adhesive fully sets.

b) Thin or Hollow Surfaces: Place spacers on studs, place sign in position with spacers pinched between sign and substrate, and install washers and nuts on stud ends projecting through opposite side of surface, and tighten.

3. Through Fasteners: Drill holes in substrate using predrilled holes in sign as template. Countersink holes in sign if required. Place sign in position and flush to surface. Install through fasteners and tighten.

4. Brackets: Remove loose debris from substrate surface and install backbar or bracket supports in position so that signage is correctly located and aligned.

5. Adhesive: Clean bond-breaking materials from substrate surface and remove loose debris. Apply linear beads or spots of adhesive symmetrically to back of sign and of suitable quantity to support weight of sign after cure without slippage. Keep adhesive away from edges to prevent adhesive extrusion as sign is applied and to prevent visibility of cured adhesive at sign edges. Place sign in position, and push to engage adhesive. Temporarily support sign in position until adhesive fully sets.

6. Two-Face Tape: Clean bond-breaking materials from substrate surface and remove loose debris. Apply tape strips symmetrically to back of sign and of suitable quantity to support weight of sign without slippage. Keep strips away from edges to prevent visibility at sign edges. Place sign in position, and push to engage tape adhesive.

Mounting Locations: See Drawings for locations of signs.

Attachment: Attach as detailed on the drawings.


CLEAN-UP AND PROTECTION

General:

1. Remove and replace damaged or deformed signs and signs that do not comply with specified requirements. Replace signs with damaged or deteriorated finishes or components that cannot be successfully repaired by finish touchup or similar minor repair procedures.

2. On completion of installation, clean exposed surfaces of signs according to manufacturer's written instructions, and touch up minor nicks and abrasions in finish. Maintain signs in a clean condition during construction and protect from damage until acceptance by Owner.

3. Remove all debris from Work area.

4. Remove protective covers at Project Completion.

SIGN SCHEDULE

Sign Schedule:

1. See Sign Schedule on Drawings.

END OF SECTION




SECTION 16010

BASIC ELECTRICAL REQUIREMENTS

PART 1 - GENERAL


A. This Section covers the basic electrical requirements specifically applicable to Division 16 Sections, in addition to Division 1 – General Requirements.

B. Specific work elements include permits, project staffing and coordination, cutting and patching, construction facilities and controls, record documents, commissioning of systems, and instruction manuals for operations and maintenance.

C. Provide electrical systems as indicated in the Contract Drawings.

1. Drawings are diagrammatic, contractor shall verify dimensions prior to installation. Contractor shall coordinate all work with other division trades to provide a complete and operable system.

2. Contractor shall coordinate location of fixtures, devices, etc. with other trades in order to avoid interferences.

3. All work shall be performed as required by applicable section of the National Electric Code (N.E.C.), latest edition, and all governing local codes, laws and/or regulations.





D. All sections of Division 13

E. Section 15782 – Packaged Heating and Cooling Units

F. Section 15850 – Fans and Blowers

G. Section 15950 – Controls

H. All other Sections of Division 16

1.03 SUBMITTALS

A. Product Data: Submit manufacturer's descriptive literature, product specifications, published details, performance/capacity rating schedules or charts and installation instructions, as specified in Section 01300 and as additionally required by related sections.

B. Shop Drawings:

1. Submit shop drawings certified for construction by product manufacturers.

2. Submit shop drawings applicable to items listed under ‘Submittals’ in each related section and such items as may be Scheduled or noted on the Drawings.


3. Include (as applicable) details indicating construction and materials of construction; dimensions; equipment, and weights of principal parts and of the completed assembled item.

C. Submit manufacturer installation and maintenance manuals along with shop drawings. Verify documentation submittals are complete as part of contract closeout process.

D. Adherence to Contract Documents: Review each submittal for completeness and for compliance with the Contract Drawings and Specifications. Failure to comply, even though the submittal is based on the manufacturer and equipment specified, will result in rejection of the submittal.

1.04 REGULATORY REQUIREMENTS

A. Requirements of Regulatory Agencies: Conform to the building and electrical code requirements of State. Modify the electrical work to be in conformity with such laws, ordinances, rules and regulations without additional expense to SEPTA. Note: All NFPA codes referenced in these specifications shall be the latest editions of those codes in effect at the time of the bid.

B. Certificates and Permits:

1. Upon completion of work, and prior to final payment, furnish formal certification of final inspections to SEPTA from authorities having jurisdiction.

2. Secure required permits or certificates from such authorities. Prepare detailed diagrams and drawings, which may be required by those authorities having jurisdiction.

3. Submit a copy of each piece of correspondence to and from the authorities having jurisdiction.

C. Source Quality Control: Products as specified in these Specifications and as indicated on the Drawings are those of companies having established reputations in the manufacture of the particular materials, equipment or apparatus specified. Provide products from manufacturers that are either of their own make, or products of others, for which the manufacturer assumes full responsibility. Utilize only products for which replacement parts are available.

D. UL Listing: Provide UL Listed products whenever comparable, products of like design, function and appearance have been submitted to UL and have received the UL Label. Provide products labeled for the specific use intended and the location where it will be installed. Provide and include evidence or proof of UL listings by respective references on product data or shop drawing document submittals. Provide UL listing cards, where such information is not otherwise evident, or obvious on the submittal documents.

E. Code Compliance Inspection: Have electrical work that is within the traction power substation yard fence inspected by an authorized inspection agency for compliance with the applicable Electrical Code and obtain certificates of approval, acceptance, and compliance with code regulations. Work shall not be deemed complete until such certificates have been delivered to the Owner with copies furnished to the Engineer for review.

PART 2 - PRODUCTS

NOT USED


PART 3 - EXECUTION

NOT USED

END OF SECTION




SECTION 16050

BASIC ELECTRICAL MATERIALS AND METHODS

PART 1 - GENERAL


A. This Section covers the requirements of the basic materials and methods of installation of electrical systems, which include the following:

1. Metal framing system (also known as strut system)

2. Cable tray systems

3. Cable (vertical support) strain relief grips, bus drops, and conduit risers when cable end is not available

4. Cable fire-proofing tape system

5. Floor and wall sleeves

6. Beam Clamps

7. Concrete Inserts (anchors)

8. Duct watertight cable plugs

9. Padlocks for various traction power and auxiliary power equipment






E. Section 15782 – Packaged Heating and Cooling Units

F. Section 15850 – Fans and Blowers

G. Section 15950 – Controls

H. All other sections of Division 16

1.03 SUBMITTALS

A. List proposed manufacturers with model or catalog numbers, identifying the materials and equipment proposed.

B. Brochures, catalog cuts, or shop drawings shall be submitted for materials and equipment as designated on the returned list of materials.

C. Submit samples of any materials for review by SEPTA’s Project Manager. Samples shall be sent to the Project site and stored by the Contractor.

D. Submit certification from manufacturers verifying that the equipment furnished conforms to the specified requirements.


E. Submit the following cable tray related documents and samples for SEPTA’s review and approval:

1. Drawings of cable tray and accessories including clamps, brackets, hanger rods, splice plate connectors, expansion joint assemblies, and fittings, showing accurately scaled components.

2. Product Data: manufacturer's data on cable tray including, but not limited to, types, materials, finishes, rung spacing, inside depths and fitting radii. For side rails and rungs, submit cross sectional properties including Section Modulus (Sx) and Moment of Inertia (Ix).

3. Shop Drawings. Submit shop drawings for SEPTA’s approval showing the following:

a) Cable tray layout

4. Samples: Submit a sample of each type of cable tray and accessories, along with a description of its intended use.


A. ASTM International (ASTM)

1. A123/A123M – Standard Specification for Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products

2. A276 – Standard Specifications for Stainless Steel Bars and Shapes

3. A480/A480M – Standard Specifications for General Requirements for Flat-Rolled Stainless and Heat-Resistant Steel Plate, Sheet, and Strip

4. A370 – Standard Test Methods and Definition for Mechanical Testing of Steel Products

5. A1011/A1011M – Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength, Low-Alloy, and High-Strength, Low-Alloy with Improved Formability

6. ASTM D635 Standard Test Method for Rate of Burning…of Plastics

7. ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials

8. E814 – Standard Test Method for Fire Tests of Through-Penetration Fire Stops

B. National Fire Prevention Association (NFPA)

1. 70 – National Electrical Code (NEC)

C. National Electrical Manufacturers Association (NEMA)

1. FG-93 – Fiberglass Cable Tray Systems

2. FG-1 – Non-metallic Cable Tray Systems

D. Inspection of Materials

1. Inspection of the material will be made at the point of delivery. However, SEPTA’s Project Manager reserves the right to make any tests or inspection that he may deem necessary at the Contractor’s plant.


2. In the event inspection is made at the plant, grant SEPTA’s Project Manager, and/or representative, free entry at all times while work under this specification is being performed, to all parts of the plant that concern the manufacture of the pertinent material/equipment.

3. Render all assistance to satisfy SEPTA’s Project Manager that the material/equipment is being furnished in accordance with this specification.

4. Assume the responsibility to impose these conditions in contracts with the equipment manufacturer.

5. In all cases, notify SEPTA’s Project Manager when the finished material/equipment is ready for shipment in order that plant inspection of the material/equipment may be made if desired.

E. Regulatory Requirements: The construction code requirements of State, County, City, Utility Companies or other political subdivision, which exceed the requirements of NFPA 70, shall be met and complied with. Modify the electrical work to be in conformity with such laws, ordinances, rules and regulations.

F. Use electrical materials, which are new, UL listed, meet UL requirements, and bear the UL label. In lieu of the UL listing, or where standards have not been established by UL and label service or certification service is not available, material and equipment shall be listed by one of the following laboratories:

1. Canadian Standard Association (CSA)

2. ETL Testing Laboratories, Inc.

3. MET Electrical Testing Company, Inc.

4. United States Testing Company, Inc.

5. Applied Research Laboratories, Inc.

G. Perform Work of this Section in accordance with requirements of NFPA 70 (NEC) applicable to basic electrical materials and as modified by this Specification.

H. Code Compliance Inspection: Have the work inspected by an authorized electrical inspection agency for compliance with NFPA 70 and obtain certificates of approval, acceptance, and compliance with code regulations. Work shall not be deemed complete until such certificates have been delivered to SEPTA’s Project Manager for review.

1.05 OPERATION AND MAINTENANCE DATA

A. Furnish SEPTA’s Project Manager with one set of Final Drawings, in reproducible form and on CD-ROM disk in AutoCAD format, of the material and equipment supplied under this Agreement, in their accepted, as-built form.

PART 2 - PRODUCTS

2.01 MATERIALS AND EQUIPMENT

A. Metal Framing Systems

1. The following metal framing system manufacturers are approved for use on this Project:

a) Unistrut Buffalo-P1000 Series


b) Versabar Corporation

c) Cooper B-Line

d) SEPTA-approved Equal

2. Material

a) All Metal framing system components that are in unheated spaces, shall be fabricated from structural grade steel that is hot-dipped galvanized, conforming to ASTM A101 1 and A123.

b) All metal framing system components that are installed outdoors, shall be fabricated from structural grade stainless steel conforming to ASTM A480 and A276.

c) Cables shall be supported using Unistrut, Porce-A-Clamp (thermoplastic elastomer insulator) with stainless steel clamps and hardware or approved equal.

B. Cable Tray

1. General: Except as otherwise indicated, provide non-metallic cable trays, of types, classes, and sizes indicated; with splice plates, bolts, nuts and washers for connecting units. Construct units with rounded edges and smooth surfaces; in compliance with applicable standards; and with the following additional construction features. Cable tray shall be installed according to the latest revision of NEMA VE-2.

2. Material and Finish: Straight section structural elements; side rails, rungs and splice plates shall be pultruded from glass fiber reinforced polyester or vinyl ester resin.

3. Pultruded shapes shall be constructed with a surface veil to insure a resin-rich surface and ultraviolet resistance.

4. Pultruded shapes shall meet ASTM E-84, Class 1 flame rating and self-extinguishing requirements of ASTM D-635.

5. Ladder Cable Trays shall consist of two longitudinal members (side rails) with transverse members (rungs) mechanically fastened and adhesively bonded to the side rails. Rungs shall be spaced 9 inches on center. Rung spacing in radiused fittings shall be industry standard 9” and measured at the center of the tray’s width. Each rung must be capable of supporting a 200 lb. concentrated load at the center of the cable tray with a safety factor of 1.5.

6. Cable tray inside widths shall be 12 inches or larger, with final size as determined by fill calculations prepared by the contractor.

7. Straight and expansion splice plates will be of “L” shaped lay-in design with an eight-bolt pattern in 5” fill systems and four-bolt pattern in 3” and 2” fill systems. Splice plates shall be furnished with straight sections and fittings.

8. All fittings must have a minimum radius of 12 inches.

9. Cable trays shall be as manufactured by the companies listed below, or approved equal:

a) B-line


b) Power-Strut

c) Allied Electrical

C. Cable Strain Relief Grips

1. Select appropriate type cable strain relief grips for the application and be fully aware of the breaking strength, safety and technical data regarding the product.

2. Provide support of AC cables in vertical conduit drops.

3. Cable Strain Relief Grips shall be manufactured by the companies listed below:

a) Hubbell Kellems

b) Daniel Woodhead

c) Ericson

d) SEPTA-approved Equal

D. Cable Fire-Proofing System

1. All cables that are supported and run exposed in manholes, vaults, substations (including cable tray installations), electrical rooms and such locations, shall be protected along its entire exposed length by a fire retardant electric arc-proofing tape system.

2. The fire retardant electric arc-proofing tape shall be a non-halogenated, chlorine-free, and low-smoke product.

3. Fireproof tapes shall be provided by the manufacturers listed below or an approved equal:

a) Scotch 77 in conjunction with bands of Scotch 69 Glass Cloth Electrical Tape per manufacturer’s recommended procedure

b) Grace Construction Products, FlameSafe CFR Series in conjunction with Scotch 69 Glass Cloth Electrical Tape per manufacturer’s recommended procedure

c) SEPTA-Approved Equal

4. Wrap exposed length of cable so that tape overlaps itself in half laps to provide and effective thickness of two layers.

E. Sleeves

1. Sleeves shall be rigid galvanized steel tubing. Extend sleeves through floor or two inches above the finished floor and two inches below ceilings.

2. Seal conduits penetrating walls below grade with a waterproof, modular, mechanical expansion seal consisting of interlocking synthetic rubber links shaped to continuously fill the annular space between the conduit and wall opening. Assume responsibility for the sizing of links and wall sleeve. Seal conduits in fire rated walls with fire seals of the same rating as wall composition.

a) Fire retardant sealant shall be asbestos-free; UL classified, and meet ASTM E814. Forming and backing material installed with the sealant shall be bulk ceramic fiber or rigid fiberboard rated for 2300 degrees Fahrenheit.


3. For slabs above grade, plastic core form block-outs may be used to form sleeve opening where exposed in electrical closets and other areas not subject to flooding.

F. Beam Clamps

1. Shall be galvanized steel, with tapped holes in base and face for bolts or hanger rods.

G. Concrete Inserts

1. Anchor Bolts, Nuts Washers, and Screws:

a) Less than 3/8-inch trade size shall be stainless steel

b) Greater than or equal to 3/8-inch trade size shall be galvanized

c) For steel work utilize either machine screws, welded threaded studs, or spring-tensioned clamps

2. Channel Inserts:

a) Not lighter than 12-gauge carbon steel hot-dip galvanized after fabrication

b) Not smaller than 1-1/2 inches by 1-1/12 inches, and have 13/32 inch by 3-inch slots on 4-inch centers

c) Pullout load rating shall be not less than 1,500 pounds per linear foot uniformly distributed

d) Inserts embedded in concrete shall have solid base plate with concrete anchors welded to base plate and coated with cold-applied zinc-rich paint

3. Spot inserts:

a) Rated 800 pounds

b) Carbon steel galvanized after fabrication

c) Safety factor of five

d) Covered to prevent concrete from filling insert during installation

H. Duct Watertight Cable Plugs

1. Cable watertight cable seals shall be as manufactured by Jack Moon, Inc., OZ Gedney, or approved equal.

I. Padlocks

1. Provide Padlocks for the following equipment:

a) Interrupter Switch Operating Mechanism Handles

b) Grounding Switches Operating Mechanism Handles

c) SCADA RTU cabinet

d) SCADA Interface Cubicle

e) Manhole and handhole entry protection bars, except locks shall be keyed alike per a SEPTA standard

2. Padlocks shall have 2”-wide solid brass body with 1” brass shackle clearance, 3/8” shackle diameter. Each padlock shall be keyed differently and each provided with two keys.


3. Acceptable Manufacturer: Wilson Bohannan Padlock Company (Model 92120-2-A) or SEPTA-approved equal.

4. Provide a durable metal key box, wall-mounting type, with hinged doors to organize the keys. Provide as a minimum, 50 assignment key hangers mounted on a wall inside the SFC building control room.

PART 3 - EXECUTION

3.01 PREPARATION

A. Transmit submittals and deliverables required by this Section.

B. Furnish products as indicated on the Drawings.

C. Ensure substrates are in suitable condition to receive the work of this Section.

D. Review the Drawings and Specifications thoroughly in preparation for installation of the materials and equipment. Materials shall be procured and stored, and planned for use in a manner that minimizes waste and substitutions and maximizes installation efficiency and quality of the end product.

E. Determine the exact location of all equipment within the space assignments designated on the drawings. The right to make any reasonable change in location of equipment, before installation, is reserved by SEPTA’s Project Manager.

F. Design and install all electrical equipment and apparatus in a manner that provides accessibility and arrangement suitable for maintenance and replacement.

G. Examine all Contract and Reference Drawings, to verify and properly coordinate the placement of conduits and outlets; check all drawings including mechanical drawings, equipment drawings, and shop drawings, for apparatus that must be connected.

3.02 INSTALLATION, APPLICATION, OR EXECUTION

A. Metal Framing System

1. Provide metal framing material, fittings, and related accessories to support the equipment, conduits, and cables as specified and as shown on the Contract Drawings

2. Provide labor, supervision, engineering, and fabrication required for installation of the metal framing systems.

B. Cable Tray

1. Cable trays shall be supported by metal framing systems.

2. Maximum distance between tray supports shall be in accordance with the manufacturer instructions, but no greater than eight (8) feet.

3. Support Horizontal Straight Sections: Within two feet of splices.

4. Support Horizontal Elbows: At the midpoint of the arc.

5. Support Horizontal Tees: Within two feet of each opening.

6. Support Horizontal Crosses: Within two feet of each opening and diagonally under the cross for two feet and three feet radii fittings.

7. Support Vertical Elbows: At each end.


8. Support Dropout at End of Runs: Under the fitting.

9. Trays shall be ruggedly clamped in place at every support. Sliding glide clamps may be used in horizontal runs, where provision for thermal expansion is required. Sloping and vertical trays shall be through-bolted or positively anchored to the support by means other than friction, so as to support the specified design load. Make provisions to allow tray supports to accommodate thermal expansion of the tray system.

10. Maintain a minimum vertical clearance of one (1) foot from the top of trays to the underside of beams, ceilings, ducts, piping, and other obstructions, and one (1) foot from bottom of tray to switchgear and one (1) foot between non-intersecting trays.

11. Mark tray runs with the tray numbers at both ends and every 25 feet. Stencil 2 inch high black letters in a visible location on the outside of the tray side channel.

12. The following partial list is intended to serve as an example of the kinds of equipment that shall be supported using metal framing systems:

a) Automatic transfer switches

b) Disconnect switches

c) Panel boards

d) Battery chargers

e) Bus ducts

f) Light fixtures

g) Conduits

h) Pull boxes and splice boxes

i) Cable strain relief grips

j) Exposed cables run along the wall or ceiling

k) Interrupter switches

C. Beam Clamps:

1. Beam clamps may be used for support of raceways, enclosures, panelboards or equipment where attached to/from fixed steel supports or structures.

2. Beam clamps fastened to steel supports not horizontal or vertical shall be provided with a swing connector.

3. Beam clamps fastened to structures in a horizontal position (where bolt is horizontal) shall not be used for support of equipment exceeding 10 pounds.

D. Concrete Inserts (Anchors):

1. Holes for anchors placed in pre-stressed and post-tensioned concrete shall be made so as not to weaken tendons or tensioning wires.

END OF SECTION


SECTION 16052

GENERAL ELECTRICAL REQUIREMENTS -TRACTION POWER EQUIPMENT

PART 1 - GENERAL


A. Provide all traction power equipment to withstand the specified project conditions and be capable of operation without impairment at the specified performance levels. This shall include performing electrical studies identified herein.

B. Design the switching station to be capable of working via local control in the event of failure of SCADA, communication link, local area network, or the bay modules.

C. Advise SEPTA if there are any additional conditions to which the equipment may be sensitive.

D. Provide all equipment with minimum functional life expectancy of 40 years.








G. Section 16060 – Grounding and Bonding

H. Section 16075 – Electrical Identification

I. Section 16262 – Static Frequency Converter

J. Section 16290 – Protective Devices and Instrument Transformers – T.P. Equipment

K. Section 16310 – Transmission and Distribution

L. Section 16335 – Surge Arresters

M. Section 16950 – Testing of Electrical Equipment

N. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS

A. Documentation indicating compliance with the required standards and codes and this specifications.

B. Bring any item of non-compliance with this Specification or with the required standards and codes to the immediate attention of SEPTA.

C. Traction Power System Studies as specified herein.


A. Comply with applicable provisions of the following references:


1. ANSI C.2 National Electrical Safety Code

2. NECA National Electrical Contractor’s Association Standard of Installation Uniform Building Code

3. NFPA 70 National Fire Protection Association, National Electrical Code

4. Applicable Standards and Codes. All work performed and materials supplied under the Contract shall conform to or exceed the requirements of the latest editions of standards and codes issued by the following organizations:

a) Aluminum Association of America (AAA)

b) American Hot Dip Galvanizers Association

c) American Institute of Steel Construction (AISC)

d) American Iron & Steel Institute (AISI)

e) American National Standards Institute (ANSI)

f) American Society for Testing & Materials (ASTM)

g) American Society of Mechanical Engineers (ASME)

h) American Welding Society (AWS)

i) Construction Specifications Institute (CSI)

j) Industrial Fasteners Institute (IFI)

k) Institute of Electrical & Electronics Engineers (IEEE)

l) Insulated Cable Engineers Association (ICEA)

m) National Electrical Manufacturers Association (NEMA)

n) National Electrical Testing Association (NETA)

o) National Fire Protection Association (NFPA)

p) Occupational Safety and Health Administration (OSHA)

q) Society of Automotive Engineers (SAE)

r) Underwriters Laboratories (UL)

B. A partial list of applicable standards is provided in each equipment section of the Technical Specifications. Identify and consult all applicable industry standards as well as local, state and utility codes and practices.

C. Provide all systems in accordance with the most stringent applicable industry standard, code or practice and requirement.

1.05 PROJECT CONDITIONS AND PERFORMANCE REQUIREMENTS

A. Indoor Climatic Conditions:

1. Design all indoor equipment to be suitable for operation in industrial environment throughout temperature range of 10°F to 100°F and 90% relative humidity.

B. Outdoor Climatic Conditions:

1. The outdoor climatic conditions existing in the Project locale are shown in Table 16052-1.


TABLE 16052-1 – Outdoor Climatic Conditions

Design Conditions Climatic Condition Minimum Value Maximum Value Temperature (deg. C) -22 +104 Ice Thickness (inches) 0 0.25 24-Hour Rainfall (inches)

0 10

Humidity (%) 40 100 Wind Speed (mph) 0 90 - 110

C. Altitude:

1. The altitude of the project site does not exceed 3,300 feet.

D. Seismic Conditions:

1. Provide electrical equipment and material suitable for Seismic Use Group II, Seismic Design Category C, Site Class D, as defined by the Interstate Building Code (IBC).

E. Operating Environment:

1. 36 kV Output Transformer Circuit Breakers and Associated Equipment

a) The 36 kV Output Transformer Circuit Breakers and its associated equipment will be installed outdoor. The breaker controls and relays shall be installed in the SFC control room.

b) The equipment will not be exposed to damaging fumes, vapor steam, salt air, oil vapors, excessive dust, and abnormal vibration or tilting

F. Operating Conditions:

1. Voltage and Frequency. The following operating conditions can occur simultaneously:

a) Voltage: 110% of rated value due to rolling stock regeneration

b) Frequency: 95% of rated value

2. Fluctuating Loads. The traction power system is subject to rapidly fluctuating load currents as trains accelerate, decelerate, and encounter gradients. The fluctuating load results in axial and radial pulsating forces in the substation equipment.

3. Short Circuits. The traction power system is subject to a high occurrence of short circuits. The short circuits occur as follows:

a) Between the overhead 12 kV trolley and ground or rail

b) Between the overhead 24 kV feeder and ground or rail

c) Between the overhead 24 kV feeder and the overhead 12 kV trolley

4. Harmonics. The traction power system operates with a significant content of harmonics caused by power electronic equipment switching. The harmonics consist of two parts:


a) Harmonics generated by the traction load. The traction load consists of number of multi-car trains operating simultaneously on the system. The propulsion system of the existing cars is thyristor controlled. The new fleet of the cars expected to be procured by SEPTA over next several years will have propulsion system based on integrated gate bipolar thyristors (IGBTs).

b) Harmonics generated by the static frequency converters (SFCs).

c) The SFC manufacturer, ABB, performed extensive studies of the system harmonics and their results are shown in Table 16052-2. The Table shows the overall system harmonics when one SFC is operating at 100% rated power and at 200% rated power. (This table will be updated for the 60% after harmonic measurements are taken.)

d) Since SEPTA could operate four SFCs in parallel, all equipment shall be designed for the simultaneous operation of all four units. For operation of four SFCs in parallel, the system harmonic current shall be assumed to increase proportionally.


TABLE 16052-2 – Harmonic Content of the Power System Currents for One SFC

Harmonic Frequency (Hz)

Current Harmonics at Converter Load 15MVA 30MVA (A) % of

Fundamental (A) % of

Fundamental 1 25 1,456 Fundamental 2,686 Fundamental 3 75 269 18.48 367 13.66 5 125 444 30.49 633 23.57 7 175 100 6.87 144 5.36 9 225 41.7 2.86 52.8 1.97 9.6 240 5.6 0.38 11.1 0.41 11 275 16.7 1.15 44.5 1.66 11.6 290 5.6 0.38 11.1 0.41 13 325 8.8 0.60 33.32 1.24 13.6 340 5.6 0.38 11.1 0.41 15 375 5.6 0.38 27.8 1.03 15.6 390 19.4 1.33 50.0 1.86 17 425 5.6 0.38 8.3 0.31 17.6 440 36.1 2.48 61.1 2.27 19 475 5.6 0.38 5.6 0.21 19.6 490 63.9 4.39 80.6 3.00 21 525 5.6 0.38 5.6 0.21 21.6 540 75.0 5.15 55.6 2.07 23 575 5.6 0.38 2.8 0.10 23.6 590 33.3 2.29 41.7 1.55 25.6 640 5.6 0.38 5.6 0.21 27.6 690 19.4 1.33 5.6 0.21 29.6 740 2.8 0.19 11.1 0.41 31.6 790 16.7 1.15 5.6 0.21 33.6 840 33.3 2.29 5.6 0.21 35.6 890 30.6 2.10 5.6 0.21 37.6 940 19.4 1.33 5.6 0.21

PART 2 - PRODUCTS

2.01 SERVICES REQUIRED

A. Scope

1. This specification covers the rehabilitation of the Wayne Junction Static Frequency Converter (SFC) Station at Wayne Junction, Philadelphia, PA.


2. The design, supply, construction, testing, and commissioning into full service of four new SFCs, with an input of 13.2 kV, 60 Hz, 3-phase and an output of 36/24/12 kV, 25 Hz, single phase. The continuous full-load power capacity of the new SFCs are specified in specification section 16262.

3. Each new SFC shall be fully interoperable and compatible with the existing SFCs so that it can perform its function either alone or with any combination of the existing SFCs on line.

4. The new SFC system shall have an expected lifetime of no less than forty years. The equipment supplied with the SFC system includes the following:

a) SFC power block equipment

b) SFC input and output transformers

c) SFC harmonic and power factor correction filters

d) SFC pre-charging circuit breakers and auxiliary transformers

e) SFC control system

f) SFC cooling system, including pumps, piping, and heat exchangers

g) SFC power distribution system and UPS equipment

h) SFC protection system equipment

i) Sequence of events recorder

j) Transient disturbance recorder

k) Remote terminal units (RTUs)

l) SFC interconnecting cabling, conduits, and accessories

5. The 25 Hz Traction Power Substation 12 kV and 24 kV protection schemes shall be recalibrated in order to incorporate SFC #4.

6. The construction of a new building for the fourth SFC, attached to the existing SFC #3 building.

7. Modifications to the existing SFC Control Room for SFC control and protection equipment for the new SFC system.

8. Modifications to the existing Wayne Junction TPSS Control Room for the output circuit breaker protection equipment for the new SFC system.

9. A new isolation switch and protective relays supplied in the Wayne Junction 25 Hz Traction Power Substation.

2.02 COMPLEXITY OF THE PROJECT

A. The traction power work included in this Contract is very complex and requires high degree of coordination between suppliers, contractors, and SEPTA. It is expected that the required electrical equipment will be procured from multiple manufacturers. The Contractor shall be required to integrate all equipment into one operable system.

B. Multiple levels of testing shall be required, including design and production tests at manufacturer’s plants, tests in specialized laboratories, and field tests at the site.


2.03 PRODUCTS, MATERIALS, AND EQUIPMENT.

A. Provide only new and unused products, materials, and equipment as approved by SEPTA

B. Provide products, materials, and equipment that are standard products of manufacturers regularly engaged in the production of such products, materials and equipment to the extent feasible except for provision of additional features that are required per these specifications, Provide the manufacturer’s latest standard design that conforms to the Contract Documents.

C. Provide products, materials, and equipment listed and labeled by an electrical safety testing laboratory acceptable to SEPTA where available and that meets the specification requirements,

D. Where two or more units of the same class of product, material or equipment are required, provide products from a single manufacturer. Incidental component parts of equipment are not required to be the products of the same manufacturer.

E. Where finish of products, materials, and equipment is referenced or stated, provide the finish exactly as shown or specified. Where no finish or color is listed, provide the manufacturer’s standard finish, suitable for the environment intended, and as approved by SEPTA.

F. Provide all products, materials, and equipment designed to ensure satisfactory operation and operational life in the environmental conditions of the Project locale.

G. All, materials, and equipment are subject to inspection by SEPTA at any time.

H. Correct or replace at no additional cost to SEPTA any products, materials, and equipment not in accordance with the Contract Documents or found to be deficient or defective.

PART 3 - EXECUTION

3.01 GENERAL REQUIREMENTS DURING MANUFACTURE

A. Perform all phases of equipment manufacture by qualified and experienced personnel using proper tools and equipment under competent supervision.

B. Manufacture and install all equipment to withstand and be capable of operation without impairment at the specified performance levels at the specified Project Conditions.

C. Select all equipment and hardware, including seals, elastomers, and lubricants, suitable for the specified Project Conditions. Use only products and materials free of asbestos and other potentially harmful substances.

D. Procure materials and manufacture equipment and components based on the contract specifications and contractor’s final designs approved by SEPTA. Provide only service proven components, equipment, and materials that are standard products of manufacturers regularly engaged in the production of such components, equipment, and materials.

E. For equipment manufacture and fabrication use materials of the highest possible quality. Provide high grade workmanship conforming in all respects to the best manufacturing practices for electrification system equipment.

F. Locate and install all equipment to be readily accessible for operation and maintenance. SEPTA reserves the right to require minor changes in location of raceways or equipment for operational flexibility. The contractor shall implement these changes at no additional cost to SEPTA.


G. All system components shall be capable of being maintained without impairment resulting from natural or induced environmental conditions within which SEPTA will operate the system.

H. Provide insides of all enclosures free of burrs and sharp edges.

I. Insure that no equipment is damaged during manufacture and factory testing and SEPTA will be the sole judge of whether the equipment can be repaired/reconditioned or new equipment will have to be manufactured if such damages do happen.

3.02 GENERAL REQUIREMENTS DURING INSTALLATION

A. After obtaining from SEPTA’s Substation Maintenance Department categorical permission in writing to disconnect and remove each piece of equipment to be removed under this Contract, test and ensure that the equipment are de-energized prior to proceeding with the removal.

B. After removal and disposal of the equipment, per stage, per the governing codes, rules and regulations, proceed with the site clean-up meeting the environmental regulations.

C. Perform all civil and structural work including transformer foundations, pads for the breakers, underground conduit and ductbank installation.

D. Install all electrical equipment.

E. Install disconnect switches and surge arresters.

F. Install all cables and perform all necessary connections.

G. Install feeder and trolley connections.

H. Ground all traction power equipment.

I. Provide fully operational system.

J. Perform all phases of equipment installation by qualified, licensed, and experienced personnel using proper tools and equipment under competent supervision.

K. Insure that no equipment is damaged during shipment, storage, installation, and field testing.

L. As required, install raceway stub-ups in accordance with field conditions and equipment Shop Drawings. Cap raceway runs with seals manufactured by the raceway manufacturer.

M. Securely fasten in place and protect all equipment and raceways against earthquakes.

N. Keep openings in boxes or equipment closed during construction.

O. Install equipment using procedures defined in NECA Standard of Installation.

P. Energize any space heaters in equipment or provide temporary heat.

Q. Construction progress and workmanship quality is subject to inspection by SEPTA at any time.

R. Correct any work not in accordance with the Contract Documents and contractor’s detailed design drawings or found to be deficient or defective at no additional cost to SEPTA.

3.03 PROTECTION OF PRODUCTS DURING CONSTRUCTION

A. Provide protection of products against loss or damage.


B. Protect all products from the effects of weather. Prior to installation, store products in clean, dry, indoor locations.

C. Store items subject to corrosion and items containing insulation, such as conductors, in a clean, dry, heated, indoor location.

D. Following installation, protect products from corrosion, dust, dirt, physical damage and the effects of moisture.

E. Ensure that operating portion of the substation is unaffected by the construction activities and safety of the workers is fully taken care of.

3.04 EQUIPMENT INSTALLATION

A. Contractor shall develop detailed installation procedure with detailed step by step procedure for all the work including General requirements for Installation specified above included in the scope of Contract and submit it to the SEPTA approval prior to commencement of any field work. The procedure shall clearly show that the substation will be in revenue operation during the entire period of construction under this contract. Without the approved installation procedure, Contractor will not be allowed to perform any field work.

3.05 TESTING

A. Factory Testing

1. Perform comprehensive tests of all components and equipment during the manufacturing process and upon its completion.

2. Perform all factory design and production tests as specified in the individual equipment sections in accordance with specified standards.

3. Do not proceed with the production of equipment until satisfactory completion of design tests and approval by SEPTA.

B. Field Testing

1. Perform system installation inspection upon completion of all installation work for each phase.

2. Perform test prior to system energization and tests following system energization as specified in Section 16970.

END OF SECTION




SECTION 16060

GROUNDING AND BONDING

PART 1 - GENERAL


A. This section covers requirements for grounding and bonding of indoor and outdoor electrical equipment, manholes, hand holes, pull boxes, junction boxes, fences, doors, metallic structures, and overhead distribution system structures.

B. Install ground grid, ground rods, ground meshes, grounding wires, grounding pigtails, ground busbars, grounding lugs and fittings; and, ground and bond all equipment and structures as specified. Provide an extension to the existing ground ring around the SFC building to surround SFC unit 4. Provide additional clean low resistance backfill as specified herein.





D. All sections related to crushed stone and electrical work of Division 2

E. All sections of Division 13

F. All sections related to electrically powered products and related controls of Division 15

G. All other sections of Division 16

1.03 SUBMITTALS

A. Submit the following documents and samples for SEPTA’s review and approval:

1. Description of exothermic welding process

2. Description of jointing process

3. Test Procedures. Submit the following test procedures:

a) Test procedure for measuring ground grid resistance

b) Test procedure for measuring electrical continuity of the grounding system

4. Test Reports. Submit the following results:

a) Ground grid resistance

b) Results of electrical continuity measurements

5. Product Data: Submit data on the following products:

a) Grounding conductors and pigtails

b) Ground rods

c) Mesh

d) Ground bus bars


e) Connectors, compression joints, lugs and fittings

f) Exothermic welding molds, weld metal, and electronic ignitor

g) A test report demonstrating that the ignitor meets EEC standard requirements for electromagnetic and electrostatic compatibility, including radiated emissions and electrostatic discharge.

6. Shop Drawings. Submit shop drawings for SEPTA’s approval showing the following:

a) Ground grid layout

b) Location plan: ground rods, connectors, and pigtails

7. Samples: Submit a sample of each type of mechanical and compression connector proposed, along with a description of its intended use.



1. ASTM B3 – Specification for Soft or Annealed Copper Wire

2. ASTM B187 – Specification for Copper Busbar, Rod and Shapes

3. EEC EN6 1000-6-2 – Electromagnetic Compatibility

4. EEC EN5501 – Limits & Methods of Measurement of Radio Disturbance Characteristics of Industrial, Scientific & Medical (ISM) Radio Frequency Equipment

5. IEEE 80 – IEEE Guide for Safety in AC Substation Grounding

6. IEEE 837 – IEEE Standard for qualifying permanent Connections Used in Substation Grounding NFPA 70 National Fire Protection Association, National Electrical Code (NEC)

7. UL 467 – Grounding and Bonding Equipment

8. UL 506 – Specialty Transformers

PART 2 - PRODUCTS

2.01 GROUNDING MATERIALS

A. Bare Conductors

1. Use class B stranded, 4/0 AWG minimum, annealed copper conductors, conforming to ASTM B3 for the ground grid and for all non-flexible grounding connections.

2. Use braided copper conductors, 4/0 AWG minimum, for all pigtails and flexible ground grid connections. Use 1/0 AWG for bonding steel stairs, catwalk and handrail to each other. 8 AWG and 6 AWG may be used for non-traction power equipment ground taps, unless NEC requires a larger gauge conductor.

3. All connections shall be capable of carrying the rated short circuit current.

4. Aluminum conductors are prohibited.

B. Insulated Conductors


1. Select conductors conforming to the requirements for 600 V system grounding. Provide green insulation for conductors No. 2 AWG and smaller and black insulation with green taped ends for conductors larger than No. 2 AWG.

C. Ground Rods

1. Use steel ground rods copper-clad by the molten weld casting process. Use 3/4-inch diameter, 10-foot long rods.

2. Use UL-approved ground rods.

D. Grounding Busbars

1. Busbars for grounding shall be minimum 2 inch x 1/4 inch conforming to ASTM B187, 98% conductivity copper, minimum.

E. Ground Mesh

1. Provide 2 feet x 2 feet opening, 6 feet overall square mats, #6 solid copper conductors.

F. Ground Grid Access Well

1. Provide polymer concrete ground grid access well with cover, nominal 12 inch diameter.

2. Cover shall be of the type that is bolted in place using stainless steel hardware.

G. Standoff Insulators

1. Provide flame resistant fiberglass-reinforced thermoset polyester insulators.

2. Insulators shall be suitable for outdoor use within the Rail Return Cabinet.

3. Insulators shall be ROCHLING, Model 1872-2A or approved equal.

H. Accessories

1. Lugs

a) Select suitable lugs for attaching grounding conductors to equipment or metallic surfaces.

b) Use UL listed NEMA 2-hole, compression type lugs manufactured of tin plated or silver plated copper. Crimp the lugs onto grounding conductors with a hydraulic tool.

2. Use stainless steel or silicon bronze bolts

3. Use braided, flexible tin-plated copper jumpers.

2.02 EXOTHERMIC WELDING MATERIALS

A. Molds

1. Use synthetic graphite material molds capable of withstanding high temperatures generated during the welding process.

2. Use molds bearing permanent marking indicating the name of manufacturer, type and size of welding mixture compatible with the welding process, and the size of cable or bus connection.


3. Use molds furnished with safety information, connection preparation, and welding procedure.

B. Weld Metal

1. Use weld metal consisting of copper oxide.

2. Use weld metal packages that identify the type of weld metal and the metals to be connected

C. Electronic Ignitor

1. Provide rugged and water resistant ignitor meeting the requirements of UL 506, EEC EN61000-6-2, and EEC EN5501.

2. Provide the ignitor with a high intensity LED indicator viewable in sunlight. Use an ignitor with overvoltage protection.

3. Provide field replaceable, 18 AWG, 142-strand, individually insulated, copper leads.

2.03 MECHANICAL CONNECTORS

A. Mechanical connectors shall be solid copper and rated for at least 100% of the current carrying capacity of the conductor terminated.

B. Mechanical connectors may be used in above ground connections to copper bus bars as indicated on the Contract Drawings.

C. Manufacturer shall be DOSSERT, or approved equal

2.04 RAIL RETURN CABINET

A. Cabinet shall be free standing, NEMA 4 rated.

B. Cabinet shall be constructed of 12 gauge steel and include a 3-point latch and handle.

C. Cabinet shall include condensation heater to remove excess moisture from interior.

D. Cabinet shall be mounted on equipment pad in location as indicated on the Contract Drawings.

E. Manufacturer: Hoffman enclosures or approved equal.

2.05 ACCEPTABLE MANUFACTURERS

A. Burndy

B. Erico

C. Harger

D. Thermoweld

E. Thomas and Betts

F. Or approved equal

2.06 CLEAN BACKFILL

A. Backfill for use below and above the buried grid conducts shall be free from rocks and debris.


B. Provide backfill as a mixture of surface soils and loam with negligible amounts of sand and gravel.

C. Backfill bulk resistivity shall not exceed 20 ohm-meters.

PART 3 - EXECUTION

3.01 GENERAL GROUNDING REQUIREMENTS

A. Provide grounding as required by the Contract Drawings, and as specified below.

B. Weld all grounding connections exothermically, including tees, crosses, pig tail connections and ground rod connections. Compression or mechanical connections underground are prohibited.

C. Compression type connections may be used in dry, above grade locations with the approval of SEPTA. Attach lugs to items being grounded with stainless steel or silicon bronze bolting hardware.

D. Protect grounding conductors from physical and environmental damage. Wherever possible, enclose grounding and bonding conductors in non-metallic raceways. Where conductors are required to be exposed, support grounding conductors by corrosion resistant metallic hardware at 4-foot intervals or less.

E. Use bi-metallic strips and oxide inhibiting compound for all mechanical connections where copper to aluminum or copper to steel connections are made. Abrade all contact surfaces prior to application of the inhibiting compound, and before attachment of the bolted connection. Apply the compound to all copper, aluminum, and steel parts.

F. Make all grounding and bonding connections by continuous, un-spliced grounding conductors via shortest possible route and without unnecessary bends and kinks in the conductors.

3.02 EXOTHERMIC WELDING

A. Clean and dry the surfaces to be welded. Wire brush or file the points of contact to clean bare substrate metal surfaces.

B. Use suitable welding cartridges and molds for the type of weld performed. Perform welding in accordance with the manufacturer's recommendations. Discard worn or damaged molds.

C. Place powdered welding metal in the mold along with the conductors to be welded. Ignite the powder to produce molten copper to weld the conductors to each other or to a surface.

D. After welds have been completed and cooled, brush slag from the weld area and thoroughly clean the joint.

E. Where exothermic grounding connections made between copper wire and steel surfaces are direct-buried, coat the connection with a coal tar epoxy (CTE) coating before backfilling. Also, coat the entire area of the steel surface disturbed by the exothermic welding.

F. Where exothermic welds are made to a galvanized surface, remove the galvanizing and expose a clean surface by grinding wheel. After welding, touch up the steel surface with zinc rich primer.

G. Test all welds by striking with a two pound steel hammer. Replace any defective welds.


3.03 GROUND GRID INSTALLATION

A. Excavate and prepare subgrade by leveling and compacting soil. Should rock be encountered, over-excavate. Provide twelve inches (12”) minimum of clean backfill.

B. Construct the grounding grid as shown on the Contract Drawings using copper conductors arranged to form a mesh.

1. Install the ground grid 12 inches below the building and equipment foundations, curbs and footings, in areas where grid underlays those structures. Alternatively, coordinate the placement of non-metallic conduit sleeves that pass through the structure at the specified grid elevation with the structure installer.

2. Install the ground grid 30 inches below top of subgrade (below crushed stone) in open areas.

C. Connect conductors at each cross and tee intersection using exothermic welding.

3.04 GROUND ROD INSTALLATION

A. Install ground rods as shown on Contract Drawings. Install ground rods in line with the grid.

B. If extensive rock formation is encountered, inform SEPTA and obtain direction to relocate the ground rods, or provide supplemental ground rods. Supplemental ground rods are those needed in addition to the grounding system as shown on Contract Drawings to make the grounding system conform to the design calculations.

C. Connect ground rods to grid conductors using exothermic welding.

3.05 GROUND GRID ACCESS WELL INSTALLATION

A. Install each ground rod in a well to enable measurement of the ground grid resistance.

B. Weld the ground rod to the ground grid.

C. Ground rods in manholes need not have a separate inspection well.

3.06 PIGTAIL INSTALLATION

A. Provide flexible conductor pigtails required for the following connections:

1. Ground grid to substation indoor and outdoor electrical equipment

2. Ground grid to grounding busbars

3. Grounding conductor or ground grid to fence posts

4. Ground grid to steel catwalk around prefabricated substation

B. Install “pigtails” as shown on Contract Drawings. Protect all pigtail conductors with stubbed-up conduits.

C. Coordinate pigtail stub up location with the General Contractor.

D. Indoor and outdoor equipment

1. Provide pigtails from ground grid to grounding busbars and ground termination plates.

E. Electrical equipment yard fence pigtails


1. Install pigtails from ground grid to enable the following:

a) Grounding every fence at nominally 25 foot intervals, or each fence section between masonry pillars, whichever is greater.

b) Grounding of each fence hinge-side gate post and at or within 25 feet of each fence latch-side gate post.

3.07 GROUNDING BUSBARS

A. Provide grounding busbars at the following locations, as shown on Contract Drawings:

1. Inside the switchgear over the entire length of the switchgear.

2. Within ten (10) feet of each indoor 25 Hz and 60 Hz control or power piece of equipment.

B. Support busbars at four (4) feet intervals.

C. Connect switchgear and transformers to the grounding bus by at least two (2) connections to provide redundant grounding.

3.08 RACEWAY BONDING AND GROUNDING

A. Bond all metallic raceways together to provide a continuous metallic electrical path to ground. Bond metallic raceways to other raceway components using insulated grounding bushings. Connect grounding bushings to the grounding system using conductors sized in compliance with NEC.

B. Bond metal conduits, raceways, pull boxes and cable shields to the ground bus.

C. Install grounding conductors in non-metallic raceway systems in accordance with the NEC.

3.09 SUBSTATION BUILDING GROUNDING AND BONDING

A. Connect exposed substation structural steel to the ground bus as shown on the drawings.

B. Bond adjacent shipping modules in two places each.

3.10 OCS AND YARD STRUCTURES

A. Bond each column to the ground grid if within ten (10) feet, and the static wire.

B. Bond operating handles and surge arrestors to either a ground grid conductor or a solidly grounded structural column.

C. Install a ground mesh mat 2 feet below grade on the operating handle side for each rod-driven 25 Hz disconnect switch. Bond to the ground grid if within 10 feet of it, otherwise bond the mesh mat to the base of the structure with the disconnect switch.

D. Bond all handrails and steel catwalk panels and steel frames to each other.

3.11 INSPECTION AND TESTS

A. Notify SEPTA prior to backfilling the ground grid. Place no backfill or concrete until inspection by SEPTA is completed and the grounding installation is approved.

B. Perform grounding tests of the completed ground system in accordance with Section 16970.

C. Notify the engineer if the ground grid resistance exceeds 0.5 ohms.


END OF SECTION


SECTION 16070

HANGERS, ANCHORS AND SUPPORTS

PART 1 - GENERAL


A. This section covers Hangers, Anchors and Supports as specified herein for use in substations.

B. Types of hangers, supports, anchors, and seals in this section include the following:

1. Hanger-rod attachments

2. Building attachments

3. Miscellaneous materials

4. Anchors

C. Supports, anchors, and seals furnished as a part of factory-fabricated equipment, are specified as part of the equipment assembly in other sections of this specification.





1.03 SUBMITTALS

A. Shop Drawings and Manufacturer's Literature shall be submitted in accordance with Section 01300 - Submittals.

B. Product Data: Catalog cuts, specifications, installation instructions, and dimensioned drawings shall be submitted for each type of support, anchor, and seal.


A. Products shall be provided which are Underwriter Laboratories listed and Factory Mutual approved.

PART 2 - PRODUCTS

2.01 HANGER-ROD ATTACHMENTS

A. General: Except as otherwise indicated, factory fabricated hanger-rod attachments shall be provided in compliance with ANSI/MSS SP-58. Only one type by one manufacturer shall be used for each service. Size of hanger-rod attachments shall be selected to suit hanger rods.

B. Steel turnbuckles shall be MSS Type 13.

C. Steel clevises shall be MSS Type 14.

D. Swivel turnbuckles shall be MSS Type 15.

E. Malleable iron sockets shall be MSS Type 16.


F. Steel weldless eye nuts shall be MSS Type 17.

2.02 BUILDING ATTACHMENTS

A. Building attachments shall be coordinated with the building construction.

B. Steel strut shall be galvanized steel type channel, 1-5/8” or larger on a side, complete with spring nuts, clips, conduit clamps, bolts and accessory fittings.

2.03 MANUFACTURERS OF HANGERS AND SUPPORTS

A. Manufacturer: Subject to compliance with requirements, hangers and supports shall be provided from one of the following or an Engineer approved equal:

1. C&S Mfg. Corp.

2. Carpenter and Patterson, Inc.

3. Elcen Metal Products Co.

4. F&S Central Mfg. Corp.

5. Fee & Mason Mfg. Co., Div. of A-T-O Inc.

6. ITT Grinnell Corp.

2.04 MISCELLANEOUS MATERIALS

A. Metal Framing: Products shall be in compliance with NEMA STD ML 1.

B. Steel Plates, Shapes and Bars shall comply with ANSI/ASTM A-36.

PART 3 - EXECUTION

3.01 PREPARATION

A. Installation of hangers, supports and anchors shall proceed only after required building structural work has been completed in areas where the work is to be installed. All inadequacies shall be corrected at no additional cost to SEPTA.

B. Prior to installation of hangers, supports, anchors and associated work, Contractor shall meet at project site with installer of each component of associated work, inspection and testing agency representatives, installers of other work requiring coordination with work of this section and Engineer for purpose of reviewing material selections and procedures to be followed in performing the work in compliance with requirements specified.

3.02 INSTALLATION OF BUILDING ATTACHMENTS

A. Building attachments shall be installed at required locations on structural steel for proper equipment support. Additional building attachments shall be installed where support is required for additional concentrated loads.

3.03 INSTALLATION OF HANGERS AND SUPPORTS

A. Hangers and supports shall be installed complete with necessary inserts, bolts, rods, nuts, washers and other accessories. Except as otherwise indicated, hangers and supports shall be installed of same type and style as installed for adjacent similar equipment.

B. Adjust supports to allow adequate clearances between equipment.


END OF SECTION




SECTION 16075

ELECTRICAL IDENTIFICATION

PART 1 - GENERAL


A. This section covers the requirements for electrical equipment identifications consisting of the following:

1. Nameplates

2. Labels

3. Identification signs

4. Warning signs





D. Section 15050 – Basic Mechanical Materials and Methods

E. Section 16010 – Basic Electrical Requirements

F. Section 16050 – Basic Electrical Materials and Methods

1.03 SUBMITTALS

A. Submit the following documents to the SEPTA Project Manager for review and approval:

1. Tabulation of all equipment that require nameplates

2. Drawings of all nameplates

3. Text of all labels and signs

4. System for numbering control wires and cables

5. System for numbering of terminal blocks

PART 2 - PRODUCTS


A. Nameplates

1. Provide all major items of equipment, such as autotransformers, switchgear, and circuit breakers, with permanent nameplates identifying the equipment, relevant parameters, manufacturer, SEPTA-assigned equipment designation number, and other appropriate information such as serial numbers.

2. Design the nameplates in accordance with applicable IEEE, ANSI and NEMA standards.

B. Labels


1. Provide equipment cubicles and wall mounted equipment with black lamicoid labels. Provide primary equipment description using white lettering two inches (2") high and secondary description using lettering 3/4 inch high.

2. Identify all external and internal devices mounted on enclosure doors and panels, such as protective relays, auxiliary relays, control switches, instruments, transducers, indicating lights, test blocks, terminal blocks, and fuse blocks with engraved labels. Securely attach labels in the vicinity of the device.

3. Provide control wires and cables with identification numbers.

4. Provide terminal blocks with identification numbers.

C. Identification Signs

1. Provide the identification signs for each lineup.

2. Provide the identification signs for switchgear cubicles in each lineup, as appropriate.

3. Provide identification signs for the additional facilities and equipment, such as:

a) Medium voltage cabinets, hand holes and manholes

b) Switchboard cubicles

c) Panelboards

d) Transformers

e) RTU and SCADA Interface Cabinet

f) Battery equipment

g) Communication equipment

h) Disconnect switch and grounding switches and their operating rods at ground level

i) Contactors

j) Communications and Signal manholes

k) Cables, at each end and at intermediate points where accessible (inside enclosures and manholes)

D. Warning Signs

1. Provide graffiti-resistant, stain-resistant, and airborne pollutant-resistant signs. Select easily cleanable signs with high resistance to abrasion, bleaching cleaning agents, and fading due to UV radiation present in sunlight.

2. Provide “Danger - High Voltage” warning signs, in vendor’s standard sizes, at following locations:

a) Front and back panel of each cubicle

b) Substation exterior doors

c) Outdoor circuit breakers, front and back

d) Autotransformers, fronts and on side facing fence

e) Disconnect switches, by operating handle

f) On each switchyard fence gate


3. Warning signs should include Arc Flash Boundary Limit signs, which should be included and installed on all electrical equipment.

PART 3 - EXECUTION

3.01 PREPARATION

A. Clean all surfaces in preparation for attaching the nameplate.

B. After drilling tap holes, clean off all metal filings and oil residue.

C. Verify nameplate text against approved shop drawing before attaching.

3.02 INSTALLATION

A. Attach all nameplates, labels, and signs with non-corrosive screws, except signs in areas external to the substation yard shall be attached with tamper resistant stainless steel hardware.

B. Color code 600 volt and below power conductors as indicated in the following table:

Phase 480/277 Volts 208/120 Volts

A Brown Black

B Orange Red

C Yellow Blue

N White with Yellow

Tracer White

EGC Green Green

C. Color code communications cables as indicated by industry standards.

END OF SECTION




SECTION 16120

CONDUCTORS AND CABLES

PART 1 - GENERAL


A. The work specified in this Section consists of material and labor for furnishing, installing, connecting, energizing, testing, cleaning and protecting communications cable and accessories.





D. Section 01600 – Material and Equipment





I. Section 16138 – Duct Work, Electrical Manholes and Hand Holes

J. Section 16950 – Testing of Electrical Equipment

1.03 SUBMITTALS

A. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card. If not available, provide from product manufacturers a written statement indicating why an item does not have quality assurance verification. Such statements are subject to the approval of the Project Manager.

B. Product Data and Catalog Cuts: Provide product data for the following products; indicate clearly the project specific usage of each product:

1. Conductors and cables, along with installation details and contractor-detailed conduit and cable schedules

2. Terminations and splices

3. Tools for terminations

C. Tension Calculations:

1. Submit Cable Pulling calculations for all underground runs. Calculations shall include both pull load and tensions, along with safety factors, for all cables.

2. Design conduit runs so as not to exceed tension limits of manufacturer.

D. Project Record Documents: Record actual installed lengths and locations, both concealed and exposed work, on the record drawings.


E. Project Closeout: Submit record drawings, product data, and installation and maintenance instructions.


A. Unless products meeting the requirements of nationally recognized testing laboratories are not readily available for a category of products, provide products that are listed and labeled by Underwriters Laboratory (UL), or certified as meeting the standards of Underwriters Laboratory by the Electrical Testing Laboratory (ETL).

B. All work shall conform to regulatory requirements of all state and local codes and requirements.

C. All work shall conform to NFPA 70, National Electrical Code.

D. Install work under supervision of skilled licensed electricians.

E. References:

1. Institute of Electrical and Electronic Engineers (IEEE):

a) IEEE 1202: IEEE Standard for Flame Testing of Cables for Use in Cable Tray in Industrial and Commercial Occupancies.

2. National Electrical Manufacturers Association (NEMA):

a) WC26: Packaging of Wire and Cable.

3. National Fire Protection Association (NFPA):

a) NFPA 70: National Electrical Code (NEC).

4. Underwriters Laboratories, Inc. (UL):

a) UL 83: Thermoplastic-Insulated Wires and Cables

5. Rural Utilities Service (RUS)

a) PE-39: Specification for Filled Telephone Cables

1.05 QUALIFICATIONS

A. Installer Qualifications: Firm specializing in installing work of this Section with sufficient previous experience to conduct satisfactorily the installation indicated.

1.06 DELIVERY, STORAGE AND HANDLING

A. Protect items from damage during delivery, storage and handling in accordance with Section 01600, and as detailed below.

B. Packaging of wire and cable shall conform to NEMA WC-26.

1.07 FIELD SAMPLES

A. Samples: Provide one 36-inch long sample of each type of wire to be used.

PART 2 - PRODUCTS

2.01 MULTI-PAIR COMMUNICATION CABLE

A. Provide twisted pair conductors of UL listed soft-drawn copper with solid, virgin high density polyethylene, with telephone industry color-coding.


B. Provide 25 pair 22 AWG communication cable for inside plant cable in the substation building.

C. Provide 4 pair UTP cable per paragraph 2.02 (below).

D. Provide outside plant cable of flooded with a water-blocking compound, filling the air space between the insulated conductors.

E. Outside and inside plant cables shall be provided with an overall .005" thick corrugated solid copper tape shield applied longitudinally with overlap to provide 100% electrical shielding coverage.

F. Each outside plant cable shall be provided with an outer jacket of black, low density, high molecular weight virgin polyethylene, compounded to withstand sunlight, temperature variations, and other environmental conditions, as well as installation handling without damage. Jacketed cable shall be rated for a combination of aerial, lashed, in conduit or underground duct, or direct burial applications.

G. Each inside plant cable shall be provided with a light grey jacket of the standard type produced by the manufacturer for telephone applications, except for UTP Ethernet cable.

H. Imprint the jacket with the date of manufacture, wire type, and manufacturer name.

I. Wire and cable manufactured more than 12 months before delivery to the job site shall not be used.

J. Acceptable Manufacturers:

1. Clifford of Vermont, Inc.

2. Or SEPTA-approved equal

2.02 UNSHIELDED TWISTED PAIR (UTP) DATA CABLE

A. Provide inside cable plant which meets the following:

1. Cable fabricated using solid (24 AWG) un-coated copper conductors with polyethylene insulation, color coded conductor insulation and overall PVC jacket

2. Unshielded cable with controlled dielectric properties for ethernet category 5E or better

3. UL listed with a blue jacket

4. Dry (not flooded)


a) Belden Corporation

b) Or SEPTA-approved equal

2.03 SIGNAL CABLE

A. Provide multi-conductor insulated and jacketed cable for installation in direct contact with the earth, in ducts, in air or any combination of these types of installations, and for single conductor insulated and jacketed wire for installation in wired housings, on circuits rated at 0-1000 volts.

B. Include with bid, preferably in the form of a cross-section drawing, a description of the proposed cable. Include cable shape, construction, number of conductors and size,


insulation thickness and type, insulation shield thickness, jacket thickness and type, and approximate cable weight per foot.

C. State the following information on the Purchase Order for each kind of cable:

1. Total length in feet

2. Number of conductors

3. Gauge of conductors by AWG

4. Solid or stranded conductors

5. Length of cable on each reel

6. Special Constructions such as armored, flexible, preassembled, aerial, shielding from inductive interference

7. Reference to the Specification

D. Qualifications

1. The manufacture of cable in accordance with the requirements of the Specification shall be accomplished in compliance with a Quality Assurance Program that meets the intent of ASQC Standard C1-1968: General Requirements for a Quality Program. Such compliance shall assure the production of properly designed, well made, and thoroughly tested cable which will render long service life to SEPTA. Efficient methods of production, test, and product evaluation shall be used, but prime concern must be focused on the necessary formal quality requirements in insure that cable failure cannot be attributed to actions or lack of actions by the manufacturer.

2. Provide material and workmanship of the wire and cable assuring durability for the 40-year design life of the installation.

3. Certify the manufacturer offering cable designs and insulation materials for this service has minimum of fifteen years reliable experience on vital circuit signal cables and shall meet the qualification tests specified herein.

E. Perform factory qualification tests that establish the insulation as consistently uniform, and suitable for service at potentials to 15,000 volts. Demonstrate dielectric strength stability by voltage aging a minimum of ten feet between terminals of a single conductor No. 14 AWG or larger size with 80 mil or thicker insulation, suitably finished. Test the cable in free air with the ends appropriately terminated.

1. Apply one of the following stresses to voltage-age the sample:

Test Voltage (volts/mil) Time

225 2 years, or

180 3 years, or

135 5 years


2. Use the voltage-aged sample and apply 60 Hz voltage in 10 kV steps for five minutes at each step until breakdown. Start the test at the voltage-aging stress used in Paragraph 1.

3. No cable breakdown shall occur during the voltage-aging test and the same sample shall withstand a minimum test stress of 350 volts/mil on the step breakdown test in Paragraph 2.

F. Perform insulation thermal aging tests in a circulating air oven on 80 mil thick slabs with elongation not less than 50% after a minimum aging time of 25 hours at 136C and 100 hours at 121C.

G. Conduct moisture resistance tests of a single conductor No. 14 AWG or larger size with 80 mils or thicker insulation, with at least 10 feet immersed in water at room temperature. The insulated conductor without any coverings over the insulation shall be continuously energized as follows:

1. Moisture test conditions

DC Voltage (volts/mil) Time

325 2 months, or

280 3 months, or

240 4 months, or

200 6 months

2. No insulation failure shall occur within the test period.

H. Conductor

1. Solid conductor: Conductor shall be soft or annealed copper coated with pure lead, lead alloy, or tin in accordance with ASTM B-189, or B33 for tin, lead, and lead alloy coated conductors. No factory splices or brazes shall be made in solid conductors after final drawing.

2. Stranded Conductors: The conductor shall conform to ASTM B-8, latest revision, and tinned or lead alloy coated to conform to ASTM Designation B-33 or B-189, latest revision, where applicable.

I. Insulation

1. The conductor insulation shall be a vulcanized rubber compound.

2. The insulating compound shall be clean and free stripping, leaving the coated conductor unimpaired and ready for soldering.

3. Part 3 of ICEA standard S-19-81 does not apply to this product.

4. Aerial multi-conductor and protected surface constructions will have insulation thicknesses per AAR Class B in Table I (not used on this project).

5. The average thickness of insulation shall be not less than the specified thickness. The minimum thickness at any point shall not be less than 90% of that specified.

6. The insulation shall not crack during installation at temperatures as low as -40F.


Table I (from AAR) Multi-conductor Signal Cable

AAR CLASS

CONDUCTOR SIZE AWG

THICKNESS OF INSULATION

A 14 to 8 78 mils

6 to 2 94 mils

B 16 to 8 62 mils

6 to 2 78 mils

J. Underground cable to be installed in duct shall be made by assembling individual

conductors as specified per AAR Class “A” in Table I. Individual conductors shall be cabled helically with adjacent layers wound in opposite directions. Fillers are to be used where necessary to assembly the cable into a tight cylindrical core. The core shall be covered with a shock-absorbing layer of moisture resistant core tape or an extruded elastomeric material if a bronze tape is not used, or layers of moisture resistance tape if bronze armor tape is used. When core tape or elastomeric material is used for a cushion layer, the thickness of the layer shall be in accordance with the following Table V. The outer jacket shall be made of extruded black low density high molecular weight polyethylene which shall be capable of meeting material Type I, Class C, Grade E5 of ASTM D-1248 with thickness in accordance with Table VI, Column A. When the cable is furnished with a bronze tape, the jacket thickness shall be in accordance with Table VI, Column B.

Table V

Calculated Core Diameter (Inches)

Average Cushion Layer Thickness

0 to 1.500 47 mils

1.501 and larger 62 mils


Table VI

Calculated Core Diameter (inches)

Outer Jacket Thickness

A B

0 to 0.425 62 mils 47 mils

0.426 to 0.700 78 mils 62 mils

0.701 to 1.050 94 mils 78 mils

1.051 to 1.500 109 mils 94 mils

1.501 to 2.000 125 mils 109 mils

K. Conductor identification of multi-conductor signal cables shall be as follows: One

conductor in each layer shall be suitably marked to serve as a tracer. The method used to distinguish the tracer shall be subject to the approval of SEPTA. The assembly shall be capable of easy separation without damage to any of the conductors or loss of the tracer conductor identification.

L. Each length of multi-conductor cable shall be permanently identified with the manufacturer and year of manufacture, at intervals not more than one (1) foot, with a moisture resistant marker tape under the jacket and parallel to the longitudinal axis of the cable.

PART 3 - EXECUTION

3.01 PREPARATION

A. Inspect conduits, junction boxes, and manholes for cleanliness, lack of burrs, alignment and completeness. Correct deficiencies before proceeding.

B. Ensure that grounding fittings are installed at places called for in Section 16060.

C. Swab conduits with a nylon bush and steel mandrel.

D. Ascertain that pulling calculations have been made and are available for long runs and pulls as indicated in this Section. Ascertain that a means of controlling pulling tension is installed on mechanical assist devices for pulling cable.

E. Pre-lubricate conduits for which the pulling tension calculations are based on a coefficient of friction less than that of a dry conduit.

3.02 INSTALLATION

A. General:

1. Install all wiring outside of equipment in conduit. For the SCADA indications for disconnect switches, make control cable splices from larger count to smaller-count cables within a sealed splice/pull box within the manholes adjacent to the structures.

2. Do not perform wiring work until other work that might cause damage to the wires, cables or conduits has been completed. Take the necessary precautions to prevent the accumulation of water, dirt or other foreign material in the conduits during the execution of the work.


B. Cable Pulling:

1. Comply with the manufacturer’s recommendations for the inspection, handling, storage, temperature conditioning prior to installation, bending and training limits, pulling limits, and calculation parameters for installation of all cable. Use quadrant blocks located properly along the cable run. Remove from the job-site and replace all cables that were subjected to excessive bending and tension and all cables that are cracked or have damaged or nicked outer jackets.

2. Pull cables down grade with the feed-in point at the manhole, handholes or buildings of the highest elevation. Flexible cable feeds shall be used to convey cables through the manhole opening and into the duct runs. Lubricate all cables during pulling with lubricants specifically recommended by the cable manufacturer.

3. Limit cable pulling tensions to the maximum pulling tensions recommended by the cable manufacturer. Use dynamometer to measure pulling tensions on all runs pulled with mechanical assistance and for all runs where calculations are required to be submitted. If pulling tension is exceeding during pulling, cables shall be removed and marked as defective, and not reused.

4. Installation of cables in manholes: Install cable along those walls providing the longest route and the maximum spare cable lengths. Form cables to closely parallel walls so as not to interfere with duct entrances. Support cable on brackets and insulators spaced at a maximum of two feet apart. Lubricants must be used and must be approved by the cable manufacturer.

C. Wiring Identification:

1. Color code wires and cables as specified in Section 16075.

2. Identify all control wiring with wire numbers corresponding to record drawings.

D. Wire and Cable Splices:

1. Splices between termination points are prohibited without prior written authorization of the Project Manager. The intent of this Section is to prohibit intermediate splices unless they are explicitly shown on the Contract Drawings.

3.03 FIELD QUALITY CONTROL

A. Conduct verification field tests prior to energizing cables or utilizing fibers prior to final tests specified in section 16950.

3.04 SIGNAL CABLE FACTORY AND FIELD TESTS

A. Perform a dry “spark” test during the process of cabling or immediately prior to any non-conducting covering operation. This test utilizes 10 kV, 3 kHz or greater frequency to insure detection of damage to conductor insulation.

B. SEPTA’s Inspection: SEPTA shall have the right to make such inspection and tests as necessary to determine if the cable meets the requirements of this Specification. The Inspector for SEPTA shall have the right to reject the cable that is defective in any respect.

C. Tests may be made at place of production or on samples submitted, or at destination as specified by SEPTA. The manufacturer shall notify the Director of Purchasing & Stores when they will have materials ready for inspection. Prior notification of desire to witness particular tests on specific cables shall be furnished by the manufacturer.


D. The manufacturer shall provide, at the point of production, apparatus and labor for making any or all of the following tests under the supervision of SEPTA’s Inspector. Such tests include:

1. Conductor size and physical characteristics

2. Insulation HV and IR Tests

3. Physical Dimension Tests

4. Special tests on materials in coverings

5. Final HV, IR, and Conductor Resistance Tests on shipping reels

E. The manufacturer shall furnish the Purchaser with six (6) certified copies of the results of all tests and measurements made to determine the quality and serviceability of the cable manufactured in accordance with this Specification. Such results shall show compliance with all the requirements of this Specification. Final approval shall be contingent upon receipt and approval by SEPTA of these certified tests.

F. Cable that does not meet the requirements of this Specification and order shall be rejected. Wire or cable that shows defects or non-compliance with the Specification and order, after arrival at destination, may be rejected and the Seller shall, on request, advise disposition of the wire or cable in question and pay all transportation charges on the rejected material.

G. Minimum Shipping Lengths: Cable shall be furnished in lengths of approximately 1000 ft., unless otherwise specified. All cable shall be shipped on reels, adequately protected from damage in shipment by heavy wrapping or wood lagging.

H. Reel Design: Reels shall be substantial to withstand reasonable handling and shall be so designed that the inner end of the cable will be accessible, but protected from injury. They shall be designated and constructed as non-returnable when drum size and cable weight and volume permit.

I. Cable Winding on Reels: Cable shall be closely and tightly wound in each layer on reels and both ends shall be sealed to prevent the entrance of moisture and securely fastened so that they will not become loose in transit.

J. Each reel shall contain on the outside flange plainly legible and weather resistant, information to show the manufacturer’s name, purchaser’s requisition number, lengths of each section of cable, number of conductors, gauge of conductors, and the name and address of the consignee.

K. An arrow shall be painted on one head of each reel pointing the opposite direction from the outer end of the cable with the words “Roll This Way”.

L. The Seller shall expressly warrant that the insulated wire and cable furnished under this Specification shall be free from defects in material and workmanship. The Seller shall be responsible for the cable for the life of the installation, except that obligation under this warranty shall not apply to any wire or cable which has been subject to misuse, negligence, or accident after it has been accepted and shipped.

M. The Seller shall covenant and agree to indemnify Southeastern Pennsylvania Transportation Authority against all claims, suits, actions, or proceedings, damages, costs, fees, and expenses by reason of infringement or alleged infringement of patents, or for patent royalties involved in consequence of the purchase and use of the material covered hereby.


N. Splicing of the cable between termination points shown on the Contract Drawings is prohibited.

END OF SECTION


SECTION 16121

MEDIUM VOLTAGE CABLE

PART 1 - GENERAL


A. This section specifies furnishing, installing, testing and terminating of medium voltage traction power, single-conductor, shielded power cable.

1. 1/c - 46 kV, 133% insulation, 1000 kcmil, shielded cable (250 kV BIL), for connecting the WJSFC output transformers to the 25 Hz Wayne Junction Traction Power Substation (WJTPSS). The 12 kV, 24 kV, and rail return circuits shall all use this cable type in order to match the existing cables in the Wayne Junction 25 Hz Traction Power Substation.

2. 1/c - 15 kV, 100% insulation, 1000 kcmil, shielded cable (110 kV BIL), for use on underground circuits, for connection between the Wayne Junction 230 kV Control Building 13.2 kV, 60 Hz switchgear and the SFC input transformers/reactors.

3. 3/c - 15 kV, 100% insulation, 500 kcmil, shielded cable (110 kV BIL), for use on underground circuits, for connection between the Wayne Junction 230 kV Control Building 13.2 kV, 60 Hz switchgear and the SFC input transformers/reactors.





D. Section 16138 – Duct Work, Electrical Manholes and Hand Holes

E. Section 16262 – Static Frequency Converter

F. Section 16310 – Transmission and Distribution

G. Section 16330 – Medium Voltage (2-pole) Breakers, Switching and Protection

1.03 SUBMITTALS

A. The Contractor shall submit the following shop drawings and data for the Project Manager’s review in accordance with Section 01300.

1. Shop drawings, catalog cuts, and other forms of descriptive data delineating the construction of the cables specified herein

2. Installation and test instructions

3. Special storage instructions, if applicable

4. Recommended pulling lubricants, compatible with the jacket and semiconducting shield materials

5. Recommended termination materials and procedures

6. The Contractor shall submit five (5) certified copies of test reports for all the tests conducted at the factory and in field for Project Manager's approval. Test reports


shall be submitted to the Engineer within two weeks after completion of tests. In case of “Factory Tests”, test reports shall include original data, detailed calculation of test data to arrive at the results and interpretation of results. Test reports shall contain the characteristics, curves, etc. where required for interpretation of results. Authorization to ship will not in any way relieve the Contractor of this responsibility under this Contract.

7. Certificate of Compliance: Submit certificate certifying that the cables comply with the requirements specified herein, comply with the standards designated herein, and that the cables have been tested as specified herein.

8. Following Contract award, the Contractor shall submit the following technical data for each cable specified in this specification for approval of the Project Manager. The characteristics of the cable shall be fully explained by providing the information required in the following tabulation:

TECHNICAL DATA

a) Conductor stranding

b) Conductor material

c) Conductor coating

d) Insulation material

e) Insulation thickness mils

f) Shielding:

1) Conductor mils

2) Insulation (non-metallic) mils

3) Insulation (metallic) mils

g) Maximum Copper Temperature:

1) Continuous C

2) Emergency C

3) Short Circuit C

h) Minimum installation temperature C

i) Jacket material C

j) Jacket thickness (nominal) - mils

k) Physical Requirements Insulation Jacket

1) Tensile strength psi psi

2) Elongation at rupture (Set) % %

l) Aging Requirements: Insulation Jacket

1) After air oven test

(indicate condition) _______ ______ Tensile strength, change in


unaged value ______% ______% Elongation at rupture, change

in unaged value ______% ______% 2) After oil immersion test Jacket Only

(Indicate conditions) Tensile strength, percent of

unaged value % Elongation at rupture, percent

of unaged value % m) Accelerated Water Absorption:

1) Electrical method increase in capacitance:

1 to 14 days %

7 to 14 days %

2) Gravimetric method water absorption mg/in.

n) Electrical Requirements (insulation):

1) AC Voltage Test KV/min.

2) DC Voltage Test KV/min.

3) Insulation Resistance (min.) megohms

o) Cable outside diameter (nominal) inches

p) Allowable minimum bending radius inches

q) Allowable pulling tension lbs

r) Allowable sidewall pressure psi

s) Reel Data:

1) Diameter inches

2) Width inches

3) Drum diameter inches

4) Tare weight lbs

5) Arbor diameter inches

t) Ampacities:

Cable in ducts, one or two cables per duct per the duct bank drawing sections, earth temperature 20oC, RHO = 90, conductor temperature 90oC. 1) Three cables per duct bank

100% load factor amperes



2) Six cables per duct bank





u) Electrical Characteristics (indicate conditions):

1) Resistance ohms/1000 ft.

2) Reactance (inductive) ohms/1000 ft.

3) Impedance ohms/1000 ft.

v) Cable weight lbs/1000 ft.


A. Applicable provisions of the following standards shall apply to the work of this Section, except as modified herein, and are hereby made part of these Specifications to the extent required:

1. American Society for Testing and Material (ASTM):

a) ASTM B3: Specification for Soft or Annealed Copper Wire

b) ASTM B8: Specification for Lay-Stranded Copper Conductors, Hard, Medium-Hard or Soft

c) ASTM D257: Test Methods for DC Resistance or Conductance of Insulating Materials

d) ASTM D412: Test Methods for Rubber Properties in Tension

e) ASTM D470: Methods of Testing Cross-Linked Insulations and Jackets for Wire and Cable

f) ASTM D471: Test Method for Rubber Property - Effect of Liquids

g) ASTM D573: Test Method for Rubber - Deterioration in an Air Oven

h) ASTM D624: Test Method for Rubber Property - Tear Resistance

2. Insulated Cable Engineers Association, Inc. (ICEA):

a) ICEA S-93-639/NEMA WC74 5-46 kV Shielded Power Cable

3. Underwriter's Laboratories, Inc. (UL):

a) UL 44: Thermoset-Insulated Wires and Cables

b) UL 1072: Shielded and Non-shielded Single and Multiple Conductor Power Cables

c) UL 1581: Reference Standard for Electrical Wires, Cables and Flexible Cords


a) NFPA 70: National Electrical Code (NEC)

b) NFPA 258: Research Test Methods for Determining Smoke Generation of Solid Materials

5. Institute of Electrical and Electronics Engineers (IEEE):


a) IEEE C2: National Electrical Safety Code

b) IEEE 386: Separable Insulated Connectors for Power Distribution Systems above 600 V

c) IEEE 404: Standard for Power Cable Joints

B. Furnish and install medium voltage power cables having a performance record demonstrating a minimum of 20 years successful operating experience in utility and industrial power cable applications.

1.05 DELIVERY AND STORAGE

A. Ship cable on reels, suitably covered to protect the cable from injury during shipment. Ship only one length of cable on a reel. Seal, secure, and protect cable ends from injury. Make both cable ends available for testing, unless cable size or reel construction precludes that possibility.

B. Suitably store cables to protect them from injury.

PART 2 - PRODUCTS

2.01 DESCRIPTION

A. Cable covered by this specification is intended for use on 25 Hz, single-phase traction power systems operating at 12 kV, 24 kV, and rail return potentials, and subjected to such additional strains of potential as may occur on the account of switching and operation of a traction power supply system. The three-phase voltage classes below are equivalent to what is required for the single-phase application mentioned above. Cables furnished shall be constructed in accordance with the following requirements:

1. 46 kV, 133% insulation, 1000 kcmil, single conductor, shielded cable (NEMA WC74):

a) The conductor shall be annealed after stranding, uncoated, soft copper wire, Class B, stranded, compact round per ASTM B496.

b) Conductors shall meet the electrical resistance requirements of ICEA S-93-639.

c) An extruded layer of semiconducting ethylene propylene rubber thermosetting compound that is compatible with the insulation thermosetting compound, will be applied directly over the conductor and have a volume resistivity not in excess of 10 ohm-meters at 105 degrees C and minimum elongation of 100 percent after an air oven test at 120 degrees C.

d) The conductor shield shall be in intimate contact with the strands and shall be clean stripping from the conductor and inseparably bonded to the overlying insulation.

e) Conductor Insulation:

1) Ethylene-propylene rubber, 133 percent insulation level, Class III per ICEA S-93-639

2) The insulation thickness shall be 550 mils minimum and 630 mils maximum for 46 kV, 133%. The min./max. thickness at


any cross-section of the insulation shall be per Table 4-1 of ICEA S-93-639.

3) The insulation shall be triple-tandem extruded, with the conductor and insulation screens and passed through a continuous vulcanization tube in a single pass to prevent inter-surface contamination. Three separate inline extruder heads shall perform the extrusion process.

4) Physical Properties

Original

- Tensile strength 700 PSI min. - Elongation percentage 300 min. After Aging - Air over test (168 hours at 121 C)

- Tensile strength (percentage of original) 75 min.

- Elongation (percent of original) 75 min.

After Aging - Air pressure test (80 psi for 40 hours at 127 C

- Tensile strength (percentage of original) 75 min.

- Elongation (percentage of original) 75 min.

5) Electrical Properties

Insulation Resistance Constant (K)

at 15.6 C 20,000 min.

SIC at 75 C 3.5 max.

Power Factor at 75 C - percentage 2.5 max.

Stability Factor after 14 days 1.0 max.

6) Moisture Resistance

Mechanical moisture absorption

mg per square inch 5.0 max.

Maximum percent change in SIC

(75 C water)

- One to 14 days 4.0 max. - Seven to 14 days 2.0 max.

7) Ozone Resistance (ICEA Publication S-19-81, Part 6.8)

.030% concentration at No cracks after

room temperature 24 hours exposure

.005% concentration at 125 C No cracks after

24 hours exposure


8) Cold Bend

No cracks at minus 40 degrees centigrade.

9) Corona Level

The following corona level test must be made on completed shielded single conductor cable on long length factory reels. Certified test reports shall be submitted only for cut lengths although the actual values reported are those for the completed long lengths.

The corona values shall comply with the maximum discharge in Pico-Coulombs specified in the following table with a detection sensitivity of 5 PC and using the method specified in the referenced AEIC specification.

10) Insulation Color: The insulation shall be an orange color, so that semi-conducting material on the insulation can be visually detected.

f) Insulation Shield (Screen):

1) The insulation shield shall be an extruded semi-conducting all EPR compound verifiable with infrared spectrometry with a volume resistivity not in excess of maximum acceptable values when tested in accordance with AEIC CS-8 requirements. The screen shall be clean stripping from the insulation with a force of between 4 – 24 pounds on a 0.5-inch wide strip when tested in accordance with AEIC CS6

2) The insulation shall be completely shielded with a layer of semi-conducting extruded ethylene-propylene rubber compatible with the insulation and have an average thickness of 30 mils. It shall be in intimate contact with the insulation. The legend "semi-conducting shielding, remove before splicing" shall be printed in white indelible non-conducting ink along with entire surface.

g) The cable shield shall consist of a metallic shield over the semi-conducting shield. The insulation semi-conducting metallic shield shall be flat copper strap. The shield straps shall be designed utilizing .020” x .175 flat straps helically applied in sufficient numbers to meet the fault requirements of Table 2-1.

h) Include a marker tape along the core. It shall show the name of the manufacturer, the year in which the cable was manufactured, conductor size, and a consecutive serial number for identification purposes; all to appear at intervals of approximately one foot, so that this information can be obtained without destroying more than one foot of cable.

i) A nonmetallic high temperature jacket of crossed-link polyolefin shall be extruded over the sheath. The minimum jacket thickness shall be in accordance with the requirements of ICEA S-93-639, Part 7. The jacket shall be rated as low smoke, zero halogen material.


j) Print on cable over its jacket at regular intervals of no more than 36 inches, showing the manufacturer, date of manufacture, voltage, conductor size, type and thickness of the insulation.

k) Furnish cable with approved stress cone indoor terminations and suitable outdoor synthetic terminations. Quantity of stress cone terminations shall be adequate for all terminations indicated on the Contract Drawing plus 10 percent spare terminations.

l) Provide on the outside end of each length of cable a pulling-in eye. Hermetically seal both ends of every length of cable before leaving the factory and make accessible on the reel for testing.

m) Furnish a manufacturer's guarantee stating that the cable supplied under these specifications is of first-class material and workmanship throughout and in lieu of other claims against it, agrees to replace any length of cable failing during normal and proper use, within two years of date of placing in service, which shows defects of material or workmanship, provided in each case that immediate written notice of such failure is given to the manufacturer and he is given all reasonable opportunity to inspect such failure.

n) The date of placing in service is to be interpreted as the date on which operating voltage was first applied, but in no case shall it be interpreted to be later than six months after the shipment of the cable from the factory.

o) The completed cable will be inspected by the Engineer at time of delivery. In case of any doubt arising as to the intent or meaning of these specifications, the decision of the Engineer shall be final and binding on the Contractor.

p) Reel dimensions shall not exceed 72 inches in height and 48 inches in width, unless otherwise approved by SEPTA.

Table 2-1

Parameter Values Nominal Voltage 12 kV, 24 kV, and rail return Nominal insulation rating 46 kV 250 kVBasic impulse level 250 kV Size 1000 kcmil stranded (61 strands) Number of conductors per cable One Conductor Soft-drawn bare copper Insulation type Ethylene propylene rubber (EPR) Insulation thickness 133% level, 550 mils min, 630 mils max ac test voltage 116 kV Shield 8 x 0.175" x 20 mil tinned CU flat straps Jacket type Crosslinked polyolefin (XLPO) Jacket thickness 100 mils Normal Operation Temperature 105C Emergency Operation 140C Short Circuit Operation 250C


B. Cable covered by this specification is intended for use on 15 kV, 60 Hz, 3-phase power

distribution systems. Cables furnished shall be constructed in accordance with NEMA WC 74-2006/ICEA S-93-639 and meet the following requirements:

Table 2-2

Parameter Values Rated Voltage 15 kV rms Voltage withstand 35 kV rms Size 1000 kcmil stranded 500 kcmil stranded Number of conductors per cable One (1) Conductor Soft-drawn bare copper Insulation type XLPE Insulation thickness 100% insulation level, 175 mils Shield 5 mil copper tape, >10% overlap Jacket type PVC Jacket thickness >70 mils Normal Operation Temperature 105C Emergency Operation 140C Short Circuit Operation 250C

2.02 GENERAL REQUIREMENTS

A. Cables that will be used on 12 kV and 24 kV, 25 Hz power systems, and 15 kV, 60 Hz power systems as described in paragraph 1.01.A, shall be manufactured to the following requirements:

1. Furnish cable that is single conductor and UL-listed.

2. The cables shall be suitable for use for power distribution feeders, indoors or outdoors, in wet or dry locations, as open runs of cable, in cable tray, in conduit, ducts or as aerial cable. The cable shall be sunlight resistant.

3. The insulation shall be triple-tandem extruded with the conductor and insulation screens.

4. The cable shall be insulated with an ozone-resistant and discharge-resistant, flexible, thermoset ethylene propylene rubber (EPR) dielectric and meet or exceed the latest editions of the standards listed in Paragraph 1.03-References.

5. Medium voltage cables shall be rated 105 degrees C for continuous normal operation, 140 degrees C for emergency overload operation, and 250 degrees C for short circuit conditions. Cables shall be suitable for emergency overload operation that may occur for periods up to 1500 hours cumulative during the life of the cable.

2.03 FIRE PROOFING

A. The Contractor shall furnish and install a form of arc and fire protection tape for all cables, such as 3M Scotch 77 Fire and Arc Proofing Tape with an overwrap of Scotch 69 Glass Cloth Electrical Tape, or an approved equal.


2.04 CABLE DUCT LUBRICANT

A. Furnish high-performance cable pulling lubricant specifically developed for compatibility with low-smoke/zero halogen jacketed cables. The lubricant properties shall include: slow drying, thin slippery film residue that remains for two or more months after use, not flame sustaining, stringy gel that clings to cables and temperature stable with no flash point.

B. Cable lubricant shall be capable of being hand or pump applied, and cleaned away with water.

C. Provide cable lubricant as manufactured by American Polywater types LZ or WLZ, or an approved equal.

D. Provide and utilize a cable pull-planning software as recommended by the lubricant manufacturer for pulls distances in excess of 300 linear feet or where cumulative bend angles exceed 210 degrees.

2.05 PRODUCT VENDORS

A. Medium Voltage Cable Assemblies

1. Select a cable manufacturer who is regularly engaged in the production of similar wire and cable. Provide products from one of the following manufacturers, or approved equal:

a) The Okonite Company

b) Kerite Cable

c) BICC

d) SEPTA-Approved Equal

B. Terminations for Medium Voltage Cable

1. Terminations (Outdoor) of 25 kV-rated cables shall be as manufactured by one of the following:

a) Tyco Raychem (HVT-Z series)

b) 3M

c) SEPTA-approved equal

2. Terminations (Outdoor) of 46 kV-rated cables shall be as manufactured by one of the following:

a) Tyco Raychem (EHVT series)

b) 3M

c) SEPTA-approved equal

PART 3 - EXECUTION

3.01 INSTALLATION

A. General

1. Cable shall not be pulled until conduits have been cleaned and swabbed, and are free from obstructions.


2. Pull, install and protect cables as follows:

a) Use factory installed compression type pulling eyes for all pulls except as otherwise specified.

b) Seal all cable ends before pulling into ducts. The ends of a cable when cut shall not be left with the insulation exposed to moisture unless splicing is to be done immediately.

c) Strip reels of all nails in outside edges of reel heads before pulling of cable. Conveniently locate reels for feeding cable into the duct or conduit without excessive binding or possible injury to cable by abrasion. Reels shall be jacked to clear ground level by at least 6 inches before pulling of cable.

d) Attach pulling ropes to cables with ballbearing swivels to prevent twisting of cable during pulling.

e) Pull cable into ducts and conduits under moderate tension. Manufacturer's recommended maximum pulling tensions shall not be exceeded. Any lubricant used shall not have a deleterious effect on the conductor insulation.

f) Station sufficient personnel between the reel and the duct entrance during pulling operations to inspect, control and direct the passage of cable. Equip duct mouth with a form of bell end to prevent chafing of the cable while being inserted.

g) Minimum bending radii as measured to inside surface of the cables shall not be less than those recommended by the manufacturers, NFPA 70 Section 300.34, and not less than 33 inches for 46 kV power cables, whichever is the larger.

h) Lubricate cables with cable manufacturer approved material which shall be placed into the duct prior to the installation of the pulling rope.

i) Do not allow cable to chafe on the ground, pull boxes, or any sharp surfaces during pulling. Provide timbers and flexible cable pulling tubes to guide and protect the cable, where necessary.

j) All cables installed shall be continuous from terminal to terminal.

k) Mark all cables with printed numbers on cable tags at all terminal points. Refer to Contract Drawings for numbering of cables.

l) Install cables as shown on Contract Drawings. Provide supports, conduit and other hardware as required. All ferrous hardware shall be hot-dip galvanized.

3. Handle cable reels carefully to avoid injury to persons or cables. Control movement of reels on loading skids or sloping grades by use of a snub line or wedge. Always block reels after positioning.

4. When a cable is cut, seal the ends properly. Cut back cable ends which have been exposed to the weather, a minimum of one (1) foot and properly seal. If this seal is broken, repair it immediately.

One of two following methods shall be used for sealing rubber or thermoplastic cable ends. In both cases, clean the cable jacket and buff so that all cable wax, pulling compounds, and contaminations are removed from the surface.


a) For the first method the end shall then be sealed with epoxy resin using a procedure which shall be approved by the Engineer.

b) For the second method a combination of rubber and vinyl tape may be used to provide a seal. The end shall first be sealed with high voltage electrical tape and then overwrapped with vinyl electrical tape.

5. Signal power feeder cable shall be pulled into place by the Contractor, then terminated at each end by SEPTA. No splices over the installed route are permitted, unless specifically approved by SEPTA.

B. Terminations

1. Make 15 kV and 46 kV cable terminations in strict accordance with the manufacturer's instructions unless otherwise directed by the Project Manager.

2. Terminations of power cables shall be made at the equipment as shown. It is of the utmost importance that perfect electrical contact be secured at the points of connection of each cable. All connections shall have a conductivity and insulation resistance at least equal to that of the cable.

3. Splicers shall have a minimum of five years’ experience in splicing and terminating medium voltage power cables of the type and size(s) involved under similar conditions. Prior to making of a termination, the Contractor shall submit to the Project Manager, for approval, the name of each individual who will perform this type of work including the background of each such individual on similar previous projects.

4. Each splicer shall be certified by the Project Manager. SEPTA may request the splicer to make a test termination in the presence of the Project Manager before the approval is granted.

3.02 TESTS

A. General

1. The Contractor shall provide all instruments, materials, and labor required for tests specified herein.

2. The Contractor shall formulate overall test program of the equipment and installation which shall include but not be limited to the tests specified in this Section to ensure equipment and material compliance with the relevant standards, this Specification, and satisfactory and reliable performance in actual intended operation.

3. Tests at the factory shall include but not be limited to:

a) Tests as listed in Article 3.02 F of this section

b) Manufacturer's standard tests

c) Tests as per relevant NEMA, IEEE, and ANSI standards not included in manufacturer's standard tests

d) Any other tests to ensure satisfactory performance of the product

4. Tests and checkouts in the field shall include but not be limited to:

a) Tests as listed in Article 3.02 G of this section


b) Tests as per relevant NEMA, IEEE, and ANSI standards not included in these specifications

c) Any other tests to ensure satisfactory performance of cable and installation

B. Conditions for Tests

1. Prior to testing of any cable and the installation, the following conditions shall be fulfilled by the Contractor:

a) Contractor shall have in his possession approved shop drawings.

b) Contractor shall have submitted testing procedure for Project Manager’s approval at least 45 days in advance of the testing.

c) For factory tests, a minimum of four (4) weeks advance notification shall be given to the Project Manager on the schedule date of tests to enable him to witness the tests. Field tests shall be scheduled in consultation with the Project Manager.

C. Witnessing Tests

The Project Manager will (at his option) witness complete or partial testing on all the cable and installation unless a waiver is granted for witnessing factory tests, in which case test reports of the product for which waiver was granted shall be submitted for review to obtain clearance for packing and shipping. Waiver of witnessing factory tests on any cable shall not be construed as a waiver for all future supplies either of the same type or different cable.

D. Responsibility

The Contractor shall assume full responsibility during the factory and field testing of all cable and installation provided by him. Should there be any loss or damage to such cable or installation as a result of these tests, the Contractor shall be fully responsible for replacing the damaged cable. Replacement of damaged cable shall include all costs, including, but not limited to, removal of damaged cable, furnishing of, transportation of, and installation of replacement cable.

E. Rejection and Retesting

1. Failure of cable or termination to withstand tests or to meet ratings shall be sufficient grounds for rejection of the item tested.

2. Any cable or splice rejected shall be retested in the presence of the Project Manager after rectification. If the modifications or changes are such as to affect any of the drawings, diagrams, or any other documents submitted and accepted by the Engineer, revised drawings or diagrams, etc., shall be obtained before changes or modifications are made on the installation. Modifications or changes which do not warrant revision of any drawing, shall be furnished to the Project Manager along with notice of retesting.

3. If it is not possible to rectify rejected cable. New cable shall be manufactured and requirements of drawings and design calculations of original item shall be applicable for the new items.

F. Factory Tests

1. Ethylene-Propylene Insulated Cable


a) Manufacturer shall conduct all applicable factory tests specified in the referenced standard.

b) Manufacturer shall furnish test certificates for each reel of cable for approval.

G. Field Tests

1. General

a) All tests shall be successfully completed to show that the installation meets the specification requirements before final acceptance. Contractor shall perform the specified tests on all cable installed under this Contract.

b) Tests and checkouts shall be conducted in accordance with the approved test procedure specified in Article 3.02 A of this section, National Electrical Code, and applicable standards and specifications of ANSI, NEMA, ICEA, AEIC, etc.

c) Field tests are required for all cable.

d) Contractor shall provide properly qualified personnel who shall be responsible for supervising, coordinating, and performing all electrical field testing and checking work, and who will maintain a written record of all tests conducted.

e) Testing and checkouts shall be performed in the presence of the Engineer.

f) Contractor shall furnish four (4) copies of all test results to the Engineer. Result sheets shall include date of test, personnel involved, items tested, type of tests and test data. Test certificate shall show the type and ratings of test instruments used and details of their calibration including dates of their last calibration.

g) Any equipment or cable damaged due to improper test procedure or test apparatus handling shall be replaced or restored to original condition by Contractor at his expense.

h) Safety devices including but not limited to rubber gloves and blankets, screens and barriers, danger signs, padlocks, etc., shall be used to protect and warn all personnel in the vicinity of the tests.

2. Power Cable Field Tests

a) Procedure

1) All single conductor cables shall be tested as specified herein. The object of these tests is to ascertain the following:

Dielectric strength of the cable insulation has not been impaired during installation.

Cable splices and terminations are made properly.

Integrity of the cable system prior to energization.

2) The tests shall include, but not be limited to, the following:

Continuity test.

Insulation resistance test.


High potential direct current test.

3) The test or tests shall be carried out under the supervision of a competent, qualified and trained Technician in the presence of the Project Manager. All the technicians involved in the testing shall be fully aware of the detailed test procedures and hazards involved in the high potential direct current testing.

4) For high potential tests, the area around the ends of the cable under test shall be roped off and warning signs posted. A guard shall be posted at each end for the duration of the tests to prevent unauthorized people entering the test area.

5) Prior to testing, the Contractor shall submit for approval a detailed step by step testing procedure, the list of personnel involved and the make and model number and details of the instruments he intends to use. Written approval of the procedure, personnel and instruments must be obtained before commencement of testing of any cable. Approval of the procedure does not in any way relieve the Contractor from his responsibility with regard to safety of personnel, equipment and property.

6) The factory test voltages specified herein for high potential direct current testing shall be in accordance with Part 6 of ICEA Publication No. S-68-516 for the single-conductor EPR-insulated cable, for the voltage and insulation levels of the cables included.

b) Installation Tests/Acceptance Tests

1) After installation of the entire length of cable run and completing all terminations, Contractor shall perform the below listed tests on each cable circuit.

2) To preclude damage to equipment and devices, all equipment normally connected to the power circuit shall be disconnected from the cable to be tested.

Continuity test shall be performed to prove the continuity of the conductor. Immediately after the test, both ends of the cable shall be tagged with cable identification number.

Phasing test shall be performed to establish the phase identification of the cable for the purpose of phasing. This test shall be done at both ends of a length of installed cable.

Insulation resistance test shall be performed to determine the cable insulation resistance to ground and between the conductors in the case of the two phase cables. A total of three (3) measurements are required for each circuit: one (1) from conductor-to-conductor, two (2) from conductor-to-sheath.

3) Tests shall be conducted with a 2500 volt, motor operated megger. Each measurement shall be held until each reading reaches a constant value for five minutes. Megger test values of insulation resistance obtained shall not be less than five (5)


Megaohms. Contractor shall bring to the attention of the Project Manager similar readings which are unequal with the variations of 25 percent or more.

4) Contractor shall also record the temperature, humidity, duration of test and voltage for each test.

5) High potential test shall be performed only after the insulation resistance test has been successfully completed.

Before conducting the high potential direct current test, Contractor shall make sure that the following requirements are complied with:

Equipment and the shields, ground wire of nearby insulated conductors not under test and the ground stick are all securely tied to the manhole or station grounding system.

The insulated conductor under test must have a safe clearance from adjacent grounded conductors, insulation shield and surrounding metal objects. A 1/4 inch clearance for every 1000 volts of DC test voltage is regarded as a safe distance.

High voltage test gloves are worn by each participant.

The test voltages meet the recommendations of cable manufacturer, splice kits and termination manufacturers.

Danger signs and sentries are posted at all critical points along the entire cable route under test.

Operator's manual for particular test set being used has been read and understood.

All safety precautions have been observed at the testing end and at the far end of the cable.

Each insulated conductor in a conduit shall be tested separately while grounding test equipment and all conductors not under test, with metallic shield or ground wires to the manhole or station ground. The test equipment shall be supplied from a stable, constant voltage source having a maximum variation of the voltage of plus-minus five (5) percent. Preferably, a motor-driven alternator shall be used for the supply. The output voltage of the test set must be filtered, regulated and spike-free. The following test procedure shall be followed:

Ground each conductor to be tested with ground stick before test. Connect test lead to conductor that is to be tested. Then, remove ground stick from conductor to be tested; conduct test. Upon completion of testing that conductor, allow voltage to decay to approximately 5 kV before re-applying ground. Follow above procedure for each conductor being tested.

Apply the direct current test voltage between the conductor and the grounded sheath slowly in equal steps (in steps of five to seven (5-7) percent of full test voltage) until the designated


voltage is reached. The rate of voltage acceleration shall be consistent under each step.

Allow sufficient time after each step for the leakage current to stabilize.

Record total leakage current in micro amperes after each step. The same length of time shall be allowed after each step for the total current to stabilize before taking the readings.

The equivalent DC test voltage shall be eighty (80) percent of the AC factory test voltage. Maintain the test voltage after it has reached the specified value, for fifteen (15) minutes.

Record total current values in micro-amperes at one-minute intervals for the duration of the test.

Set the test voltage control to zero at the end of the test period. Allow the residual voltage on the circuit to decay to approximately 5.0 kV before applying manual grounds.

The tested conductors should remain grounded for at least thirty (30) minutes after completion of the test.

Failure of the initial leakage current to decrease, or any increase in the leakage current at any time during the test shall be presumed to be indicative of a cable defect and the test shall be continued until cable failure occurs.

c) Proof tests

1) The Project Manager reserves the right to have the Contractor proof-test the cable installed under this Contract any time during the warranty period of the Contract-Work or at any time during the performance of this Contract.

2) The proof-test shall consist of a high-potential direct current test as described above with the test voltage specified to the Contractor at the time of the test; the test voltage is to be applied and maintained for a period of five (5) minutes.

3) Contractor shall include in his bid proposal the cost of performing a total of two proof-tests (per cable tested). The cost of performing the tests shall include all labor for isolation of cable to be tested and for performing the work according to the instructions and direct supervision of the Project Manager. The Project Manager will arrange for isolation of the cable from the switchgear inside the Substations.

4) Any defects found as a result of the high potential proof-test shall be corrected by the Contractor at no expense to SEPTA.

5) After successful completion of proof-test, the Contractor shall provide all material, labor and equipment to re-establish the integrity of the installed cable to its original status which prevailed before the cable was isolated for testing.


d) Any cables found defective during the testing shall be replaced with new cables by the Contractor. Rectification of defects of any cable shall be done only with the specific approval of the Project Manager.

END OF SECTION


SECTION 16123

BUILDING WIRE AND CABLE

PART 1 - GENERAL


A. The work specified in this Section consists of material and labor for furnishing, installing, connecting, energizing, testing, cleaning and protecting building wire and cable, and accessories.





D. Section 01600 – Material and Equipment





I. Section 16130 – Raceways and Boxes

J. Section 16950 – Testing of Electrical Equipment

1.03 SUBMITTALS

A. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card. If not available, provide from product manufacturers a written statement indicating why an item does not have quality assurance verification. Such statements are subject to the approval of the Owner and the Engineer.

B. Product Data and Catalog Cuts: Provide product data for the following products; indicate clearly the project specific usage of each product:

1. Wires and cables

2. Lugs and connectors

3. Tools for crimp connectors

4. Tapes and pulling lubricant

C. Tension Calculations:

1. Submit Cable Pulling calculations for all underground power runs. Calculations shall include both pull load and tensions, along with safety factors, for all cables.

2. Design conduit runs so as not to exceed tension limits of manufacturer. Provide additional pulling points as required to limit the tension.


D. Project Record Documents: Record actual installed elevation and locations of feeders, both concealed and exposed work, on the record drawings.

E. Project Closeout: Submit record drawings, product data, and installation and maintenance instructions.


A. Unless products meeting the requirements of nationally recognized testing laboratories are not readily available for a category of products, provide products that are listed and labeled by Underwriters Laboratory (UL), approved by Factory Mutual (FM), or certified as meeting the standards of Underwriters Laboratory by the Electrical Testing Laboratory (ETL).

B. All work shall conform to regulatory requirements of all state and local codes and requirements.


D. Install work under supervision of skilled licensed electricians.

E. References:

1. American Society for Testing Materials (ASTM):

a) ASTM B8: Specification for concentric-lay-stranded copper conductors, hard, medium hard, or soft

2. Institute of Electrical and Electronic Engineers (IEEE):

a) IEEE 383: Standard for Type Test of Class 1 E Electric Cables and Field Splices, and Connections for Nuclear Power

b) IEEE 1202: IEEE Standard for Flame Testing of Cables for Use in Cable Tray in Industrial and Commercial Occupancies.


a) WC70: Non-shielded 0-2 kV cables.

b) WC26: Packaging of Wire and Cable.


a) NFPA 70: National Electrical Code (NEC).

5. Underwriters Laboratories, Inc. (UL):

a) UL 44: Rubber-Insulated Wires and Cables.

b) UL 1277: Electrical Power and Control Tray Cables with Optional Optical Fiber Members.

c) UL 1569: Metal-Clad Cables.

d) UL 1581: Electrical Wires, Cables, and Flexible Cords.

1.05 QUALIFICATIONS




A. Protect items from damage during delivery, storage and handling in accordance with Section 01600 and as detailed below.

B. Packaging of wire and cable shall conform to NEMA WC-26.

1.07 FIELD SAMPLES

A. Samples: Provide one 36-inch long sample of each type of wire to be used.

PART 2 - PRODUCTS

2.01 LOW VOLTAGE COPPER BUILDING WIRE

A. UL listed conductors of 98 percent conductivity copper with type XHHW indoors and RHW outdoors with insulation rated 600 volts.

B. Provide conductors of proper size and ampacity ratings according to NEC Article 310.

C. Minimum Conductor Size:

1. No. 12 AWG in power and branch feeder circuits.

2. No. 14 AWG in control circuits.

3. No. 14 AWG in alarm and status circuits.

D. Except for control wires or where otherwise indicated on the Drawings, do not exceed four conductors (three phase conductors and one neutral) plus ground in raceways or conduits.

E. ROMEX and BX cable and aluminum conductors are not permitted for use in this project.

F. Imprint insulated conductors with the date of manufacture, wire type, and manufacturer. Wire and cable manufactured more than 12 months before delivery to the job site shall not be used.

G. Acceptable Manufacturers:

1. Cablec Continental Co.

2. Rome Cable Corp.

3. Okonite Co.

4. Or approved equal

2.02 SHIELDED INSTRUMENTATION CABLE (2/C CABLE)

A. Provide cable which meets the following:

1. Cable fabricated using stranded (19 x 29 AWG) tin-coated copper conductors with polyethylene insulation, color coded conductor insulation and overall PVC jacket.

2. Cable 100 percent shielded, utilizing aluminum-polyester foil, incorporating #18 AWG stranded tinned copper drain wire.

3. Cable shall be NEC Class CL2 and passing the CSA Vertical Flame Test FT-1.

4. Cable UL (recognized) Style 20253 having a 600 volt insulation and 90 degree C temperature rating, two-conductor, twisted pair, #16 AWG.



a) Belden Corporation

b) Or approved equal

2.03 WIRE AND CABLE CONNECTIONS

A. Grounding: Conform to Section 16060.

B. Service wires and cables, and wires and cables larger than No. 6: For equipment connection provide connectors approved by the equipment manufacturer and of the types specified below. For all other types of connections provide connectors of one of the types specified below:

1. Split Bolt Connectors or Compression Type Connectors: UL Listed connectors for making parallel or butt splices of stranded copper wire. Use companion preformed plastic insulating covers or tape insulation conforming to NEC requirements.

2. Mechanical compression connectors: Provide compact high copper bronze or brass alloy, two-hole, capable of being installed with one wrench with two clamping bolts, single conductor, or multiple conductor, brass or bronze bolts, plated steel screws are unacceptable. Provide silicon-bronze fasteners for bolting connectors to connections.

3. Crimped compression connectors: Provide two-hole crimped connectors of high conductivity seamless electrolytic wrought copper, electrolytically tin-plated, with two holes, color coded to match dies. Provide adequate area for conduction of the flowing current. Provide tooling to crimp connectors from same manufacturer as connectors.

C. Control Wiring Connections: Provide crimped nylon-insulated ring terminals for all connections at terminal boards and nylon insulated butt splices with insulation grip. When more than two control wires are to be joined provide junction boxes with terminal boards as specified in Section 16130.

D. Instrumentation Cable Connector:

1. Provide companion type connectors for instrumentation cable and for the equipment being furnished under this contract.

2. Where providing cable to equipment controllers/enclosures furnished under other sections of this contract, connectors provided with furnished equipment.

3. Terminate wiring as required for proper installation.


a) Thomas & Betts Corp.

b) AMP Inc.

c) IIsco Corp.

d) Buchanan Construction Products

E. Other Conductors: Provide one of the following types of connectors.

1. Any of the types listed for larger wire.

2. Screw terminals, crimped compression terminals: Provide nylon insulated crimped terminals with copper barrels for making terminal connections of stranded copper wire to screw terminals.


3. Wire Nuts: Pre-insulated, UL Listed, hand or tool installed, solderless connectors of the spring-lock type or compression type for making splices of solid copper wire. Wire nuts for site lighting shall be of the type intended for use in wet locations and shall be pre-filled with a waterproofing compound by the manufacturer.

4. Screw lock connectors: for making terminal connections of solid copper wire.


a) Thomas & Betts Corp.

b) AMP Inc.

c) Ilsco Corp.

d) Burndy

e) Or Approved Equal

2.04 TAPE

A. Arc-proofing Tape: Scotch 77

B. Vinyl Insulating Tape: Scotch 33+, black

C. Rubber Splicing Tape: Scotch 1 30C.

D. Grounding Braid: Scotch 25

E. Heat Shrinking: Amp HST1125

F. Acceptable Manufacturers:

1. 3M, Scotch

2. Plymouth

3. Permacel

4. Or Approved Equal

PART 3 - EXECUTION

3.01 PREPARATION

A. Inspect all conduits, junction boxes, electrical vaults and hand holes for cleanliness, lack of burrs, conduits alignment, completeness, and correct deficiencies.

B. Ensure that two locknuts are installed on all conduits without threaded hubs, that bushings are installed in all conduits with wires larger than No. 10, that grounding bushings and fittings are installed at all places called for in Section 16060.

C. Check that proper sized boxes are installed. Boxes and conduit fittings must conform to NFPA 70 (NEC) for bending requirements.

D. Swab all conduits with a nylon bush and steel mandrel.

E. Ascertain that pulling calculations have been made and are available for long runs and pulls as indicated in this Section. Ascertain that a means of controlling pulling tension is installed on mechanical assist devices for pulling cable.


F. Pre-lubricate all conduits for which the pulling tension calculations are based on a coefficient of friction less than that of a dry conduit.

3.02 INSTALLATION

A. General:

1. Install all wiring outside of equipment in conduit.

2. Do not perform wiring until work which might cause damage to the wires, cables or conduits has been completed. Take the necessary precautions to prevent the accumulation of water, dirt or other foreign material in the conduits during the execution of the work.

3. Make wire and cable splices in outlet or junction boxes per NEC, and install such boxes in accessible locations.

B. Equipment Ground Conductors: Include a green equipment ground conductor with all runs; wire type and size as specified in Section 16060.

C. Neutral Conductors:

1. Provide separate neutral conductors for all branch circuits.

2. Size each neutral to the same size as the largest phase conductor.

D. Cable Pulling:

1. Comply with the manufacturer’s recommendations for the inspection, handling, storage, temperature conditioning prior to installation, bending and training limits, pulling limits, and calculation parameters for installation of all cable. Use quadrant blocks located properly along the cable run. Remove from the job-site and replace all cables that were subjected to excessive bending and tension and all cables that are cracked or have damaged or nicked outer jackets.

2. Pull cables down grade with the feed-in point at the manhole, hand holes or buildings of the highest elevation. Flexible cable feeds shall be used to convey cables through the manhole opening and into the duct runs. Cable lubricant shall be soapstone, graphite or talc for rubber of plastic jacketed cables.

3. Lubricate all cables during pulling with lubricants specifically recommended by the cable manufacturer.

4. Limit cable pulling tensions to the maximum pulling tensions recommended by the cable manufacturer. Use dynameter to measure pulling tensions on all runs pulled with mechanical assistance and for all runs where calculations are required to be submitted. If pulling tension is exceeding during pulling, cables shall be removed and marked and not reused.

5. Installation of cables in manholes: Install cable along those walls providing the longest route and the maximum spare cable lengths. Form cables to closely parallel walls so as not to interfere with duct entrances. Support cable on brackets and insulators spaced at a maximum of two feet apart. Lubricants must be used and approved by the cable manufacturer.

E. Wiring Identification:

1. Color code wires and cables as specified in Section 16075.

2. Identify all control wiring with wire numbers corresponding to record drawings.


3. Identify all power wiring by circuit and panelboard, switchboard, and motor control center number.

F. Cable Terminating:

1. Protect termination of insulated power and lighting cables from accidental contact, deterioration of coverings and moisture by the use of terminating devices and materials. Terminations shall be made using materials and methods as indicated or specified herein or as designated by the written instruction of the cable manufacturer and termination kit manufacturer.

G. Wire and Cable Splices:

1. Splice cables only in accessible location. Install all service and feeder conductors from end to end without splice. Install all motor conductors from starter to motor without splice.

2. Protect termination of insulated power and lighting cables from accidental contact, deterioration of coverings and moisture by the use of terminating devices and materials. Terminations shall be made using materials and methods as indicated or specified herein or as designated by the written instruction of the cable manufacturer and termination kit manufacturer.

3. Locate splices in underground systems in accessible locations with manhole entrances above the 100-year flood elevation. Make below-grade splices using a compression connector on the conductor. Insulate and waterproof below-grade splices by methods suitable for continuous submersion in water using either method that follows:

a) Gravity Poured Method: Employ materials and equipment contained in an approved commercial splicing kit with a mold suitable for the cables to be spliced. When the mold is in place around the joined conductors, prepare and pour the resin mix into the mold.

b) Cast-Type Splice Insulation: Employ materials and equipment contained in an approved commercial splicing kit employing a thermosetting epoxy resin insulating material applied by a gravity poured method or by a pressure injected method. Fix cables in place to not be moved until the splicing materials have completely set.


A. Electrical Testing: Field test prior to energizing wire and cable as specified in Section 16950.

END OF SECTION




SECTION 16129

FIBER OPTIC CABLE

PART 1 - GENERAL


A. This section specifies the requirements for providing (furnishing and installing) fiber optic cable. Use industry-standard construction practices so that project management, project coordination, and construction techniques comply with all federal, state, and local codes and regulations.

B. Included is providing a fiber optic with vital signal and communications data between WJSFC Building and a fiber optic node outside the project area located in the 25 Hz Wayne Junction Traction Power Substation.

C. Furnish and Install the most recent version of equipment available at the time of installation.

D. Furnish and install all necessary equipment and materials identified in this section and the drawing package for the successful performance of the identified Work.

E. Cabling shall be installed in such a manner so that SEPTA’s normal day-to-day operations are not affected, and that interruptions to SEPTA’s normal workday activities are kept to a minimum.





D. Section 16060 – Grounding and Bonding

E. Section 16075 – Electrical Identification

F. Section 16130 – Raceways and Boxes

G. Section 16138 – Duct Work and Electrical Manholes

H. Section 16910 – Electrical Systems Control (SCADA)

I. Section 16950 – Testing of Electrical Equipment

1.03 SUBMITTALS

A. Provide proof of manufacturer’s certification, within ten business days of the Contract Award that you or your sub-contractor is manufacturer-certified to install the specified cabling systems. Certify that warranty is a minimum of 5 years (minimum).

B. Submit for approval to SEPTA’s Project Manager, sets of catalog cut-sheets for all materials to be used in this installation, in accordance with Section 01300, Submittals. Each cut-sheet shall be identified with the manufacturer’s name, part number, acquisition lead time, and date of submittal. SEPTA will not be responsible for any materials ordered prior to SEPTA’s approval for the cut-sheet item in question.


C. Failure to provide a complete cut-sheet submittal for a specific item will result in rejection. Upon rejection, resubmit the specified documentation for re-approval.

D. Submit cut-sheet submittals in a timely manner to permit proper consideration and approval. Coordinate the timing of each submission to assure adequate lead time for procuring items required by this contract, and inform SEPTA’s Project Manager of any time constraints concerning submittal approvals that are critical to the completion of the project. Delays attributable to rejected cut-sheet submittals shall not serve as a basis for extending time for contract completion.

E. After an item has been approved, changes in make, manufacturer, or part number shall not be permitted, unless:

1. Satisfactory written evidence is presented, and approved by SEPTA, that the manufacturer cannot make the scheduled delivery date of an approved item; or

2. Other conditions become apparent indicating approval of the item to be substituted will be in the best interest of SEPTA.

F. Submit a cable and outlet identification plan and an interconnection block diagram to SEPTA’s Project Manager for approval before final cable and faceplate labels are installed.

G. Submit pulling calculations (tensions and side wall pressure).

H. Submit field monitored pulling tension forces measured during actual installation of the cable.

I. As part of the “as-built” submission, submit copies of the completed test results (in accordance with Section 01300, Submittals) within 15 working days of test completion, in both electronic and printed format. The submission shall include copies of the print-outs of all cables tested.

J. Submit copies of the marked-up “as-built” drawing(s) to SEPTA’s Project Manager within 15 working days of completion of the Work (or each phase of the Work). As a minimum, annotate on a clean set of prints, the following information:

1. The approximate routing of cabling installed

2. Other pertinent information, such as actual pulled lengths, concerning the performance of the Work regarding “as-built” conditions that will provide a more accurate set of drawings.


A. National Fire Protection Association (NFPA)

1. NFPA 70 – National Electric Code, 2008

B. Telecommunications Industry Association/ Electronic Industries Alliance (TIA/EIA)

1. 568-B.1 – Commercial Building Telecommunications Cabling Standard, Part 1: General Requirements

2. 568-B.2 – Commercial Building Telecommunications Cabling Standard, Part 2: Balanced Twisted Pair Cabling Components

3. 568-B.3 – Optical Fiber Cabling Components Standard


4. 569-A – Commercial Building Standards for Telecommunications Pathways & Spaces

5. 607 – Bonding and Grounding for Telecommunications Cabling and Equipment in Commercial Buildings

C. BICSI

1. “Telecommunications Distribution Methods Manual”

1.05 PERFORMANCE REQUIREMENTS

A. Work shall be performed in a professional manner, using practices of good craftsmanship.

B. Provide cables with the specified connectors affixed using the tools specified by the manufacturer.

C. Terminate cables using the tools specified by the manufacturer.

D. Label cables and outlets in accordance with Paragraph 3.07, Cable Labeling and Identification.

E. Remove trash, debris, spent reels, and all other refuse related to this installation, daily.

1.06 QUALIFICATIONS

A. Provide the services of personnel having at least five years’ experience in the installation and termination of single mode optical fiber.


A. Develop and submit:

1. Certified Factory Test Reports

2. Pulling Calculations

3. Certified detailed field test reports that verify the total db losses

4. As-built documents

1.08 WARRANTY

A. Provide the standard warranty with a 5-year minimum term as indicated in this section, Article1.03 A (above). The warranty shall begin upon SFC Building Rehabilitation commissioning by SEPTA.

1.09 SYSTEM ACCEPTANCE

A. Final acceptance will be made by SEPTA upon satisfactory completion of the Work, including all cable testing and an integrated SCADA/Communications systems test, that will insure that all equipment and cabling have been properly installed. Additionally, SEPTA’s acceptance is based upon the submission and approval of all test records, cable run summaries, and as-built drawings.

B. The work will not be considered complete until:

1. It has been inspected and accepted by SEPTA.

2. All discrepancies have been resolved.


3. All test records, cable run summaries, and as-built documentation have been received.

PART 2 - PRODUCTS

2.01 GENERAL

A. Items not listed in this document or shown on the drawings, but necessary for the complete and proper performance of the Work as specified, shall be considered part of the Work. Verify exact types and quantities of all materials with SEPTA before purchase.

2.02 OUTSIDE PLANT FIBER OPTIC CABLE

A. Provide single mode optical fiber (SMF) for outside plant operations that can be applied in underground duct, in aerial duct, and lashed to an aerial messenger wire as offered by Superior Essex (Series F1), or an approved equivalent.

B. Fiber and cable characteristics for cable to be supplied are as follows:

1. Fiber count: 24, unless shown otherwise on the Contract Drawings

2. Nominal diameter: 0.55 inches

3. Minimum bending radius: 11 inches

4. Outer construction consisting of:

a) Provide ultraviolet (UV) protection that shall no promote the growth of fungus

b) Rigid dielectric outer strength members imbedded just under a UV resistant jacket

c) Rip cords to remove outer jacket

d) A dielectric water blocking strength member layer over a single gel-filled tube

5. The inner construction of the cable shall be a loose tube design, highly flexible and dry, with individual Type 3, reduced water peak, single mode fibers.

2.03 INSIDE PLANT FIBER OPTIC CABLE

A. Provide inside plant fiber optic cable compatible with the equipment specified in Section 16910, Electrical Systems Control (SCADA).

2.04 CABLE TERMINATIONS

A. Terminations for Fiber Optic Elements

1. Single-Mode fiber optic elements of the composite copper/fiber optic cable shall be terminated on ST connectors installed within fiber optic patch panels.

2.05 FIRE STOP

A. Provide UL-listed fire-stopping for all conduits, sleeves, floor openings, and wall penetrations used for this cable installation.


B. Submit for approval the method(s) and material(s) to be used to fire-stop all wall, floor, and ceiling penetrations, and all conduits and sleeves used as a part of the cabling installation.

PART 3 - EXECUTION

3.01 GENERAL

A. Do not exceed the recommended pulling tension of the cable manufacturer. Assume responsibility to pay all costs associated with the replacement of any cable that exhibits evidence of cuts, crimps, severe abrasions, and damage due to exceeding the manufacturer’s specified pulling tension.

B. Install, dress, and terminate cabling in a professional manner, using practices of good craftsmanship. Where communications cabling must cross power cables/conduits, they shall cross at right angles (90-degrees) to the power runs. A minimum of 12-inches separation from power cables/conduits shall be maintained where communications and power cabling follow the same route.

C. Place all new sleeves and penetrations required for successful cable installation.

D. Upon completion of the cable installation, install fire-stopping/sealing material in all sleeves and penetrations used during this installation.

E. Ground equipment racks and cabling in accordance with all manufacturer’s specifications and recommendations, the National Electrical Code, and accepted industry standards for grounding communications cable and ancillary devices.

3.02 CABLE TERMINATION

A. Each element of the specified fiber optic cabling installed shall be connectorized using the specified ST-connectors, and shall be mounted into the specified fiber optic patch panels and ST-insert panels.

B. For cable that SEPTA terminates, at the fiber node at Wayne Junction Traction Power Substation, seal ends in a manner to prevent degradation due to the respective indoor or outdoor environments.

C. Furnish and install all termination equipment according to the manufacturer’s instructions, using the required tooling and materials.

3.03 FLOOR AND WALL PENETRATIONS, FIRE STOPS

A. Install all required floor, wall, and building penetrations.

B. Submit to SEPTA’s Project Manager for approval, all required floor, wall, and building penetrations before proceeding with this portion of the Work.

3.04 INSTALLATION IN DUCT BANKS

A. In the duct bank manholes, apply a wrap of fireproofing tape and mastic between the entry points into the manhole. Install fire stop material at each duct entry point. The intent is to provide protection to vital fiber optic cables passing through manholes where unrelated C&S and ET cables may cause a fire.


3.05 SPLICES

A. SEPTA intend that outside plant cabling shall be installed in one continuous run between termination locations. No splices will be permitted.

B. Install inside plant fiber optic cable without splicing between terminations at SCADA equipment or between outside plant to inside plant splice panels and SCADA equipment (i.e. no splices between termination points shown on a final fiber plant block diagram).

C. SEPTA intend that cabling shall be installed in one continuous run between termination locations. However, should the SEPTA approved pulling calculations by the Contractor indicate the need to construct a splice or splices, assume all costs for and provide the required splices and enclosures.

3.06 DAMAGE

A. Any cuts, abrasions, burns, stretched segments, and/or other damage that will be detrimental to the performance of that cable shall be cause for replacement of that entire segment of cable.

B. Incidental damage to cables and connectors shall be corrected at the Contractor’s expense before testing and final acceptance of cables.

3.07 CABLE LABELING AND IDENTIFICATION

A. Submit a cable and outlet identification plan to SEPTA for approval before final cable labels are installed.

B. Each cable, fiber distribution panel port, and termination block position shall be labeled individually with a unique cable number, using machine-printed labels.

C. Each outlet shall be labeled individually with a unique identification number, using machine-printed labels.

D. Cable labels that are cut off during the installation process shall be replaced with new labels after final dress and termination in such a position that permits the label to be easily read.

3.08 TESTING

A. Factory and Field Testing shall be performed in accordance with the requirements of Section 16950, Testing of Electrical Equipment.

END OF SECTION


SECTION 16130

RACEWAYS AND BOXES

PART 1 - GENERAL


A. This section covers the requirements for the following conduits and ducts:

1. Metal Conduits

2. Non-Metallic Conduits

3. Metallic Pull Boxes and Splice Boxes





D. All other sections of Division 16

1.03 SUBMITTALS

A. Catalog cuts of proposed conduits

B. Drawings and catalog cuts of proposed pull and splice boxes

C. Pull and splice box size calculations and/or diagrams


A. American Society of Testing and Materials (ASTM)

1. D149 – Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulation Materials at Commercial Power Frequencies

2. Standard Specification for Smooth-Wall Polyvinyl Chloride (PVC) Conduit and Fittings for Underground Installation

B. National Fire Prevention Association (NFPA)

1. NFPA 70 – National Electrical Code (NEC)

a) Article 344 – Rigid Metal Conduit

b) Article 352 – Rigid Nonmetallic Conduit

c) Article 314 – Outlet, Device, Pull and Junction Boxes, Conduit Boxes, Fittings, and Manholes

d) Article 350 – Liquid tight Flexible Metal Conduit

e) Article 356 – Liquid tight Flexible Nonmetallic Conduit

C. National Electrical Manufacturers' Association (NEMA)

1. NEMA TC-6 & TC-8 – PVC Plastic Utilities Duct for underground Installations

D. Underwriters' Laboratories (UL)


1. UL 1 – Flexible Metal Conduit

2. UL 6 – Rigid Metal Conduit

3. UL 514B – Fittings for Conduit and Outlet Boxes

PART 2 - PRODUCTS


A. Non-metallic Conduit

1. Polyvinyl Chloride Conduit (PVC)

a) Provide PVC conduit from the following manufacturers;

1) T & B (Carlon)

2) Cantex

3) National Pipe & Plastic

4) Or approved equal

b) Concrete encased: U.L. listed, PVC plastic conduit conforming to ASTM-D1785.

c) Direct burial (sand encased): U.L. listed, type 80 PVC conforming to ASTM-D1785.

B. Flexible Metal Conduit (FMC)

1. Flexible metal conduit shall be galvanized steel conforming to UL 1.

2. Connectors shall be of the twist-in, insertion type with insulated throats.

3. FMC shall only be installed in indoor spaces.

C. Liquid Tight Flexible Conduit

1. Liquid tight flexible metal conduit shall consist of continuous lengths of wound and interlocked galvanized steel, over which is an extruded polyvinyl chloride covering.

2. Liquid tight flexible metal conduit shall be:

a) Anamet Canada Inc. (Anaconda) Type UA/CSA

b) Electro-Flex Type LA

c) Or approved equal

3. Connectors for liquid tight flexible metal conduit shall be of the throated insulated type and shall be provided with a bonding locknut.

4. Liquid-tight flexible metal conduit shall be PVC-jacketed steel core. Liquid tight flexible metal conduits less than 1-1/2 inches in diameter shall have continuous copper bonding conductor between convolutions and be approved for grounding. Conduit sizes 1 1/2-inch and larger shall be provided with separate grounding conductor.

D. Rigid Metallic Conduit (RGS)


1. Do not use RGS conduit, conduit bends, and fittings for the installation of traction power cables.

2. Provide conduits fabricated of mild steel piping, galvanized or electro-plated inside and outside, and protected against corrosion by a dichromate rinse or a zinc chromate coating. Each conduit shall bear the UL label, shall be defect free, furnished in 10-foot lengths minimum, threaded both ends, one end fitting with a coupling and of the following types:

a) Galvanized Rigid Steel Conduit (RGS) and Fittings: Product meeting requirements of NEC Article 344 for materials and uses.

3. Connectors and coupling shall be threaded galvanized malleable iron or steel.

4. Locknuts shall be of the type with sharp edges that bite into enclosure where connected.

5. Bushings shall be brown or black, high temperature type, lay-in grounding type, unless indicated otherwise.

6. Rigid Steel Conduit and Fittings:

a) Hot-dip galvanized inside and out, with threads galvanized after cutting, conforming to Federal Specification WW-C-581, UL No. 6 and ANSI C80.1.

b) Rigid Steel conduit and fittings shall be such as manufactured by Allied Tube and Conduit, or approved equal.

E. Rigid Non-Metallic Conduit

1. PVC Electrical Conduit and Fittings

a) Non-metallic conduit and conduit fittings shall be as follows:

1) All underground conduits shall be PVC, (with transition to FRE type conduit when the conduit continues exposed, above grade).

2) Conduit and fittings shall be encased in concrete and shall be thin-wall wall type EB.

3) Metallic ties shall not be used when constructing embedded conduit system. Concrete encased conduits shall be assembled utilizing plastic base and intermediate spacers to provide a minimum spacing of 7 inches between centerlines of parallel conduits.

b) Furnish UL listed material in accordance with Article 352 of the NEC for underground use.

2. Glass-Fiber Reinforced Thermosetting-Resin Conduit (RTRC) Electrical Conduit and Fittings

a) Physical Properties

Property Value Standard

Specific Gravity 1.94 g/cubic cm ASTM D-792

Barcol Hardness 54 + 2 ASTM D-2583


Glass Content 68% + 3%

Water Absorption < 1% ASTM D-570

Color Black

Application Above Ground

Coefficient of Friction (PVC jacket)

0.385 + .06

b) Electrical Data


Dielectric Strength 500 volts/mil ASTM D-149

Dielectric Breakdown Voltage

29.7 kV ASTM D-149

Dissipation Factor 0.5% ASTM D-150

c) Thermal Properties


Coefficient of Thermal Expansion

1.37 E-5 in./in./oF ASTM D-696

Thermal Conductivity 2 BTU.in/ft2.h.oF ASTM D-335

Flammability HB UL 94

Heat Deflection Temperature

312oF ASTM D-648

Flame Retardant Satisfactory UL 1684-96 Sect. 5.12

d) Mechanical Data


Tensile Strength >=9000 psi ASTM 2105

Elasticity Modulus 1.3 E + 6 psi ASTM D-2105

Resin Epoxy

Glass E-Glass

Toxicity No chlorine or trace halogens

e) Use RTRC conduit and fittings that meet the requirements of NEMA standard TC 14, Type HW.

f) Manufactured from pure, high grade, filament wound fiberglass epoxy having the following properties as a minimum:

1) Tensile strength, longitudinal: 48.26 Pa (7,000 psi) when tested per ASTM D21 05.


2) Compressive strength, axial: 82.74 Mpa (12,000 psi) when tested per ASTM D695.

3) Ultimate elongation: 2% when tested per ASTM D21 05.

4) Modules of elasticity in tension: 8618.5 Mpa (1,250,000 psi) when tested per ASTM D2105.

5) Modules of elasticity in bending: 8618.5 Mpa (1,250,000 psi) when tested pr ASTM D790.

6) Thermal conductivity: 1038 J/Hr/Sq. m/Degr. C/m (2.0 BTU/Hr./Sq. Ft./Degr. F/Inch).

7) Coefficient of linear thermal expansion: 2.25 x 10-5. m/m/Degr. C. (1.25 x 10-5 inch/inch/Degr. F).

8) Specific gravity: 1.94.

9) Temperature range: Minus 18.3C (-65F) to plus 148.9C (300F).

10) Dielectric strength: 500 volts/mil when tested per ASTM D348.

11) Dissipation factor: 0.5% average at room temperature when tested per ASTM D348.

g) RTRC conduit in 100 mm (4 inch) size and larger: Heavy wall thickness of 2.45 mm (0.096 inches), minimum, and rated for impact resistance (vandal-resistant).

h) Conduit and fittings (watertight) shall be such as manufactured by

1) Champion

2) FRE Composites Inc.

3) Or approved equal

F. Miscellaneous Fittings

1. Expansion and Deflection Fittings: Concrete-tight and weatherproof with ground continuity, shall allow four-inch movement and 3/4-inch or 30 degrees of deflection from normal, and shall have factory-installed packing ring and pressure ring designed to exclude moisture.

2. Hub fittings: Shall have nylon-insulated throat.

3. Through-wall and floor seals: Insulating and watertight type.

4. Elbows

a) Radius not less than 12 times the conductor diameters but in all instances, the cable manufacturer’s requirements shall supersede this paragraph

b) Fittings for conduits and outlet boxes shall conform to UL 514B.

G. Accessories

1. Conduit Pull Lines: Polypropylene, 1/4-inch, tensile strength not less than 1,000 pounds.

2. Conduit Thread Compound: Lead-free, corrosion-resistant, anti-seize, conductive.


3. Conduit Sealant: Silicon foam; Chase Technology Corp.'s PR855, or approved equal.

4. Galvanize Repair Coating: Cold-liquid type.

H. Pull and Splice boxes

1. Metal Pull and Splice Boxes

a) Metal Boxes that are to be installed in heated or unheated spaces shall be extra-duty hot-dipped galvanized steel. All boxes shall be sized in accordance with NEC Article 314.

1) Provide grounding means in each metal box.

2. Boxes shall have metal covers that comply with NEC Article 314.41.

PART 3 - EXECUTION

3.01 PREPARATION

A. Transmit submittals and deliverables required by this section.

B. Furnish products as indicated in Part 2 Products.

C. Ensure substrates are in suitable condition to receive the work of this section.

3.02 INSTALLATION

A. Install wiring in raceways, unless otherwise specified herein.

B. Raceways shall be exposed, or concealed in ceilings, walls, floors, or underground as specified herein.

C. Size conduit as required or as specified herein. Minimum raceway size shall be 3/4-inch.

D. Changes and offsets due to structural conditions, and coordination with equipment, piping and ductwork, shall be made.

E. Raceways that pass through expansion joints shall be provided with expansion fittings.

F. Exposed raceways shall be run parallel with, or at right angles to, the building walls.

G. Lateral runs of raceways in masonry shall not exceed 3-inch trade size.

H. Raceways shall be secured in place and protected to prevent damage to the work during construction.

I. Installation of raceways shall be complete and shall be blown-out and swabbed clear of water and trash prior to pulling wire.

J. Install junction or pull boxes to avoid excessive runs or bends. Several such boxes are indicated on the drawings. The locations shown may be varied and additional boxes installed.

K. Provide pull lines in all empty raceways. At each end, leave 12 inches of slack coiled in the box, or at the end of the conduit where boxes are not installed.

L. Provide connectors with phenolic-insulated throat and collar with grounding lugs at enclosures with concentric knockouts. Make metallic conduit and raceways electrically and mechanically continuous and ground them in accordance with Specification Section 16060 – Grounding and Bonding.


M. Cut conduit square, in a manner, which will result in conduit openings not being restricted. Clean cut ends and remove burrs.

N. Conduit spacers: Install in accordance with manufacturer's printed installation instructions.

O. Field bend conduit with tools designed for the purpose.

P. Bending radius shall be not less than nine conduit diameters for standard conduit.

Q. System-wide four-inch conduit bends shall not total more than 270 degrees (three, 90 degree bends) in any one run between an outlet, pull box and manhole.

R. Fasten conduit to hubless boxes with two locknuts and a grounding bushing.

S. Inject sealant into conduits at exterior boxes and wire ways, and at first box on conduit entering dry areas from wet areas.

T. Conduits emerging from earth or gravel, floor slabs or underground walls shall be PVC.

U. Install suitable caps or plugs in empty conduits for future extension.

3.03 APPROVED USE OF LIQUID-TIGHT FLEXIBLE METAL CONDUIT

A. Liquid-tight flexible metal conduit is approved for use in the following situations:

1. Connections to dry-type transformers

2. Connections to motors

3. Connections to all electrical equipment subject to movement or vibration where exposed to rain, spray, or a corrosive atmosphere and located in equipment mechanical rooms and shops

4. Connections to equipment subject to oil or grease

3.04 CLEANING

A. Rod and clean conduits and ducts using appropriately-sized mandrels and swabbing mandrels.


A. Confirm that all conduit bends and sweeps are properly sized during the cleaning process. Replace all bends that are improperly sized.

3.06 DEMONSTRATION

A. Test metallic conduit and boxes for electrical continuity. Perform the tests in the presence of the Engineer or their representative.

B. Arrange with SEPTA’s Project Manager for inspection and approval of embedded conduit and boxes prior to concrete placement.

END OF SECTION




SECTION 16140

WIRING DEVICES

PART 1 - GENERAL


A. The work of this section consists of material for furnishing, installing, connecting, energizing, testing, cleaning, and protecting wiring devices and cover plates.





D. Section 16050 – Basic Electrical Materials and Methods

E. Section 16060 – Grounding and Bonding

F. Section 16075 – Electrical Identification

G. Section 16123 – Building Wire and Cable

H. Section 16130 – Raceways and Boxes


1.03 SUBMITTALS

A. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card. Provide from product manufacturers a written statement indicating why an item does not have quality assurance verification. Such statements are subject to the approval of the Project Manager.

B. Product Data:

1. List of all products and accessories

2. Catalog cuts of all products and accessories to be furnished and installed.

C. Project Closeout: Submit product data, and installation and maintenance instructions.


A. Conform all quality control work to Section 01400.

B. Provide products that are listed and labeled by Underwriters Laboratory, approved by Factory Mutual, or certified as meeting the standards of UL by the Electrical Testing Laboratory (ETL) unless products meeting the requirements of these testing laboratories are not readily available, or unless standards do not exist for the products. Provide products that are for the location installed and listed and labeled or approved for the voltages and currents applied for the applications the items are intended.

C. Conform all work to NFPA 70, National Electrical Code.

D. Perform all electrical work under the supervision of a licensed electrician.


E. References:

1. National Electric Manufacturer's Association (NEMA):

a) NEMA WD 1 General Requirements for Wiring Devices

b) NEMA WD 6 Dimensional Requirements for Wiring Devices


a) NFPA 70 National Electrical Code (NEC)

3. Underwriter’s Laboratories, Inc. (UL):

a) UL 20: General-Use Snap Switches

b) UL 231: Power Outlets

c) UL 498: Standard for Safety for Attachment Plugs and Receptacles

d) UL 1681: Standard for Safety for Wiring Device Configurations

PART 2 - PRODUCTS

2.01 SWITCHES AND RECEPTACLES

A. Provide UL listed specification grade switches meeting NEMA Standard WD 1, and WD 6; and UL listed specification grade receptacles meeting NEMA Standard WD-1 and WD-6 for voltage and current indicated. Provide switches and receptacles with screw terminals. A mixture of manufacturers’ products is not permitted.

B. Toggle Handle Snap Switches: Provide 20 amp, single pole, 3-way or 4-way as indicated, quiet design Hubbell HBL1 221 series or approved equal.

1. Control switches, SPDT with center OFF and maintained contacts or SPDT with center OFF and momentary contacts to be of the same basic type, construction and rating as specified above for toggle handle snap switches. See Drawings for additional information.

C. Standard Face Design Receptacles:

1. Industrial Specification Grade: Duplex, 125 volts ac, 20 amperes, 2-pole, 3-wire, grounding, Hubbell HBL5362 series or approved equal.

D. Ground Fault Circuit Interrupter (GFCI) Receptacles:

1. Industrial Specification Grade: Duplex, 125 volts ac, 20 amperes, 2-pole, 3-wire, grounding, UL943, solid state circuitry, Hubbell GF5362A series or approved equal.

E. Acceptable Manufacturers:

1. Hubbell

2. Pass & Seymour



2.02 WALL PLATES

A. Provide a wall plate for each switch, receptacle, and special purpose outlet. Do not use sectional gang plates. Use multi-gang outlet plates for multi-gang boxes. Use wall plates of AISI 302 stainless steel (.040 inches thick) with satin finish.

B. Use wall plates for pushbutton and buzzer outlets that have openings to suit the pushbuttons and buzzers. Use plates having the same finish mentioned above.

C. Provide wet location device covers for use at locations subject to wet or rain conditions. Provide receptacles covers marked “Suitable for Wet Locations While in Use”.

D. Use 316 stainless steel type screws for the installation of wiring devices and wall plates.

E. Acceptable Manufacturers:

1. Hubbell

2. Pass & Seymour

3. Appleton

4. Crouse-Hinds


PART 3 - EXECUTION

3.01 PREPARATION

A. Inspect area to insure all surfaces are complete with the correct number, type, and location of anchors, size, and levelness. Check for spalled concrete, honeycombs, and other concrete defects.

B. Check pull and junction box for correct type, size, and location.

1. Flush boxes should be plumb and level to 1/8-inches and flush or protrude no more than 1/16-inch from the finish surface.

2. Surface mounted boxes should be plumb and level to 1/16-inch.

3. Size of box should conform to NFPA 70 Article 314.

4. Check wiring pigtails for sufficient length to re-terminate wiring twice and leave 6-inches of slack within the box.

C. Check ground wires for correct type, size, and location.

D. Correct any and all defects.

E. Remove any over sprayed paint from interior of boxes and from wiring.

F. Clean interior of box of dirt and debris.

3.02 INSTALLATION

A. Install equipment under supervision of skilled electricians and in accordance with manufacturer's printed installation instructions.

B. Where two or more switches or receptacles are shown on the drawings at the same location, they shall be ganged and covered with one overplate.

C. Use stainless steel hardware in all locations.


D. Adjust final switch and devices to be plumb and level and wall plates of flush boxes to be set flush to wall.

E. Mounting Heights: Unless otherwise specifically instructed, locate mounting heights from finished floor to centerline of devices.

1. Lighting Control Switches: 48-inches to centerline of switch above finished floor and on strike side of door, unless indicated otherwise on the Drawings. Mount switches in tandem where not possible to mount side-by-side with a common device plate.

2. Duplex Convenience Outlets: Mount 18-inches to centerline of outlet above finished floor, unless indicated otherwise on the Drawings.

F. Ground all devices to conform to Section 16060.

G. Make up all connections to devices to conform to Sections 16123.

H. Provide outlet boxes and supports to conform to Sections 16130.

I. Identify all devices to conform to Section 16075.

J. Protection:

1. Mask all items during painting operation.

2. Protect items against damage during other work.


A. Inspect all boxes for proper operation and visual appearance and mounting height.

B. Test receptacles. Refer to Section 16950.

END OF SECTION


SECTION 16240

BATTERY EQUIPMENT

PART 1 - GENERAL


A. This section specifies a battery system for use in an unattended, non-climate controlled traction power facility, including the manufacturing, testing, and furnishing requirements for the following station battery equipment:

1. Battery cells – monoblocs, VRLA, 190 A-Hr

2. Battery racks with containment barrier

3. Battery accessories

4. Battery chargers

5. Battery charger accessories

6. DC distribution panelboards are existing

7. Fused disconnect switches are existing

B. Design the battery system to replace the batteries and chargers in the existing electrical room, having the equipment as described above, as a fully integrated system and within the specified space limitations. The design of the integrated system shall provide features for the safety of personnel during installation, operation, and maintenance. Provide all cabling to connect to existing DC distribution and disconnect switches.

C. The ambient temperature will vary from -4 deg F to 113 deg F. The system shall be comprised of monoblocs, a battery rack, battery chargers and ancillary equipment.

D. Provide SCADA supervisory and alarm indications.



B. Section 01305 – Request(s) for information


D. Section 16010 – Basic Electrical Requirements

E. Section 16050 – Basic Electrical Materials and Methods


G. Section 16910 – Electrical Systems Control (SCADA)

H. Section 16950 – Testing of Electrical Equipment

1.03 SUBMITTALS

A. All documentation required per this specification shall be submitted for review and approval, prior to delivery, to: SEPTA – Engineering Manager – Power Department, 1234 Market Street, 12th Floor, Philadelphia, PA 19107.

B. Battery


1. Shop drawings, catalog cuts, illustrations, specification, schedules, and material lists showing complete details including the battery rack tier and step configuration and containment dimensions, including the volume.

2. Ventilation requirements

3. Maintenance and Installation Instruction Manual(s)

C. Battery Charger

1. Manufacturer’s product description, catalog data and information

2. Manufacturer’s arrangement, wiring, and detail outline dimensions drawings, floor plans, and one line diagrams

3. Design calculations for battery and battery charger

4. Certified test reports

a) Submit certified test reports for the following tests on battery chargers having identical requirements as described in this Section:

1) Dielectric tests

2) Voltage adjustment

3) Temperature rise

4) Current limit

5) Short circuit

6) Static voltage deviation

7) Efficiency measurement

8) Power factor measurement

9) Ripple voltage measurement

10) Audible Noise

11) Stability and response

12) Transient voltage withstand

13) No load

5. Battery charger control wiring diagram and Schematics

6. Typical values for the following battery charger test results

a) Dielectric test

b) Full load tests with a 190 ampere-hour, 10 monoblocs (6 cells each), lead-acid battery, running in parallel with, and without a battery, with momentary overload. The full load test shall show output ripple voltage lies within .06% of normal output voltage.

c) Voltage test

d) Current limit test

e) Ripple voltage measurement


f) Charging capability within 12 hours, of a battery already discharged to 105 Vdc from its nominal 130 Vdc value

g) Float voltage tests

h) Temperature compensation

i) Automatic “Equalizing Charge” capability

7. Field Test plan

8. Nameplate information

9. Training course instructors outline and a copy of the presentation materials.


A. American National Standards Institute (ANSI)

B. Institute of Electrical & Electronic Engineers (IEEE)

C. National Electrical Manufacturer’s Association (NEMA)

D. Underwriter’s Laboratories, Inc. (UL)

E. National Fire Protection Association (NFPA)

F. American Society for Quality Statistics (ASQ)

G. Utilize manufacturers that have not less than 15 years in the manufacture of batteries and battery chargers and only provide products that have proven reliability in similar applications.

H. Select a manufacturer having a certified ISO-9001 approved in-house Quality Management System.


A. Permit no more than 90 days to elapse between final manufacturing date of battery cells and installation with a functional battery charger.

1.06 WARRANTY

A. The manufacturers of each component within the complete battery system shall warrant their respective components to be free from defects in workmanship and material for a period of five (5) years from the date of delivery.

B. The manufacturers of each component within the complete battery system shall warrant their respective components to operate per this Specification for a period of five (5) years from the date of delivery, except that the warranty on the cells shall be extended and pro-rated for a period of ten (10) years.

1.07 OPERATIONS AND MAINTENANCE DATA

A. Installation, Operation and Maintenance/Repair Manuals

B. As-Built Drawings

C. Parts List Manual

D. Nameplate information


E. Manufacturer’s arrangement, wiring, and detail outline dimensions drawings, floor plans, and one line diagrams

F. Design calculations for battery and battery charger

G. Certified test reports

1.08 PATENTED MATERIAL

A. In the event that any product delivered to SEPTA under this Specification is protected by any patent or copyright, the vendor agrees to and shall defend, indemnify and save harmless SEPTA from any and all suits, claims, judgments, costs and causes of action at law or in equity arising out of or related to the sale, purchase or use of any such article, which sale, purchase or use is alleged to be in violation of any rights under a patent or copyright.

PART 2 - PRODUCTS


A. Manufacturers:

1. Battery Charger, 480 V, 3 phase, 60 Hz power input:

a) Provide battery charger manufactured by the following, or an approved equal:

1) EnerSys (Yuasa-Exide), Inc.

2) C & D Technologies, Inc.

3) Saft NiFe

4) Alcad

5) Hindle Power

2. Battery:

a) Description: The battery system shall be a 125 VDC, 190 A-Hr pure lead VRLA (valve-regulated, lead-acid) AGM (absorbent glass mat) stationary battery system of flat plat construction, comprised of ten (10) monoblocs (a.k.a. multi-cell unit or monobloc) at 12 VDC each. Each monobloc shall be comprised of six (6) cells, and shall have terminals accessible from the front, not the top, of the package. All acid shall be immobilized in the AGM. No free acid shall be present in the cell.

b) Battery manufacturer’s will be evaluated to determine SEPTA’s preference. Provide battery cells manufactured by the following, or approved equal:

1) EnerSys (Yuasa-Exide), Inc.

2) C & D Technologies, Inc.

3) ALCAD

4) Chloride

5) GNB


2.02 EQUIPMENT CHARACTERISTICS

A. Batteries:

1. The cells shall be lead-acid chemistry with a minimum design life of fifteen (15) years in float service operation under the environment and application described in this Specification. End-of-life is defined as retaining 80% of rated capacity and a voltage of 1.75 volts per cell; 10.5 V per monobloc.

2. The battery shall be comprised of 10 monoblocs, connected in series.

3. The monobloc and cell construction shall be as follows:

a) Monobloc containers and lids shall be constructed using flame retardant ABS with a UL94 rating of V0 and an LOI (Limiting Oxygen Index) of at least 28%, and shall have leak-proof joints.

b) Monobloc containers shall incorporate integrated handles designed for lifting.

c) The monobloc containers and the lid-to-container joint shall be capable of withstanding an internal pressure of at least four times the normal working pressure. Monoblocs shall be equipped with a low-pressure self-resealing one-way safety pressure relief valve, which will prevent ambient air entering the cell/monoblocs.

d) The cell plate shall be a rolled and punched grid type. Re-cycled lead shall not be used in the manufacturing process. No antimony or calcium shall be used in the plates. The grid thickness of the positive plate shall not exceed 0.049 in.

e) Monobloc internal terminals shall consist of lead-tin coated inserts machine cast into the lead.

f) The design of the cell/monobloc shall be sufficiently robust to withstand external short circuits in full compliance to IEC 60896 Part 21.

g) The battery shall have a recombining efficiency greater than 98% during normal float charge operation.

4. Monobloc external terminals shall consist of stainless steel front access, with top access copper alloy insert.

5. The external links between the monoblocs shall be made from insulated flexible connectors.

6. Monoblocs shall not exceed the following physical characteristics: 1) Length: 22.08 in

a) 2) Width: 4.92 in

b) 3) Height: 12.44 in

c) 4) Mass: 132.3 lbs

7. The battery shall consist of ten (10) monoblocs to provide a nominal 120 V output voltage.

8. The nominal capacity at the eight (8) hour discharge rate at 77 °F to 1.75 volts per cell (10.5 V per monobloc) shall be no less than 190 A.


9. Each cell in the battery system shall have the following discharge rates down to 1.75 V per cell at 77 °F:

a) Eight (8) hours - 23 Amps minimum

b) One (1) hour - 131 Amps minimum

c) Fifteen (15) minutes - 328 Amps minimum

10. Each cell in the battery system shall have the following discharge rates down to 1.90 V at 77 °F:

a) Eight (8) hours - 23 Amps minimum

b) One (1) hour - 127 Amps minimum

c) Fifteen (15) minutes - 306 Amps minimum

11. Nameplate: Each cell shall be marked or labelled with the following information:

a) Manufacturer's name

b) Month/Year of manufacture

c) Manufacturer's model number

d) Unique serial number

12. Fixed accessory equipment

a) One (1) Installation, Operation and Maintenance manual.

b) Inter-step, inter-row, inter-tier, end-to-end inter-rack, and back-to-back inter-rack prefabricated cable jumper connectors with lead-tin plated lugs.

c) Individual adhesive backed cell numbers, one (1) inch character height, numbered one (1) to ten (10).

d) Three (3) 0.24-ounce [7 gram] containers of electrical contact grease, NO-

OX-ID® "A-SPECIAL," as manufactured by Sanchem, Inc. [www.sanchem.com].

B. Battery Rack

1. A battery rack shall be furnished which shall support and distribute the weight of the connected monoblocs in the battery system.

2. The rack frame shall be coated with an acid-resistant epoxy paint.

3. The battery rack rails shall be polyethylene coated or acid-resistant epoxy painted.

4. The battery support system shall provide rack rail insulation.

C. Spill Containment Barrier

1. The battery rack shall be provided with a liquid-tight, electrolyte-resistant plastic Spill Containment Barrier with 4 inch lip extending not less than 1 inch beyond the battery rack in all directions. The volume of the containment system shall be at least equal to the volume of the liquid within the battery. Remove existing spill containment if required.

D. Battery Charger


1. The battery charger shall be solid state, fully automatic, and specifically designed to support the batteries of the type specified herein. The charger shall be built to charge and maintain ("float") the 60-cell lead-acid batteries to 130 VDC nominal. If the battery manufacturer recommends equalization, the charger shall have equalizing capabilities. The charger shall operate as a battery eliminator, i.e. operating as a power supply in addition to charging.

2. The battery charger shall have a continuous output rating of at least 15 kW.

3. The battery charger shall be at least 85% efficient under all modes of operation, as calculated by output power divided by input power.

4. The battery charger's input and output circuits shall be electrically isolated from each other and from the charger's ground.

5. Means shall be provided to prevent a faulty battery charger from shorting the battery. To meet this requirement, a blocking diode or overcurrent protection device, adequate to handle the short circuit capability of the battery, may be placed in the ungrounded output of the battery charger.

6. The battery charger shall be cooled only by air convection.

7. The battery charger shall be suitable for either floor mounting (free-standing) or wall mounting.

8. The battery charger's cabinet shall be NEMA-1 rated, with knockouts for cable or conduit, and with its front panel hinged for access.

9. The charger shall maintain float voltage within ±0.5% from zero to full load current.

10. The float voltage shall be adjustable in 100 mV increments from 95% of the nominal float voltage to 105% of the nominal float voltage.

11. The charger shall fully charge the batteries in not more than 12 hours after the batteries have been discharged to a level of 80% of their nominal voltage.

12. The output ripple of the charger shall not exceed any of the following limits:

a) 100 mV(rms) when on battery

b) ±2% when off battery,

c) 100 mV(rms) when used as a battery eliminator

13. In all cases, the cell manufacturer's published instructions regarding equalization shall be adhered to rigorously and without exception. If the cell manufacturer recommends against equalization, any equalization function shall be disabled.

E. Accessories

1. One charge ammeter.

2. One DC voltmeter.

3. One selector switch marked Automatic, Float, Manual Equalize.

4. Incoming molded case circuit breaker.

5. Output molded case circuit breaker.

6. Pilot light for AC supply.


7. Low voltage alarm relay for remote sensing.

8. Positive-to-ground and negative-to-ground relay for remote indication.

9. Test switch for verification that ground detection is functional.

10. No charge relay for remote indication.

11. All indication devices shall have identification.

12. Provide SCADA supervisory and alarm indications.

F. Nameplate

1. Provide the battery bank with a stainless steel nameplate. Attach nameplate to the battery rack by stainless steel rivets and marked with the following information:

a) Manufacturer’s name

b) Month and year of manufacture

c) Battery and cell type

d) One-minute, one-hour, and eight-hour ampere rating

e) Ampere-hour capacity at eight-hour rate, with two complete cycles of breaker operations foreseen at the end of the eight-hour period

PART 3 - EXECUTION

3.01 PREPARATION

A. Transmit submittals and deliverables required by this section.

B. Furnish products as indicated.

C. Ensure substrates are in suitable condition to receive the work of this section.

3.02 INSTALLATION

A. Install battery and specified equipment per manufacturer’s recommendation, plumb and level and in true alignment with related adjoining work.

B. Install supporting members, fastenings, framing, hangers, bracing, brackets, straps, bolts, and angles, as required to set and rigidly connect the work. Securely fasten the battery racks to the floor as required for seismic considerations.

C. Assemble battery cells on the battery racks and give an equalizing charge, following the installation of the substation circuit breakers and related equipment.

D. The electrolyte spill containment system shall be properly installed in compliance with the Fire Safety Code, prior to the installation of the battery rack and valve-regulated, lead-acid battery system.

3.03 TESTING

A. Furnish technical assistance necessary for installation and startup of the equipment.

B. Provide Factory and Field testing of the battery and charger in accordance with Section 16950 – Testing of Electrical Equipment.


3.04 TRAINING

A. Provide, arrange for, and establish battery system maintenance training for six substation maintainers. Provide all training materials, notes, CD-ROM, and classroom presentation equipment.

END OF SECTION




SECTION 16262

STATIC FREQUENCY CONVERTER SPECIFICATION

PART 1 - GENERAL

1.01 SUMMARY

The scope of this document is to provide the specifications for a static frequency converter (SFC) system for the SEPTA Wayne Junction SFC (WJSFC) Rehabilitation Project. This specification shall be used as the basis for designing and procuring new SFCs at Wayne Junction SFC Station.

This specification section for SEPTA’s Wayne Junction SFC Station is intended to define to the SFC Contractor (SFCC) the technical requirements associated with the detailed design, manufacturing, procurement, delivery, installation, testing, and commissioning of the SFC system and equipment specified herein.

The SFCC responsibilities include detailed design, manufacturing, procurement of SFC related equipment, delivery, installation supervision and support, installation of specialized equipment, testing, and commissioning of the SFC system and equipment specified herein.

The Electrical Contractor (EC) will function as the Coordinating Contractor and will remove the existing SFC electrical equipment and install the majority of SFC electrical equipment under the supervision of the SFCC.

The Mechanical Contractor (MC) will remove the existing SFC mechanical equipment and install the SFC mechanical equipment, such as the heat exchangers, coolers, and piping, under the supervision of the SFCC.

The General Contractor (GC) will remove foundations, pedestels, structures, and metal works with the retired filters yards. The GC will install the SFC foundations, anchors, and construct the new building for SFC #4.

The SFC specification covers the following equipment:

A. SFC power block equipment

B. SFC input and output transformers

C. SFC harmonic and power factor correction filters

D. SFC precharging circuit breakers and auxiliary transformers

E. SFC control system

F. SFC cooling system, including pumps, piping, and heat exchangers

G. SFC power distribution system and UPS equipment

H. SFC protection system equipment

I. Sequence of events recorder

J. Transient disturbance recorder

K. Remote terminal units (RTUs)

L. SFC interconnecting cabling, conduits, and accessories

The proposed project single-line diagram is provided as part of the Contract Drawings.





C. Section 01025 – Measurement & Payment


E. Section 01100 – Special Project Procedures

F. Section 01300 – Submittals

G. Section 01400 – Quality Requirements

H. Section 01452 – Contractor Quality Control - TP Equipment

I. Section 01830 – Operation & Maintenance Data

J. Section 01832 – Operations & Maintenance Manuals - TP Equipment

K. Section 05120 – Structural Steel

L. Section 05500 – Metal Fabrications

M. Section 05610 – Miscellaneous Metals

N. Division 16 specifications

O. Section 16262A – Appendix A - SFC Technical Data Sheets

P. Section 16262B – Appendix B - SFC Document Submittal Schedule

1.03 DEFINITIONS

CMU concrete masonry unit

NEHRP National Earthquake Hazards Reduction Program

PECO Philadelphia Electric Company (60 Hz utility company)

SEPTA Southeastern Pennsylvania Transportation Authority

SER sequence of events recorder

SFC static frequency converter

TP traction power

TPSS traction power substation

WJSFC Wayne Junction Static Frequency Converter

WJTPSS Wayne Junction Traction Power Substation (connects the Wayne Junction SFC Station output to the 24/12 kV traction power system)

1.04 PROJECT/SITE CONDITIONS

Refer to the 30% Submittal Contract Drawings for the definition of areas to be allocated for the SFC equipment at WJSFC Station.

A. Site Name: Wayne Junction SFC Station

B. Site Address: SEPTA Wayne Junction 4505 Germantown Ave Philadelphia, PA 19144


C. Project Owner: Southeastern Pennsylvania Transportation Authority (SEPTA)

D. Owner’s Address: SEPTA 1234 Market St. Philadelphia, PA 19103

E. Quadrangle Name: Germantown

F. Decimal Degrees: 40.0261 N, -75.1552 W (Google Maps)

G. Proposed Construction: PECO provides electrical power for SEPTA’s train service. At present, frequency conversion is accomplished by three 1980 vintage, 15 MVA static converters at WJSFC station. Four new 15 MVA frequency converters are proposed for WJSFC station. The existing three SFCs will be removed one at a time and replaced with three new SFCs. A new building will be constructed as shown on Contract drawings to house one new SFC.

H. Major SFC Equipment: Four identical SFCs, each rated at 15 MVA, located within a concrete masonry unit (CMU) constructed building. The SFC equipment includes four new step-down transformers, power converters, filters, cooling equipment, local controls, and step-up transformers, as required.

I. Auxiliary Equipment: An existing SFC Building contains SFC controls, SCADA, SER, power distribution switchgear, batteries, lighting, HVAC, and plumbing for the existing three SFC units. An addition will extend the building to house one new SFC unit and all appurtenances.

There are two existing 1500/2250 kVA, 13.2 kV-480Y/277 V, 3-phase, 60 Hz transformers that supply auxiliary power to the SFC Building.

J. Converter Input Voltage: 13.2 kV, 60 Hz, 3-ph from the 230 kV Substation Control Building.

480Y/277 V, 60 Hz, 3-ph, 4-wire for auxiliary equipment.

K. Converter Output Voltage: 24/12 kV, 1-ph, 25 Hz, to the SEPTA Wayne Junction Traction Power Substation (WJTPSS). The converter output transformer supplies a traction power system directly. The system voltages are 12 kV from trolley-to-rail, 24 kV from feeder-to-rail, and 36 kV from trolley-to-feeder. The output transformer secondary is rated 36 kV bushing-to-bushing with the winding tapped at 1/3 from the trolley bushing. The connection to rail is solidly-grounded.

L. Environmental Requirements

1. Equipment Location


a) The transformers, circuit breakers, filtering and power factor supporting equipment shall be suitable for outdoor installation.

b) The power equipment cubicles (thyristors, GTOs), control system equipment, protective equipment, and auxiliary distribution system for each SFC shall be suitable for either indoor or outdoor installation, depending upon the final design proposed by the SFC Contractor.

2. Atmospheric Data

Outdoor air design conditions for heating, ventilation, and air-conditioning (HVAC) will be based on the 2009 ASHRAE Handbook of Fundamentals for North East Philadelphia, PA.

Table 1 - Outdoor Design Temperatures

Parameter Value Winter Design Temperature

(ASHRAE 50 year extreme winter design condition)

-11.5⁰F

Summer Design Conditions (ASHRAE 50 year extreme summer design

condition)

104.5⁰F dry bulb

Table 2 - Indoor Design Temperatures

Parameter Value SFC rooms 77ºF cooling, 60⁰F heating

Other spaces 75ºF cooling, 70⁰F heating


A. Regulatory Requirements

The latest approved revision of all applicable Standards shall apply to all material, equipment and tests supplied under the Contract, including but not limited to the standards listed in this section.

If any conflict arises between provisions of this specification and the provisions included in the listed documents, such conflict shall be brought to the attention of the SEPTA Project Manager (PM). The SEPTA PM’s decision shall be in accordance with the Contract.

1. IEEE 315-1975(R1993), Graphic Symbols for Electrical and Electronics Diagrams.

2. ASA S1.4-1993(R2006), Specification for Sound Level Meters.

3. ASA S1.6-1984(R2011), Preferred Frequencies, Frequency Levels and Band Numbers for Acoustical Measurements.

4. ASA S1.11-2014, Specification for Octave-Band and Fractional-Octave-Band Analog and Digital Filters - Part 1.

5. ASA S1.13-2005(R2010), Measurement of Sound Pressure Levels in Air.

6. ASTM A36-2014, Specification for Carbon Structural Steel .


7. ASTM A123-2015, Standard Specification for Zinc (Hot Galvanized) Coatings on Iron and Steel Products.

8. ASTM A153-2016, Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

9. ASTM A242-2013, Specification for High-Strength, Low-Alloy, Structural Steel.

10. ASTM A307-2014, Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength.

11. ASTM A325-2014, Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

12. ASTM A490-2014, Standard Specification for High-Strength Steel Bolts.

13. ASTM A501-2007, Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.

14. ASTM A606-2015, Standard Specification for Steel, Sheet and Strip, High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, with Improved Atmospheric Corrosion Resistance.

15. ASTM A786-2015, Standard Specification for Hot-Rolled Carbon, Low-Alloy, High-Strength Low-Alloy, and Alloy Steel Floor Plates.

16. ASTM A1008-2015, Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable.

17. ASTM A1011-2015, Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High- Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength .

18. ASTM B241-2016, Standard Specification for Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube.

19. ASTM D3487-2009, Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus.

20. AWS D1.1-2015, Structural Welding Code - Steel.

21. DIN 45635-1-1984, Measurement of noise emitted by machines; airborne noise emission; enveloping surface method; basic method, divided into 3 grades of accuracy.

22. EN 50121-5-2006, Railway applications - Electromagnetic compatibility - Part 5: Emission and immunity of fixed power supply installations and apparatus.

23. EN 50178-1998, Electronic equipment for use in power installations.

24. EN 50124-1:2001, Railway applications – Insulation coordination – Part 1: Basic requirements: Clearances and creepage distances for all electrical and electronic equipment / Corrected and reprinted of French version in 2007-12.

25. EN 50124-2:2001, Railway applications - Insulation coordination - Part 2: Overvoltages and related protection / Corrected and reprinted in 2010-05.

26. EN 50160:2010, Voltage characteristics of electricity supplied by public electricity networks.

27. EN 50163:2006, Railway applications - Supply voltages of traction systems.


28. EN 50327:2003, Railway applications - Fixed installations -Harmonization of the rated values for converter groups and tests on converter groups.

29. EN 50328:2003, Railway applications - Fixed installations - Electronic power converters for substations /Corrected and reprinted in 2006-12.

30. EN 60870-5-104:2006, Telecontrol equipment and systems - Part 5-104: Transmission protocols - Network access for IEC 60870-5-101 using standard transport profiles.

31. IEC 60038-2011, Standard voltages.

32. IEC 60060-1-2010, High voltage test techniques, Part 1: General definitions and test requirements.

33. IEC 60060-2-2010, High voltage test techniques, Part 2: Measuring systems.

34. IEC 60068-2-57-2013, Environmental testing, Part 2-57: Test Ff: Vibration - Time-history method.

35. IEC 60068-2-6-2007, Environmental testing, Part 2-6: Test Fc and guidance: Vibration (sinusoidal).

36. IEC 60071-1-2011, Insulation coordination, Part 1: Definitions, principles, and rules.

37. IEC 60071-2-1996, Insulation coordination, Part 2: Application guide.

38. IEC 60146-1-1-2009, Semiconductor converters, General requirements and line commutated converters, Part 1-1: Specifications of basic requirements.

39. IEC 60146-1-2-2011, Semiconductor converters, General requirements and line commutated converters, Part 1-2: Application guide.

40. IEC 60146-1-3-1991, Semiconductor converters, General requirements and line commutated converters, Part 1-3: Transformers and reactors.

41. IEC 60146-2-1999, Semiconductor converters, Part 2: Self-commutated semiconductor converters.

42. IEC 60146-6-1992, Semiconductor converters, Part 6: Application guide for the protection of semiconductor converters against overcurrent by fuses.

43. IEC 60329-1985, Strip-wound cut core of grain oriented silicon-iron alloy, used for electronic and telecommunication equipment.

44. IEC 60529-2013, Degrees of protection provided by enclosures (IP Code).

45. IEC 60664-1-2007, Insulation coordination for equipment within low-voltage systems, Part 1: Principles, requirements, and tests.

46. IEC 60664-3-2010, Insulation coordination for equipment within low-voltage systems, Part 3: Use of coatings to achieve insulation coordination of printed board assemblies.

47. IEC 60721-3-1-1997, Classification of environmental conditions, Part 3: Classification of groups of environmental parameters and their severities; Section 1: Storages.

48. IEC 60721-3-2-1997, Classification of environmental conditions, Part 3: Classification of groups of environmental parameters and their severities; Section 2: Transportation.


49. IEC 60721-3-3-2002, Classification of environmental conditions, Part 3: Classification of groups of environmental parameters and their severities; Section 3: Stationary use at weather protected locations.

50. IEC 60747-6-2000, Semiconductor devices. Part 6: Thyristors.

51. IEC 60747-9-2007, Semiconductor devices. Part 9: Insulated-gate bipolar transistors (IGBTs).

52. IEC 61000-4-1-2006, Electromagnetic compatibility (EMC) – Part 4-1: Testing and measurement techniques – Overview of IEC 61000-4 series.

53. IEC/TR 61000-3-6:2008, Electromagnetic compatibility (EMC) - Part 3-6: Limits - Assessment of emission limits for the connection of distorting installations to MV, HV and EHV power systems.

54. IEEE 18-2012, Shunt Power Capacitors.

55. IEEE 85-1973, IEEE Test Procedure for Airborne Sound Measurements on Rotating Electric Machinery.

56. IEEE 112-2004, Standard Test Procedure for Polyphase Induction Motors and Generators.

57. IEEE 519-2014, Recommended Practice and Requirements for Harmonic Control in Electrical Power Systems.

58. IEEE 1240-2000, IEEE Guide for the Evaluation of the Reliability of HVDC Converter Stations.

59. IEEE C2-2012, National Electrical Safety Code.

60. IEEE C37.06-2009, Switchgear - AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities.

61. IEEE C37.09-1999(R2007), Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis.

62. IEEE C37.13-2008, Low-Voltage AC Power Circuit Breakers Used in Enclosures.

63. IEEE C37.20.1-2015, Metal-Enclosed Low-Voltage Power Circuit Breaker Switchgear.

64. IEEE C37.23-2003, Metal-Enclosed Bus.

65. IEEE C37.90-2005(R2011), Relays and Relay Systems Associated with Electric Power Apparatus.

66. IEEE C37.90.1-2012, IEEE Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus.

67. IEEE C37.99-2012, Guide for the Protection of Shunt Capacitor Banks.

68. IEEE C57.91-2011, IEEE Guide for Loading Mineral-Oil-Immersed Transformers and Step-Voltage Regulators.

69. IEEE C57.110-2008, Recommended Practice for Establishing Transformer Capability When Supplying Nonsinusoidal Load Currents.

70. IEEE C57.12.00-2010, General Requirements for Liquid Immersed Distribution, Power and Regulating Transformers.


71. IEEE C57.12.90-2015, Test Code for Liquid Immersed Distribution, Power, and Regulating Transformers.

72. IEEE C57.13-2008, Requirements for Instrument Transformers.

73. IEEE C57.16-2011, Requirements, Terminology, and Test Code for Dry-Type Air-Core Series-Connected Reactors.

74. IEEE C57.19.00-2004, General Requirements and Test Procedures for Outdoor Apparatus Bushings.

75. IEEE C57.19.01-2000(R2005), Performance Characteristics and Dimensions for Outdoor Apparatus Bushings.

76. IEEE C57.21-2008, Standard Requirements, Terminology, and Test Code for Shunt Reactors over 500 kVA.

77. IEEE C62.11-2012, Metal-Oxide Surge Arresters for AC Power Circuits.

78. IEEE C62.22-2009, Guide for the Application of Metal-Oxide Surge Arresters for Alternating Current Systems.

79. NEMA ICS 1-2000, Industrial Control and Systems: General Requirements.

80. NEMA ICS 2-2000, Industrial Control and Systems: Controllers, Contactors, and Overload Relays Rated 600 V.

81. NEMA ICS 6-1993(R2011), Industrial Control and Systems: Enclosures.

82. NEMA MG 1-2014, Motors and Generators.

83. NEMA PB 1-2011, Panelboards.

84. NEMA PB 2-2011, Deadfront Distribution Switchboards.

85. NEMA TR 1-2013, Transformers, Regulators, and Reactors.

86. NEMA WC 70-2009, Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy.

87. NEMA WC 71-2014, Standard for Nonshielded Cables Rated 2001-5000 Volts for Use in the Distribution of Electric Energy.

88. NEMA WC 74-2012, 5-46KV Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy.

89. NETA ATS-2013, Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems.

90. NFPA 70-2008, National Electrical Code (The 2008 version is required by City of Philadelphia).

91. UL 489-2013, Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures.

92. UL 891-2005, Safety Switchboards.

93. UL 94-2013, Standard for safety - Tests for flammability of plastic materials for parts in devices and appliances.

1.06 SYSTEM DESCRIPTION

A. General


The design and operation of the SFCs shall account for the unique operating characteristics (traction system loads) and be optimized for the highest efficiency, input power factor, reliability, and minimal harmonic effects under full load conditions. All equipment and material supplied under this Contract shall be designed to be capable of providing service at its rated power under the specified service conditions for a period of forty (40) years. Detailed design criteria and equipment requirements are as defined herein.

B. Static Frequency Converters

The SFC Contractor shall supply four new static frequency converters each rated 15 MVA continuous. Overload and short-circuit ratings are given in this specification.

C. 13.2 kV, 60 Hz, 3-phase input

The converter input transformers will be supplied at 13.2 kV, 60 Hz, 3-phase from existing 13.2 kV switchgear.

D. SFC rooms

The SFCs shall be located in separate SFC rooms. SFC #1, #2, and #3 shall be located in existing rooms. SFC #4 represents additional capacity and shall be located in a new room being constructed under this project by others. Local control equipment shall be provided for each SFC and located in corridors just outside of each SFC room.

SFC rooms shall house individual SFC units and their corresponding power distribution switchboards and control panels shall be placed just outside of these rooms. SFC input and output transformers shall be located near each corresponding SFC just outside each SFC room. The SFC rooms will be automatically de-energized upon opening a door to the room using an interlock scheme provided by the SFC Contractor.

E. 24/12 kV, 25 Hz, 1-phase output

Each of the SFC output transformers shall be connected to the 24/12 kV traction power system via a dedicated circuit breaker provided by others.

F. Auxiliary Power System

Auxiliary power, consisting of 480Y/277 V, 60 Hz, and 125 V dc shall be provided in each SFC room. Two 480 V, 3-phase feeders shall be routed to each SFC room in order to supply auxiliary power to the SFC equipment. Each feeders shall be supplied by an independent feeder circuit breaker in order to ensure power is available to each SFC in the event of an interruption on one of the incoming 13.2 kV, 60 Hz, three-phase power sources supplying the SFC Building.

G. Instrumentation and Control System

The SFC Station shall be remotely controlled by a Supervisory Control and Data Acquisition (SCADA) System via Remote Terminal Units (RTUs) from SEPTA’s 1234 Market St. location.

Control from Wayne Junction’s SFC control room shall be via a local SCADA terminal working through a RTU. RTUs shall be required in each local SFC room.

H. SCADA Interface

A preliminary tabulation of input/output points has been included in this specification. The SFC Contractor shall supply all transducers required for interface to the SCADA RTU. The SCADA System shall provide dry contacts for 125 V dc, 10 amp inductive load for each digital output from the RTU and expects to receive 125 V dc status signals for digital inputs to the RTU. Analog inputs to the RTU shall be 0 to +/-5 V dc. Current-source


signals shall be scaled by a resistor at the RTU. Analog outputs from the RTU shall be 0 to 5 V dc. The SFC Contractor shall be responsible for converting those signals to the type required for the equipment being supplied. Transducers shall be wired from the SFC points and current transformers to terminal blocks located in the appropriate control enclosures.

The SCADA System RTU shall consist of two identical (redundant) halves. The RTU shall be based on a system selected by SEPTA along with the corresponding input/output cards and auxiliary equipment. Digital output from the RTU shall be diode-ORed. Digital inputs to the RTU shall be paralleled across the input terminals of each RTU half. Analog signals to the RTU shall be paralleled across the input terminals of each RTU half. The SFC Contractor shall arrange its equipment to receive analog signals from each RTU half independently, and to receive as well a digital signal from each RTU half indicating which half is active. The inputs and outputs to each RTU half shall provide and shall indicate identical information (within the transducer and equipment tolerances for analog signals).

SEPTA requires discrete indication of switchgear open and switchgear closed and shall not accept a single signal which, if high, indicates switchgear open and, when low, indicates switchgear closed, or vice versa.

1.07 DESIGN REQUIREMENTS

The following design criteria define the system configuration and performance requirements for the station. The design of the static frequency converter integrated equipment block must be coordinated with the overall station design.

A. 60 Hz, 3-phase System

The Wayne Junction SFC Station is fed from the Wayne Junction 230 kV Substation.

Table 3 - 230 kV, 60 Hz System Characteristics

Characteristic Value Nominal operating voltage 230 kV Operating voltage range 242 kV normal high

225.5 kV normal low 218.5 kV emergency low for 15 minutes 213.5 kV load dump for 5 minutes

Phase number 3 Frequency 60 Hz

57.5 Hz for 5 seconds 58 Hz for 30 seconds Up to 62 Hz for a limited duration (typically 1 minute)

Impulse withstand (BIL) 900 kV (Note: Existing transformers are rated 750 kV BIL)

1.2 x 50 µs (lightning impulse) minimum CFO 1105 kV Minimum distance between conducting parts

89 inches @ 900 kV BIL, phase-to-phase 71 inches @ 900 kV BIL, phase-to-ground

Spacing 144 inches @900 kV BIL, phase-to-phase Fault clearing time Normal clearing time for all types of faults = 5

cycles. Fault clearing due to failed primary line relaying = 33 cycles. Fault clearing due to stuck breaker = 17 cycles.

System grounding Effectively grounded neutral (always)


Characteristic Value Harmonic voltage distortion limits 1.0% individual frequency voltage harmonic

1.5% THD in 230 kV switchyard Harmonic current distortion limits Must be low enough to meet voltage distortion

requirements.

The Wayne Junction SFC station was upgraded in 1990 for 3 x 15 MVA units, with provision for a future fourth 15 MVA unit. The two incoming PECO 230 kV, 60 Hz supply lines and switchgear were sized and installed to accommodate the initial and the future load of the entire station. The incoming PECO lines are adequate for this project.

There are no planned modifications to the 230 kV switchyard equipment within the scope of this project. The new SFC #4 and its auxiliary equipment will be supplied from these existing transformers.

Neutral grounding resistors are mounted on stands next to the transformers.

The two main transformers convert the 230 kV 60 Hz power to 13.2 kV 60 Hz with a 3 winding transformers rated at 45/60/75 MVA each. With air cooling only, the transformers are rated for 45 MVA each at 55⁰C rise. However, with fan cooling, they are capable of being loaded up to 75 MVA. When the fourth SFC is installed, the total connected load will be 60 MVA for the converters plus the auxiliary loads. Therefore, if all frequency converters are operating, and one transformer is out for maintenance, the transformers fans may be required if the load goes above 45 MVA.

These two transformers feed two separate 13.2 kV switchgear lineups, one for the static frequency converters (NPS-SWGX) and one for the auxiliary loads (NPS-SWGY).

Any modifications to the station load demand or energy usage must comply with PECO requirements and standards.

Table 4 - Existing 230-13.2 kV, 60 Hz Substation Transformer 1

Parameter Value Identification YWT-XMT1 (From PECO Line 220-42) Power rating 55⁰C Rise:

H: 45 MVA OA/60 MVA FAI/75 MVA FAII X: 45 MVA OA/60 MVA FAI/75 MVA FAII Y: 6 MVA OA/8 MVA FAI/10 MVA FAII 65⁰C Rise: H: 84 MVA FAII X: 84 MVA FAII Y: 11.2 MVA FAII

Voltage rating 230 kV Δ-13.2 kV GndY-13.2 kV GndY, 3-phase, 60 Hz

Impedance H-X: 7.64% at 45 MVA H-Y: 1.97% at 6 MVA X-Y: 24.9% at 45 MVA

Resistance H-X: 0.18% at 45 MVA H-Y: 0.08% at 6 MVA X-Y: 0.75% at 45 MVA

Insulation rating H: 750 kV BIL X: 110 kV BIL


Parameter Value Y: 110 kV BIL

Weight 230,600 lbs (complete) Tap changer No-load tap changer on H winding only Manufacturer Trafo-Union, Nuremberg, West Germany Transformer type TLUJ7954 No. N 407393 Year of manufacture 1988 Standard ANSI C57.12.00-1980 Grounding 20 ohms, 400 A, 10 seconds (each wye winding)

Table 5 - Existing 230-13.2 kV, 60 Hz Substation Transformer 2

Parameter Value Identification YWT-XMT2 Power rating 55⁰C Rise:


Voltage rating 230 kV Δ-13.2 kV GndY-13.2 kV GndY, 3-phase, 60 Hz

Impedance H-X: 7.69% at 45 MVA H-Y: 1.98% at 6 MVA X-Y: 25.3% at 45 MVA


Insulation rating H: 750 kV BIL X: 110 kV BIL Y: 110 kV BIL


The 13.2 kV switchgear NPS-SWGX is located in the 230 kV Control Building and supplies power to the SFCs with a main-tie-main automatic transfer system and a 3000 A bus. The 13.2 kV power tie-in shall consist of four independent feeders from the existing 13.2 kV, 60 Hz, 3-phase switchgear in the SEPTA 230 kV Control Building.

The 13.2 kV switchgear NPS-SWGX has one spare cubicle dedicated to supply the new SFC #4. It contains electromechanical relays for protecting the new SFC #4 feeder. The


protective relays will need to be set to the requirements of the new static frequency converter equipment. The types of relays and auxiliary devices are listed below:

1. 50/51 overcurrent, phases 1, 2, 3

2. 50GS overcurrent

3. 0-2000 A ammeter

4. 86 lockout relay

5. Ammeter switch

6. SFC No. 4 breaker control

7. Local/remote key switch

8. 50GS test switch

9. 87BX2 test switch

10. Current circuit test switch

11. PK-2 current circuit

A spare 3000 A circuit breaker, presently used during maintenance activities, is available for use by the future SFC #4. The new SFC #4 will be supplied using this spare 3000 A circuit breaker from the allocated cubicle. All existing protective relays will be used.

Each SFC unit shall be fed via an independent 13.2 kV circuit breaker.

Table 6 - SFC Input Circuit Breaker Ratings

Parameter Value Identification SFC #4 Input Breaker Manufacturer Siemens Type 15-GM-1000-3000-77 Amps 3000 Frequency 60 Hz Serial No. R-80650B-1 Manufacture Date August 1989 Rated Max. Voltage 15 kV Voltage Range Factor K=1.30 BIL 95 kV Rated Short-Circuit Current 37 kA Close and Latch 77 kA Interrupting Time 5 cycles Motor Voltage and Current 100-140 V dc, 3 A nom. Close Circuit Voltage and Current 100-140 V dc, 5 A nom. Trip Circuit Voltage and Current 70-140 V dc, 5 A nom.

Table 7 - 13.2 kV, 60 Hz System Characteristics

Parameter Value Nominal operating voltage 13.2 kV


Parameter Value Operating voltage range 13.86 kV normal high




Rated maximum voltage 15 kV Power frequency withstand 36 kV Lightning impulse withstand (BIL) 95 kV BIL indoors

110 kV BIL outdoors Minimum distance between conducting parts


Phase spacing - vertical break disconnect switches and bus supports

24 inches @110 kV BIL, centerline-to-centerline

Phase spacing - horizontal break disconnect switches and bus supports

30 inches @110 kV BIL, centerline-to-centerline

Short-circuit availability 381 A 1LG 24,594 A 3LG

Earth fault factor 1.732 (resistive grounded-wye) Fault clearing time Approx. 8 cycles at maximum 3-ph fault current

(3 cycles for relays, 5 cycles for breaker) System grounding Effectively grounded neutral (always), low-

resistance grounded (20 ohms per transformer)

The allowable power factor range on the 60 Hz side, over the entire operating range of the 25 Hz side power demand shall be as defined in the attached PQ curves. The allowable power factor requirement shall be met regardless of the station loading, load power factor, input voltage and the reactive losses in transformers.

It shall be possible to preset the magnitude of the output voltage in the range of plus or minus 5% of the nominal output voltage. The magnitude of the output voltage shall be automatically held within plus or minus 1% at all times for an input change of plus or minus 5% on the 13.2 kV system.

The 13.2 kV input power frequency may drift between 60Hz +/-2% (57.5 Hz to 62Hz)

SFC design must limit harmonic voltage distortion to limits given in IEEE 519 and PECO design standards at the 230 kV bus in the PECO 230 kV Wayne Junction switchyard. In addition, an output capability curve or table as a function of the electrical stiffness between the specified minimum and maximum values shall be provided.

Voltage distortion limits for the SFC units shall be limited to 1.0% individual frequency voltage harmonic and 1.5% total harmonic distortion (THD) on PECO side of the point of common coupling.

The 60 Hz current distortion limits for harmonics shall be in accordance with IEEE 519.

The voltage and current distortion limits shall be based on the total harmonic spectrum


(including sub-harmonics, integer harmonics and non-integer harmonics).

PECO prepared a short-circuit model for Wayne Junction and simulated faults at the primary and secondary sides of the Wayne Junction 230-13.2-13.2 kV transformers.

Figure 1 - PECO 230 kV System Supplying Wayne Junction

Table 8 - 60 Hz Short-Circuit Characteristics

Location and Type Value YWT-XMT1, 230 kV (From PECO Line 220-42) 32,111 A, 3LG

24,109 A, 1LG YWT-XMT2, 230 kV (From PECO Line 220-28) 25,903 A, 3LG

18,630 A, 1LG YWT-XMT1, 13.2 kV, X winding (TRF 1, X1) 24,594 A, 3LG

381 A, 1LG YWT-XMT1, 13.2 kV, Y winding (TRF 1, Y1) 13,000 A, 3LG

380 A, 1LG YWT-XMT2, 13.2 kV, X winding (TRF 2, X2) 24,206 A, 3LG

381 A, 1LG YWT-XMT2, 13.2 kV, Y winding (TRF 2, Y2) 12,867 A, 3LG

380 A, 1LG

Two SFCs are supplied by YWT-XMT1-X1 and the other two from YWT-XMT2-X2.

The minimum short-circuit current availability shall be obtained by the SFC Contractor upon award of the Contract in order to perform the harmonic studies required for designing the converter facility.


The SFC Contractor shall provide a tabulation of harmonic current and voltage distortion values, in amperes, for operation of the SFCs in the following circumstances. Included in the tabulation shall be all distorting frequencies (whether even or odd multiples of the fundamental, non-integer multiples of the fundamental, or frequencies below the fundamental) generated by the dc-link converters, as seen at the 230 kV, 60 Hz bus. Both the minimum and maximum available short-circuit current values at the 230 kV level shall be considered.

• One (1) converter in operation

• All of converters in operation, including the existing cycloconverter

• The combination of converters which results in the worst case amount of distortion injected into the Utility.

The SFC Contractor shall identify the magnitude of any dc bias that may be present in the SFC output resulting from their equipment.

B. 25 Hz, 1-Phase System

The existing output transformers are located on the west side of the SFC building. Each transformer is surrounded on its sides by CMU firewalls. Electrical bus duct supplies the transformers from the converter. Insulated cable connects the transformer output to the 25 Hz filter yard via duct banks that run underneath the road between the transformers and filter yard.

The transformers are grounded through the rail bus that is common to all output transformers located in the 25 Hz filter yard.

Table 9 - 25 Hz Output Transformer Specifications

Parameter Value Identification T2 Power rating Temperature rise 60⁰C

X1 X2: 15.366 MVA OA H1 H2: 12.5 MVA OA H2 H3: 7.5 MVA OA

Voltage rating X1 X2: 1.62 kV H1 H2: 13 kV H2 H3: 25.8 kV Single-phase, 25 Hz

Impedance X1 X2/H1 H2: 4.19% @ 15.366 MVA, 1.62/13 kV X1 X2/H2 H3: 8.94% @15.366 MVA, 1.62/26 kV H1 H2/H2 H3: 3.72% @15.366 MVA, 13/26 kV X1 X2/ H1 H3: 5.44% @15.366 MVA, 1.62/39 kV

Insulation rating X1 X2: 60 kV BIL H1 H2: 250 kV BIL H2 H3: 250 kV BIL

Weight 106,648 lbs Tap changer None Oil type Mineral oil


Parameter Value Oil quantity Oil in tank: 2985 gal

Oil in coolers: 420 gal Manufacturer ASEA Transformer type TMZ 31 Serial No. 7288530 Year of manufacture 1984 Standard ANSI C57.12-1980 Grounding Solid, H2 bushing

Each SFC output transformer shall be connected to the 24/12 kV, 25 Hz system through its own circuit breaker supplied by others.

Table 10 - 24/12 kV, 25 Hz System Characteristics

Parameter 12 kV trolley system 24 kV feeder system Nominal operating voltage 12 kV 24 kV Operating voltage range -5% to +10% (due to train regenerative braking) Phase number Single-phase, two-pole Frequency 25 Hz Insulation class 27 kV 46 kV Impulse withstand (BIL) 150 kV 250 kV

The SFCs shall provide full rated output power over the output frequency of 25 Hz +/- 2% (24.5 Hz to 25.5 Hz) as defined by the fixed ratio of 5/12 of the input frequency, which can drift by 60 Hz +/- 2%.

C. 25 Hz Harmonics

The traction power system operates with a significant content of harmonics caused by power electronic equipment switching. The harmonics consist of two parts:

1. Harmonics generated by the traction load. The traction load consists of number of multi-car trains operating simultaneously on the system. The propulsion system of the existing cars is thyristor controlled. The new fleet of the cars expected to be procured by SEPTA over next several years will have propulsion system based on integrated gate bipolar thyristors (IGBTs).

2. Harmonics generated by the static frequency converters (SFCs). The SFCs are thyristor controlled cyclo-converters connected in twelve-pulse arrangement.

The SFC manufacturer, ABB, performed extensive studies of the system harmonics and their results are shown below. The Table shows the overall system harmonics when one SFC is operating at 100% rated power and at 200% rated power.

Table 11 - Harmonics from One Existing Cycloconverter


Current Harmonics at Converter Load 15 MVA 30 MVA

(A) % of Fundamental


1 25 1,456 Fundamental 2,686 Fundamental 3 75 269 18.48 367 13.66 5 125 444 30.49 633 23.57



Current Harmonics at Converter Load 15 MVA 30 MVA



7 175 100 6.87 144 5.36 9 225 41.7 2.86 52.8 1.97

9.6 240 5.6 0.38 11.1 0.41 11 275 16.7 1.15 44.5 1.66

11.6 290 5.6 0.38 11.1 0.41 13 325 8.8 0.60 33.32 1.24

13.6 340 5.6 0.38 11.1 0.41 15 375 5.6 0.38 27.8 1.03

15.6 390 19.4 1.33 50.0 1.86 17 425 5.6 0.38 8.3 0.31

17.6 440 36.1 2.48 61.1 2.27 19 475 5.6 0.38 5.6 0.21

19.6 490 63.9 4.39 80.6 3.00 21 525 5.6 0.38 5.6 0.21

21.6 540 75.0 5.15 55.6 2.07 23 575 5.6 0.38 2.8 0.10

23.6 590 33.3 2.29 41.7 1.55 25.6 640 5.6 0.38 5.6 0.21 27.6 690 19.4 1.33 5.6 0.21 29.6 740 2.8 0.19 11.1 0.41 31.6 790 16.7 1.15 5.6 0.21 33.6 840 33.3 2.29 5.6 0.21 35.6 890 30.6 2.10 5.6 0.21 37.6 940 19.4 1.33 5.6 0.21

The maximum harmonic voltage distortion levels for the new SFCs shall be limited as follows for the measurement of voltage distortion into a resistive load (unity power factor load). The voltage distortion limits shall be based on the total harmonic spectrum (including sub-harmonics, integer harmonics and non-integer harmonics):

Table 12 – Maximum Voltage Distortion Limits at Full-Load through a Resistive Load

Supply Current Through a Resistive Load

Individual Voltage Distortion %

Total Voltage Distortion THD %

No-Load 1.5 2.5 Full-Load 3.0 5.0

D. Station Loading/Operating Conditions

The rail traction power demand is of a highly fluctuating pattern. It is non-sinusoidal in wave form due to harmonics generated by the thyristor equipment both in the SFC and on board rail cars that subjects the traction equipment to pulsating forces. The heating effect on the converter due to non-sinusoidal current wave form is greater than that produced by a steady current equal to the mean value of the fluctuating current.

The 12 kV trolley and 24 kV feeder system are susceptible to many electrical short-circuits due to pollution, vandalism, icing, bird life, and other factors. The short-circuits are


repetitive and of varying duration and severity, subjecting the SFC equipment to significant compressive and tensile forces.

The SFC Contractor shall measure the voltage and current waveforms at Wayne Junction to determine the characteristics of the line that the converter shall be synchronized to and the type of load the converter shall be feeding. However, the SFC Contractor must ensure that his design is compatible with existing wave forms.

E. Harmonics

1. 60 Hz Harmonics

The SFC Contractor shall ensure that the existing harmonics on the single-phase side of the converter are taken into account during the equipment design and that their effects shall not reduce the specified performance or life expectancy of the converter equipment or the 60 Hz source equipment. The SFC Contractor shall state what, if any, limitations on converter performance are to be expected from these harmonics, and the amount of harmonic power “let thru” the filter bank to the converter itself. The SFC Contractor shall also indicate the effect of the 25 Hz side harmonics on the 60 Hz system.

2. 25 Hz Harmonics

The SFC Contractor shall perform an analysis of the station 25 Hz power distribution system to determine the size and characteristics of any required harmonic filter equipment to limit harmonic currents and voltages generated by the converter system to acceptable levels. The harmonic frequencies generated by the 25 Hz system load profile shall be considered in the design and rating of all SFC equipment.

3. Harmonic Analysis Objectives

The objective of the harmonic analysis shall be:

a) To characterize the existing harmonics at the 230 kV, 60 Hz substation and 24/12 kV, 25 Hz traction power substation,

b) To evaluate the impact of the new harmonic producing source, i.e., the SFCs,

c) To use the results of the study to design harmonic controls into the SFC equipment, if required, and

d) To size the SFC equipment load carrying capacity based on total harmonic current.

4. Harmonic Measurements and Modeling

In order to ensure that SEPTA’s harmonic voltage distortion at the 230 kV, 60 Hz substation and 24/12 kV, 25 Hz traction power substation is not degraded by the addition of the new SFCs, the following procedure shall be followed:

a) Preliminary simulations shall be performed to identify expected harmonic levels and system response characteristics. Different system conditions shall be modeled in accordance with IEEE 519.

b) Perform harmonic voltage measurements at PECO’s 230 kV, 60 Hz substation and SEPTA’s 24/12 kV, 25 Hz traction power substation prior to the design of the SFC equipment. Measurements shall be performed at the point of common coupling, e.g., 230 kV switchyard bus in the PECO substation and the 12 kV trolley bus and 24 kV feeder bus in the Wayne Junction Traction Power Substation.


c) Prepare a detailed model of the SFC units to analyze harmonic voltages produced by the power block equipment based on the system harmonic currents under various load conditions. Provide a tabulation of harmonic current and voltage distortion values, in amperes, for operation of the SFCs in the following circumstances. Included in the tabulation shall be all distorting frequencies generated by the converters as seen at the 230 kV and 24/12 kV point of common connections. Both the minimum and maximum available short circuit MVA values at the 230 kV and 24/12 kV levels shall be considered for the following modes of operation:

1) One converter in operation;

2) All converters in operation including the existing cycloconverters;

3) Various loads connected to the 24/12 kV switchyard through the 12 kV trolley and 24 kV feeder systems.

5. Using a detailed SFC model, demonstrate that the recommended voltage distortion limits in Table 7 can be met for no-load and full-load conditions.

6. PECO’s and SEPTA’s voltage and current distortion shall not be degraded by the installation and operation of the new converters. If existing harmonic currents and voltages are affected by the installation of the new SFC equipment, the SFC Contractor shall develop solutions to the harmonic problems caused by the SFC power block equipment and implement those solutions at the SFC Contractor’s cost.

7. At the time of final commissioning, perform harmonic voltage and current measurements at PECO’s 230 kV substation and SEPTA’s 24/12 kV traction power substation. Ensure that harmonic distortion limits are not exceeded.

F. Functional Requirements

1. The plant shall be designed to accept basic control commands (such as start, stop, raise/lower voltage, raise/lower power, etc.) locally and remotely via SEPTA’s SCADA RTU (normal source of commands). These commands shall initiate start-up, normal running, and shutdown functions that shall be controlled automatically by the SFC Contractor’s control system. The SFC Contractor shall develop a signals exchange list and identify all control, status, and metering information that shall represent the complete SFC system input/output (I/O) interface points.

2. The control equipment shall controls and supervise the SFCs. The control equipment, will among other things, control the amplitude and phase of the converter output voltage, limit the output current in case of short-circuits in the 25 Hz network, and automatically synchronize the converter to the 25 Hz network.

3. The plant shall automatically synchronize and deliver power to the 24/12 kV, 25 Hz, single-phase traction power system.

4. Each converter shall be capable of operating independently or in parallel with the other new SFCs and existing cycloconverters at the Wayne Junction SFC Station.

5. Each unit shall be able to operate in stand-alone or network operation. In stand-alone operation, each unit shall be able to black start SEPTA’s 25 Hz system. In network operation, the units shall be able to operate as synchronous machines either manually or in automatically.


6. Station load sharing controls shall be provided, in addition to local load sharing controls at each SFC.

7. The SFCs shall operate with a fixed electrical frequency ratio of 5/12 between the 25 Hz and 60 Hz systems.

8. Controls shall be provided to allow the SFC to operate in the following modes:

a) Synchronous machine mode: each unit operates similarly to a synchronous machine. The voltage magnitude, phase shift angle, and droop characteristics can be manually adjusted, with the SFC following the system load demand.

b) Automatic load sharing mode: each SFC operates similarly to a synchronous machine, while sharing load proportionally with other SFCs. Real and reactive power limits, as well as proportional load sharing settings, can be programmed.

c) Phase shifting mode: each SFC provides reactive power compensation to the 24/12 kV, 25 Hz system, such as during 25 Hz faults or loss of the 13.2 kV, 60 Hz input power.

9. The SFC shall be capable of operating independently and feed the single-phase network without working in parallel with the cycloconverters.

10. The SFC shall be capable of operating in parallel with cycloconverters and/or static converters at the same or adjacent stations. Presently, Wayne Junction Station operates as the only supply of 25 Hz power in SEPTA’s Reading Railroad System and does not synchronize with any other traction power sources.

11. The converter shall not trip for any overload or short-circuit in the 12 kV trolley or 24 kV feeder 25 Hz network extremal to the Wayne Junction Traction Power Substation. An overload or short-circuit at the local Wayne Junction Traction Power Substation may require the SFCs to trip.

G. Automatic Controls

The converter shall be equipped with a computerized automatic startup system. It shall automatically start-up and stop the converters at preset values of station load. The automatic start-up equipment shall be used to minimize the operating cost for the converter station and shall therefore be capable of the following:

1. Cycling the start and stop to equalize the hours of operation as well as equalize the number of “on/off” operations of each converter.

2. Include a memory which stores the station load measurement during SFC Contractor defined intervals in a statistical table for one week for providing a forecast of expected load to determine if the converters are to be connected/disconnected immediately.

3. The start-up system shall also connect more converters if the converters are operating in the current-limit mode or the station voltage is under the preset output values.

4. The start-up equipment shall also allow the presetting of parameters such as start-up levels, stop levels, delay times, hysteresis, etc.

5. The control shall be capable of automatically starting up the converters and synchronizing to the single phase network. The start-up time shall be less than five


(5) seconds. Converters shall start at zero MW/ zero MVAR and ramp up to the desired power level after the synchronization process is complete.

The SFC shall be capable of a black start to the 25 Hz single-phase system.

The SFC load sharing shall control the output power from the SFC to be a pre-adjusted part of the total station load demand, both active and reactive power, with a tolerance of 2% or better.

Suitable converter and load sharing controls shall be provided to facilitate light load operations where a specific number of converter units are required to remain on-line in order to develop the necessary fault current levels at the 12 kV trolley and 24 kV feeder systems for protective relay actuation during a fault.

The plant shall minimize distortion (due to harmonics) of the 60 Hz utility power system as well as SEPTA’s 25 Hz system.

Short-circuits in the SEPTA single-phase traction power network shall not decrease the life of the converters. It is anticipated that up to twenty-five thousand (25,000) of these short-circuit operations are possible over the life of the converters.

The short-circuit capability of each SFC shall be 4000 A for 2 seconds at the 12 kV output bushing of the SFC 25 Hz transformer.

The SFC Contractor is responsible for the overall system design in order to establish the corresponding requirements for transformer impedances and short-circuit capability of the SFC units.

The frequency converter and associated protective devices shall be designed so that any tripping of breakers or converters not caused by the converter station equipment shall be controlled in a manner which permits the SEPTA Load Dispatcher to reset the equipment and restart the converters from the remote control location (SCADA).

H. Seismic Requirements

The seismic requirements are provided on Contract drawing S-001. They are summarized below for reference.

Table 13 - Seismic Loading

Methodology 2003 NEHRP Site Location Philadelphia, Pennsylvania

Seismic Occupancy Category II Seismic Importance Factor 1.0

Maximum Considered Earthquake (MCE) Ground Motion

0.2 Second Spectral Response Ss = 0.274 1.0 Second Spectral Response S1 = 0.060

Seismic Site Classification D (Assumed) Short Period Site Coefficient Fa = 1.581 Long Period Site Coefficient Fv = 2.4

Maximum Considered Earthquake Short Period, Fa * Ss SMs = 0.433

1s Period, Fv * S1 SM1 = 0.145 Design Spectral Acceleration

Short Period SDs = 0.289 1s Period SD1 = 0.096


Methodology 2003 NEHRP Other

Seismic Design Category B Basic Seismic Force Resisting System Intermediate

Response Modification Factor, R 3.5 System Overstrength Factor, WO 2.5

Deflection Amplification Factor, Cd 1.75 Seismic Response Coefficient, Cs 0.144

Analysis Procedure Equivalent Lateral Force

1.08 MAINTAINABILITY

A. Panel indicating devices shall be selected to facilitate diagnostic procedures which will be employed by maintenance and/or repair personnel and be described in the SFC Contractor provided manual in a Troubleshooting Section.

B. The internal converter circuitry, insofar as practical, shall be modular in construction, and the physical implementation of such modules, components, subassemblies, and other parts shall be easily and quickly replaceable. All quick release items shall be secured by “captive hardware” to prevent their dislocation by vibration.

C. All modules, cards, and subassemblies shall have lights indicating normal circuitry operation.

D. All fuses shall be readily accessible, shall use captive hardware, and shall be provided with individual blown fuse indicators (non-incandescent) mounted inside panel. All fuses shall be sensed in such a manner to provide an alarm output.

E. All front panel indicators and other components shall be clearly identified with functional English language nomenclature.

F. All panels shall be accessible from the front and be suitable for mounting back-to-back or against walls.

G. Each individual component of the converter heavier than sixty-five (65) lbs. shall have provision for lifting by two persons and each component heavier than one-hundred (100) lbs. shall have provision for lifting by a crane or hoist.

H. The SFC Contractor shall furnish two (2) portable diagnostic test terminals and associated microprocessor adapter cards for monitoring, trouble shooting, and programming of converter control electronics. The test terminals shall permit SEPTA to read system inputs and force system outputs. The test terminal also shall permit SEPTA to adjust the system control parameters. Test terminals shall be off-the-shelf ruggedized, portable PC’s suitable for industrial service and shall be equipped with suitable software.

1.09 SERVICE LIFE

A. The converter shall be designed to be capable of providing services at its rated level under the service conditions for a period of forty (40) years.

B. The SFC Contractor shall ensure that the system harmonics are taken into account during the equipment design and that their effects shall not reduce the specified performance or life expectancy.

C. The fluctuating power demand and high incidence of short circuit faults of varying magnitude shall be taken into account during the equipment design. The converter


equipment shall be designed and constructed so that it can withstand the effects of the compressive and tensile forces without any adverse effects on the specified performance and life expectancy.

D. The SFC Contractor shall provide a recommended inspection/maintenance schedule.

1.10 PERFORMANCE GUARANTEES AND WARRANTY

A. All equipment supplied by the SFC Contractor shall be warranted in accordance with the requirements defined in the Contract from the date the commissioning testing is finally completed and SEPTA accepts the facility. The warranty shall guarantee SFC availability over the warranty period. It shall be the SFC Contractor’s responsibility for timely repair and/or replacement of defective items or parts within the warranty period.

B. The SFC Contractor’s equipment shall meet the guaranteed performance for output, efficiency, noise, and auxiliary load demand. The SFC Contractor shall provide warranties for all equipment and materials furnished as to their fitness for the service intended and the workmanship of manufacture.

C. Warranty for spare parts supply and satisfactory operation is required.

1.11 AVAILABILITY

A. The Wayne Junction SFC Station shall operate as the only source of power to SEPTA’s Regional Rail System and as such, SEPTA requires that this station be highly reliable. There is no backup power source for the 25 Hz traction power system should the Wayne Junction SFC Station be offline.

B. The SFC system is expected to continuously perform the services for which it is intended and to deliver capacity from zero to full design levels. It shall be of heavy-duty design consistent with the specified services with minimum maintenance. The system shall operate properly under the technical and ambient conditions as defined in this specification.

C. All equipment, material, and services offered shall be of such quality as to make the equipment and material safe with high availability. All items offered, including all accessories, shall be of proven reliability.

D. The design and configuration of this station shall be adequate to allow scheduled on-line and off-line maintenance of individual sub-systems and equipment so that the railroad is supplied with reliable electrical power. Standby spare equipment in the station shall be included as necessary to ensure degree of reliability proposed by the SFC Contractor and accepted by SEPTA.

E. SFC systems shall also be capable of performing the protective actions required to accomplish a protective function in the presence of any single detectable failure in a system without loss of both SFCs (no single failure shall affect more than one SFC unit). Common mode failures (multiple failures resulting from a single cause) shall be mitigated by system design and quality assurance process.

1.12 SUBMITTALS

The SFC Contractor shall prepare Project Specific Design Drawings and Specifications. Progress submissions of designs shall be made at the 30%, 60%, 90% and 100% design submittals. These designs shall be subject to review by SEPTA and the Engineer. The SFC Contractor shall gather all comments and incorporate them into a single conformed set. Necessary changes shall be implemented by the SFC Contractor at no additional cost to SEPTA for design, manufacture, delivery or testing of the equipment and material.


This specification requires specific documents to be formally submitted to SEPTA through the SFC Contractor for information, approval, or approval with subsequent certification. When required by this specification, those documents generated by the SFC Contractor’s suppliers shall also be submitted. Prior to submittal to SEPTA, the SFC Contractor shall review them for conformance to the requirements and note his approval on the face of the documents. The SFC Contractor shall submit the following for approval:

A. Detailed plans with the requirements of all control and power equipment showing anchor bolt locations, floor steel requirements, dead weights and available space for primary and secondary cables.

B. Detailed drawings for erection and installation of SFC equipment, transformers, filter capacitors and reactors, busbar, power cables, etc.

C. Equipment drawings shall include the following:

1. Location and required size of conduit.

2. Location and size of junction boxes.

3. Piping connections.

4. Location and size of all accessories.

5. Loading diagram anchorage and foundation requirements.

6. Horizontal and vertical clearances necessary for installation and dismantling purposes.

7. Approximate locations of lifting lugs.

D. Wiring diagrams, showing the interconnection of all equipment including grouping of outgoing leads in accordance with cable schedule and elementary diagrams and “from” and “to” identification of all equipment terminals by rear view arrangement. Wiring connection diagrams covering all electrical devices. The connection diagrams shall be in accordance with IEEE 315 and the following:

1. Switch developments shall be shown.

2. Internal connections of all devices and relays shall be given.

3. Control panel devices and terminal blocks shall be in their approximate physical positions.

E. Copies of data accumulated during the twenty-four (24) Hour Test and thirty (30) Day Reliability Test shall be furnished to SEPTA either as the files are written during the test or within three (3) days following the end of each test.

F. Detailed and separate operating and maintenance manuals shall be furnished covering the following information:

1. Installation procedures, including unloading, equipment placement and cable connections.

2. Operational procedures, including preliminary checks, off-line tests, on-line tests and all required adjustments.

3. Special requirements for placement of equipment by use of cranes.

4. Recommended and required maintenance.

5. Recommended troubleshooting procedures.


6. Complete parts list for individual pieces of equipment.

7. Spare parts list.

8. All electrical and electronic components shall be identified by JEDEC/EIA, or by Industry Standard part numbers. The JEDEC Solid State Technology Association, formally known as the Joint Electron Device Engineering Council (JEDEC), is an independent semiconductor engineering trade organization and standardization body. Associated with the Electronic Industries Alliance (EIA), a trade association that represents all areas of the electronics industry in the United States.

G. The final manuals, drawings and spare parts list shall be technically accurate and complete and shall represent the complete system supplied by the Vendor or SFC Contractor.

H. Test procedures for SEPTA approval prior to acceptance testing and commissioning of the equipment.

I. Analysis of the station 25 Hz and 60 Hz power distribution system to determine the size and characteristics of harmonic filter equipment to limit harmonic currents and voltages generated by the converter system to acceptable levels without overloading the harmonic filters.

J. The SFC Contractor shall perform and submit calculations to determine the design basis and safety margin required for the static frequency converter components. These calculations shall, as a minimum, address short-circuit limits and power limits under different operating modes and filter designs. As a minimum, the calculations shall cover the power electronics (thyristors, diodes, GTO’s, etc.) and SFC transformers. These calculations shall convey, as a minimum, the following specifications:

1. Design parameters and limits

2. Thermal limits

3. Losses

4. Temperature rise

5. Efficiencies

K. Provide a final point count for the equipment interface to SEPTA’s SCADA system during the 60% design submittal.

L. Provide ac and dc auxiliary power requirements during the 60% submittal.

M. Provide a relay protection study addressing equipment provided under the Contract resulting from this RFP and as the equipment interfaces to SEPTA’s existing relay protection in its traction power system. The study shall be submitted in the form of a formal calculation including relay selection tables, recommended relay set points and coordination curves. Relays to be included in this study are located in the 13.2 kV, 60 Hz switchgear in the 230 kV Control Building and the 24/12 kV, 25 Hz protective relay panels located in the 25 Hz Wayne Junction Traction Power Substation (TPSS).

N. Submit all factory test plans with detail procedures for approval.

O. Submit all field test plans with detail procedures for approval.

P. Alarm annunciation point count.

Q. An itemized list of special tools shall be submitted.

R. A list of spare parts.


S. Technical training sessions per Specification Section 01822, Demonstration and Training.

T. For additional Submittal requirements refer to Specification Section 01300, Submittals, and Specification Section 16262, Appendix B, SFC Document Submittal List.

1.13 SHIPPING REQUIREMENTS

A. The SFC Contractor shall be responsible for all storage, shipping and handling. Items shall be stored, shipped and handled in a manner which is consistent with safe and sound material handling practices and per manufacturers’ recommendation.

1.14 SUPPLEMENTAL PROVISIONS

A. Release For Material Purchase and Fabrication

Written approval of SFC Contractor Final Design to the SFC Contractor to start material purchase, and/or fabrication of the equipment covered by these specifications will be provided by SEPTA. Material purchase and/or fabrication are to be based on drawings reviewed and approved by SEPTA.

B. Tools

The SFC Contractor shall furnish two (2) complete sets of all special tools, all new and of first class manufacture, which shall be required for maintenance of the equipment installed under the project. Identification of all tools by name and number shall be provided, and this number shall appear on drawings and operating and maintenance manuals, to indicate the application of these special tools and to permit ordering replacements. These special tools shall be furnished at no additional cost to SEPTA.

C. Spare Parts

The SFC Contractor shall provide on-site sufficient spare parts for the first five (5) years of operations of the equipment following substantial completion. In addition to the warranty provided under the Contract, the SFC Contractor further warrants that if the quantity and type of spares provided are insufficient during this time period he shall provide additional spares and replace all depleted spares until expiration of the five (5) years. These spare parts shall be furnished by the SFC Contractor at no additional cost to SEPTA.

PART 2 - PRODUCTS

2.01 GENERAL

The following is a list of the major components associated with each SFC power block:

A. Static frequency converter power block

B. 60 Hz input filters, if required

C. SFC isolation transformer (3-phase, 60 Hz input transformer)

D. 25 Hz output filters, if required

E. Output transformer (1-phase, 25 Hz)

F. All associated power connections between the equipment associated with the power block

G. Cooling equipment

H. Power distribution equipment


2.02 STATIC FREQUENCY CONVERTER

A. Ratings

The static frequency converter unit shall be designed in accordance with the following technical data:

Table 14 - New SFC Requirements



Power factor (design) 0.7 pf lagging @ rated output, 24/12 kV, 25 Hz 0.95 pf lagging @ rated output, 13.2 kV, 60 Hz

Power factor (operating limit) 0.95 pf lagging @ rated output, 230 kV, 60 Hz Rated current at 60 Hz, 3-ph (Assuming a 3% loss)

15 MVA / 0.97 loss / 13.2 kV / 1.732 = 676 A rms cont. 18 MVA / 0.97 loss / 13.2 kV / 1.732 = 812 A rms for 1 hr.

Calculated load currents (four converters)

15 MVA x 4 / 0.97 loss = 61.9 MVA 61.9 MVA / 13.2 kV / 1.732 = 2707 A rms during normal operating conditions 2707 A / 0.98 pu = 2762 A rms during normal low voltage conditions 2707 A / 0.95 pu = 2849 A during emergency low voltage conditions

Rated current at 25 Hz, 1-ph (each converter)

15 MVA / 36 kV = 417 A rms balanced (no rail return) 15 MVA / 24 kV = 625 A rms feeder (feeder-to-rail) 15 MVA / 12 kV = 1250 A rms trolley (trolley-to-rail)

Operating output voltage range 24/12 kV -/+5% (25 Hz system may reach +10% due to train regeneration.)

Calculated load currents (one converter)

15 MVA / 36 kV / 0.95 pu = 439 A rms balanced (no rail return) 15 MVA / 24 kV / 0.95 pu = 658 A rms for feeder-to-rail 15 MVA / 12 kV / 0.95 pu = 1316 A rms for trolley-to-rail

Outgoing 24/12 kV feeder minimum ampacity 658 A rms feeder cable 1316 A rms trolley cable


Parameter Value Operating modes Synchronous machine mode (converter acts like a

synchronous-synchronous motor-generator set) Constant power mode (converter delivers settable power to the 25 Hz network) Phase shift mode (converter delivers reactive power to the 25 Hz network during loss of the 60 Hz network)

Power flow direction From 60 Hz to 25 Hz only. Reverse power flow not required.

Loss of 13.2 kV, 60 Hz power Converter shall continue to supply reactive power to the 25 Hz network

Loss of 480 V, 60 Hz auxiliary power supply Converter shall continue to fully function and supply both real and reactive power to the 25 Hz system during a loss of auxiliary power up to 3 seconds.

Harmonic distortion on 60 Hz system SFC design must limit harmonic voltage distortion to limits given in IEEE 519 and PECO design standards at the 230 kV cable terminations in the PECO 230 kV switchyard

Harmonic distortion on the 25 Hz system SFC design must limit harmonic voltage distortion to limits given in IEEE 519 at the 24/12 kV, 25 Hz cable terminations at the SFC 24/12 kV output transformers

B. General

1. The converter system power electronic equipment (i.e., IGBTs, IGCTs), power distribution panels, controls, and cooling pump will be installed indoors. Transformers, reactors, filters, and heat exchangers will be installed outdoors.

2. The SFC Contractor shall provide equipment that physically fits within the designated site areas as defined by this specification and project drawings.

3. The converter shall be self-protected to prevent tripping due to overloads.

4. The converter shall be capable of supplying the above power requirements over the entire range of utility input voltage.

5. The converter output frequency shall be exactly 5/12 of the input frequency (60 Hz input supply) and shall drift in that proportion with the input frequency. The control system shall also incorporate the provisions necessary to accept an external 25 Hz pilot signal.

6. The converter shall be capable of supplying the rated power specified above at a load power factor as indicated in the PQ Curve provided in this specification.

C. Fault Level at Input

The SFC will be supplied by 13.2 kV, 60 Hz, 3-phase switchgear that has a maximum available fault current of 25,000 A rms for 3-phase-to-ground faults and 381 A rms for line-to-ground faults. The 230-13.2-13.2 kV step-down transformers have a resistance-grounded neutrals that limit the line-to-ground fault levels. The SFC input transformers


shall have the neutral bushing brought out of the tank to accessible terminals on the transformer.

D. Fault Level at Output

1. During fault conditions, the static frequency converter can be subjected to fault in-feeds from other SFCs at Wayne Junction and regenerative braking power from trains.

2. Each SFC must have the capability to deliver 4000 A rms for 2 seconds at 12 kV. This is necessary to permit proper operation and coordination of existing protective relaying on the 25 Hz traction power distribution system.

3. The SFC Contractor shall coordinate the overall system design with SEPTA and PECO to establish the appropriate requirements for transformer impedances and short-circuit capabilities of the converters.

E. Standards

The SFC Contractor shall assure that the SFC’s comply with the latest issue of the applicable equipment standards identified in this specification.

F. Power Block Equipment

Power block equipment includes the power electronic devices used for converting the 60 Hz, 3-phase to 25 Hz, 1-phase voltage and current waveforms. Typical devices, for example, include thyristors, IGBTs, GTOs, and IGCTs. All power block equipment used in the SFC shall be the cataloged items of recognized manufacturers and used at their nominal ratings.

1. Ratings

The SFC shall be designed with proper ratings and designed with sufficient quantities to obtain the SFC rating as specified in Section A.

2. Power Electronic Cubicles

a) The power electronic components shall be installed on racks or in cubicles of standard design and delivered with a closed-loop cooling system (one (1) per converter unit) consisting of water-air heat exchanger (outdoor) with cooling fan, redundant circulating pumps, strainers, reservoir, filter, de-ionizer, instrumentation and control system (including gauges, control and regulating valves, isolation and shut off valves, water purity monitor, electrical controls and status/alarm system), and other associated equipment. Field piping between outdoor heat exchangers and the power electronic equipment shall be provided and installed by the SFC Contractor.

b) All cooling system equipment shall be in accordance with the applicable ANSI, IEEE, NEMA, ASTM, and ASHRAE standards. The SFC Contractor shall perform a hydrostatic test of all field piping.

c) The cooling system shall be a closed-loop self-venting system with a covered reservoir for makeup coolant. The coolant shall be a mixture of deionized water and ethylene glycol to maintain the required freeze protection. The reservoir shall be equipped with local level indication and alarm and trip level switches.


d) The heat exchanger shall be a full capacity unit with cooling fans. It shall be hydrostatically tested prior to shipment. Fan noise shall not exceed 55 dBA at 100’-0”.

e) All outdoor equipment shall come complete with manufacturer’s standard primer and finish paint coat.

f) A deionizer system with isolation valves, temperature regulating valve, drain valves, filters, and water purity monitor system (including alarm and trip functions) shall be provided.

g) Redundant full capacity coolant circulation pumps with automatic changeover and isolation valves for maintenance shall be provided. Motors greater than or equal to 3/4 horsepower shall be rated for 3-phase, 460 V, 60 Hz operation. Noise level shall not exceed 85 dBA at 3’-0”. If the SFC Contractor’s standard design is a single-capacity pump without redundancy, identify this in the proposal and provide the cost difference.

h) All pump and fan motors shall be provided with motor starters and required controls to form a complete package.

i) Instrumentation shall include as a minimum, the following:

1) Differential pressure switch and gauge across bridge

2) Coolant temperature switches (high and low) and gauge

3) Coolant resistivity (high and low)

4) Hand-Off-Auto pump control switches

5) Auto changeover control for pumps

6) Loss of power alarms (control and power)

7) Pump overload alarm

j) All gauges shall be installed with isolating shutoff valves to allow gauge removal with the system in operation.

k) Filters and cartridges that require changing shall be easily accessible. Valve handles and fill, drain, and vent connections shall be easily accessible.

l) Factory testing prior to shipment shall include as a minimum the following:

1) Hydrostatic test of complete Pumping Station

2) Hydrostatic test of outdoor heat exchanger

3) Operational check of pumps

4) Calibration and setting of all indicating devices, switches and sensors

G. Control Unit

Control equipment shall be provided to permit startup and shutdown of the converter either manually by a single pushbutton switch or automatically by a substation load sensing device, e.g., load sharing control system.

1. Control Equipment


a) After start-up, the synchronizing of the converter to the voltage magnitude and phase of the single-phase bus shall be carried out automatically. This is based on the converter being initially in its normal shutdown mode and only control power being on.

b) The SFC Contractor’s design shall take into consideration the non-sinusoidal nature of the voltage waveforms. Therefore, the control equipment shall not rely on zero-crossing for synchronization.

c) The time from initiation of start-up to the single-phase breaker closure after synchronizing shall not exceed five (5) seconds.

d) Once the SFC is connected to the single-phase busbar it shall be capable of satisfactory parallel operation with rotary converters and with any combination of the rotary converters and SFC units.

e) Once in parallel, the SFC shall be capable of no-load operation and capable of sharing the load with other converters in an adjustable ratio.

f) Initially, the SFC shall be paralleled with existing static converters on the 25 Hz system. The SFC control system must also be suitable for operation in conjunction with other paralleled SFCs.

g) All equipment needed to provide the load sharing capabilities required shall be provided by the SFC Contractor.

h) Redundancy shall be provided in the control system for providing reliable operation. No single failure of any device that controls, covers, monitors, or otherwise interacts with more than one (1) SFC unit shall result in any loss of functionality, control or information from working SFCs.

2. Individual Operation

The SFC units shall be capable of satisfactory operation on their own with no other converters in parallel.

3. Voltage Control

When the converter is not running in parallel with other converters and not supplying a fault on the system, the rms value of the single phase output voltage shall be kept within 1% of the preset value. When the converter is running in parallel with other converters or rotary converters, the voltage shall be kept within 2%.

4. Control of the Converter

a) Full manual control of the converter functions shall be possible from the local control at each SFC as well as in the Wayne Junction SFC Main Control Room. Provisions shall be made to allow for supervisory control from 1234 Market Street in Philadelphia via a local SCADA RTU located within the Wayne Junction Main Control room. A master local/remote control switch is requried with a yellow flashing beacon when in local control.

b) The converter shall be allowed to start up only when the input voltage is within its normal limits. It shall be possible to control the apparent and reactive output power flow by adjustment of the voltage and power electronics firing angles.


5. Measuring and Indicating Instruments

a) Measuring instruments indicating the converter input and output voltage, current, real power, reactive power and power factor shall be provided on the local panels together with provisions for connecting a portable recorder to each of the measuring instruments. Recording ammeter for the output current shall also be provided on the local panel. Visual indications of the positions of all main electrical equipment and alarms shall be displayed via panel mounted annunciator on the local panel.

b) Digital waveform recorders shall be installed to record thirty (30) minutes of voltage and current waveforms on both the 60 and 25 Hz sides of each converter. Triggering of each recorder shall occur (a) manually (including via SCADA), and (b) by the action of any protective relay or converter control system fault detector. Waveform records shall be automatically written to non-volatile media and available for review using Microsoft Windows based software.

c) In addition to the measuring instrument and indication instruments requirements stated in this specification section, the SFC shall provide inputs to the Main Sequence of Events Recorder in the Wayne Junction SFC Main Control room. Refer to specification section16910 for requirements.

6. Arrangement of the Control Equipment

The control equipment shall be arranged so that the functions pertaining to more than one (1) converter, such as paralleling and load sharing equipment shall be installed in one (1) cubicle or group of cubicles. Functions pertaining to an individual converter such as start up or shut down controls, synchronizing equipment, voltage control, measuring instruments, annunciators and power factor and harmonic filter equipment shall be located in a separate group of cubicles to ensure maximum reliability. Control and monitoring of the SFC station through the paralleling and/or load sharing equipment shall not be dependent on the availability of the individual converter controls.

7. Synchronizing Operation

a) If the 24/12 kV, 25 Hz, single-phase buses at the Wayne Junction Traction Power Substation are energized (live bus), the SFC control equipment shall automatically synchronize the converter based on the difference in voltage magnitude, phase angle, and rate-of-change of phase angle in order to close the circuit breaker. If the 24/12 kV, 25 Hz, single-phase buses are not energized (dead bus), the SFC control equipment shall close the single-phase circuit breaker, once the converter output can provide the required voltage and frequency, assuming the dead bus permissive relay scheme requirements are satisfied. The time from the initiation of start-up to the single-phase breaker closure shall not exceed five (5) seconds.

b) The converter shall have manual controls (coarse and fine adjustments) to change the output voltage and phase angle so that synchronizing and circuit breaker closing can take place. The output voltage shall be controlled in 1% steps and the phase angle in 2-1/2 degree steps or less, to ensure that damage cannot occur to the SFC when the circuit breaker is closed.


H. Equipment Protection

The protective equipment described in the following sections constitutes the minimum requirements. The SFC Contractor shall provide additional protection, other than that stated herein, which may be required for the safe and proper operation of the equipment.

1. General

a) Protective relays shall be of flush-mounted, withdrawable pattern and shall be mounted on the protective relay cubicle panel. The relays shall be dustproof and shall be free from effects of equipment vibration. The relays shall remain operative at the minimum and maximum ambient temperature. Relays shall be suitable for the non-sinusoidal waveforms they would be subjected to.

b) All protective relays shall be equipped with test plugs and shall be readily accessible so that routine testing, calibration, resetting and maintenance may be carried out without operating the relay

c) All relays shall be of the self-resetting type. Relay contacts shall be adequately rated for the duty. All relays shall be furnished with target indicators that may be operated either mechanically or electrically via a shunt connected coil. The target indicators shall be capable of being reset by hand.

d) It shall be possible to remove the front cover of the protective relay cubicle panel during routine maintenance without operating the protection equipment or the circuit breaker.

e) The converter system shall include voltage surge protection and full fault suppression capability for internal faults and malfunctions.

f) The frequency converters and associated protective devices shall be designed so that any tripping of breakers or converters from overloads not caused by converter station equipment faults shall be controlled in a manner which permits the SEPTA Load Dispatcher to reset equipment and restart the converters from a remote location.

g) All fuses shall be easily accessible and exchangeable.

h) The SFC Contractor shall document all parts and operation of the entire protective relay system in a system description document, including a list of all components.

2. Converter Protection

a) The protective equipment, described in this section, constitutes the basic requirement. The SFC Contractor is required to recommend additional protection if considered necessary or appropriate.

b) The thyristor equipment shall be protected and supervised with as a minimum the following. These protection systems are required and shall be designed to keep the converter operating under safe and reliable conditions:

1) Overcurrent protection

2) Ground fault protection

3) Unbalance protection


4) Circulating current protection

5) Power electronics protection

6) Cooling system protection

7) Over-temperature protection

8) Fan fault protection

c) Phase Overcurrent Protection - Primary and backup phase current protection shall be provided to prevent damage to the thyristors due to external faults. The primary and backup protection shall trip and lockout both input and output circuit breakers. The converter shall be protected against overloads and short circuits occurring in the 25 Hz network.

d) Ground Fault Protection - Ground fault protection shall be provided to trip and lockout the input and output circuit breakers if the thyristor circuit is not electrically floating. Otherwise, this protection need only provide an alarm.

e) Unbalanced Current Protection - Unbalanced current protection shall be provided to detect no current in each branch or series of thyristors. The detection of no current in one (1) branch shall sound an alarm. The detection of no current in two (2) or more branches shall result in the trip and lockout the input and output circuit breakers.

f) Circulating Current Protection - In the event that a double converter connection is used, a circulating current protection shall be provided to prevent current flow between the multiple converter bridges.

g) Power Electronic Protection - The protection circuits shall be designed to protect the devices from transient overvoltages.

h) Cooling System Protection - Required alarms and protection devices are defined in this specification.

i) High Temperature Protection - Alarms shall be provided in the event that the temperature of the SFC cooling system fluid reaches a preselected temperature. An automatic load reduction system shall activate upon receiving the high temperature alarm. If the high temperature condition persists, the converter input and output circuit breakers shall be tripped.

j) Cooling Fan Protection - The motor operating the cooling system heat exchanger fan shall be adequately protected against internal faults and overheating.

k) Control Equipment Protection - The SFC Contractor shall provide suitable protection equipment necessary for the control equipment.

l) Delayed Start Time Protection - In the event that the converter fails to start within six (6) seconds from the initiation signal, the converter shall be shut down and automatically reset for a second start-up attempt.

m) Reverse Power Protection - To protect against current flowing in the wrong direction.

3. SFC Transformer Protection


a) Gas Detector and Sudden Oil Pressure Relay - The gas detector relay for constant oil pressure systems shall be used to provide an alarm to warn against incipient faults. The fault pressure relay shall be provided to trip out the converter for a sudden transformer fault.

b) Winding Temperature Relay - Relay protecting the transformer from excessive hot-spot temperature shall be provided. The relay shall be connected to initiate an alarm and trip out the converter at preselected temperatures.

c) Liquid Temperature Relay - A two (2) stage relay monitoring the top oil temperature shall be provided to initiate an alarm and trip out the converter at preselected temperatures.

d) Phase Overcurrent Protection - An inverse time phase overcurrent protection shall be provided for both the input and output. The protection shall trip and lockout both input and output circuit breakers.

e) Ground Overcurrent Protection - A ground overcurrent protection shall be provided for both the input and output converter transformers. The protection shall trip and lockout both input and output circuit breakers.

f) Fan Motor Protection - The motor operating the cooling fans shall be adequately protected against internal faults and overheating.

g) Liquid Level Relay - A two (2) stage relay monitoring the liquid level shall be provided to initiate an alarm at the first stage and to trip and lockout the converter at the second stage of loss of cooling liquid.

4. Filter Bank Protection (if filters are required, early in the project after design calculations are prepared)

a) Overcurrent protection - Each capacitor bank shall be protected by an easily replaceable current limiting fuse.

b) Differential Protection - In the event that two (2) or more capacitor banks are required, a suitably sensitive differential type protection shall be provide

5. Potential Transformer Protection

Both windings of potential transformer shall be protected by easily replaceable fuses. Current limiting fuse is required for the high voltage winding

6. Undervoltage Protection

The converter shall be allowed to start up only when a sufficient voltage exists on all three phases of the transformer input terminals.

I. Load Sharing

1. The load sharing equipment shall be required (a closed loop control system) to control the output power from each SFC to a pre-adjusted part of the total station load demand. In event that a SFC is operating in parallel with other Wayne Junction SFCs, the load sharing equipment shall control the SFC to take an adjustable portion of the total load demand on the station.

2. The converter control equipment shall start-up and shut-down the converter automatically depending on the total substation load.


3. The load sharing control system shall be capable of optimizing the efficiency of the station by dispatching the appropriate number of SFC units necessary to be in operation and to establish load distribution among the operating units to satisfy a given demand load.

4. During normal operation, the load demand for the station and sharing of load between SFCs will be controlled by a load sharing system supplied by the SFC Contractor to be located at Wayne Junction SFC Station. The load sharing system will monitor all four SFCs on its own using equipment supplied by the SFC Contractor. The system shall be designed to calculate and predict load trending to control the SFCs automatically and will cycle the SFCs in a rotating order.

5. Incorporated into the load sharing design shall be the capability to accept a demand load signal to be provided by SEPTA’s SCADA system, which would establish the required MW output of the station, should future SFCs be installed at another site in the future. The MVAR output shall respond to the system demand within the rated capability of the equipment.

6. The load sharing control system shall poll individual SFC units to determine availability in managing the load.

7. While operating in the automatic mode, provisions shall be made to permit SEPTA to pre-select load limits for individual SFC units. The load sharing control system shall make the necessary adjustments in the distribution of the load to meet the demand requirement.

8. The load sharing control system shall schedule the operation of individual SFC units to balance their operating time.

9. Automatic scheduling of the SFC operation and loading shall not over-ride manual limits imposed by SEPTA.

10. It shall be possible to set the converter power output constant at any value between 0% and 100% of its own rating or limit it to a maximum value and have the other converters supply the rest of the load.

11. The load sharing system shall ensure that each converter shall share the total load demand in equal basis within 2% of the SFC load.

12. The converter station shall be able, by preset values from 0 to 60 MVA (full station output power), to feed the single-phase network or, as an alternative, have each converter supply its portion of the single-phase load. The control system for each converter shall be designed such that it has the same voltage and phase angle characteristics as a synchronous generator. It shall be possible to preset and adjust the voltage and phase angle shift parameters of the converter.

13. The load sharing control shall be provided with a general diagnostic program to identify internal malfunctions.

14. Should the load sharing system fail, all four converters shall still have the capability to individually share load, but may do so at reduced tolerance.

J. Converter Enclosure and Assembly

1. Open Frame Equipment Cubicles

Open frame construction is acceptable for the SFC equipment cubicles. Access to open frame equipment containing exposed or energized devices shall be prohibited by the building design when such devices are in the energized state.


2. Enclosed Equipment Cubicles

a) If personnel require access to equipment during the SFC power operation, all enclosed cubicles containing power electronic equipment or control and protective equipment shall be accessed via a hinged door or panel. A provision for locking each cubicle by padlock shall be installed.

b) The converter shall be enclosed in a ventilated, steel cabinet of the free-standing floor-mounted type suitable for power plant application. Framing shall be adequate to support all components during shipment and installation. Sheet steel for the enclosure shall be minimum No. 14 gauge.

c) The converter enclosure shall have screened ventilation openings, with filtering as required. Filters shall be designed so that cleaning or replacement is not required more often than quarterly.

d) All enclosed cubicles shall be vermin proof and suitably vented.

3. General Equipment Cubicles

a) Standard cubicle design shall incorporate indoor sheet steel, floor, free-standing design features.

b) The building housing the equipment shall not utilize underfloor ventilation ducts nor a basement ventilator area.

c) The cubicles shall be of ample size to permit ready access to all components and wiring through hinged doors or removable panels and shall allow opening of doors or removal of panels without requiring the disconnection of wiring. All steel work shall be carefully finished to remove sharp edges and burrs.

d) The assembly of components and wiring within the cubicles shall be so arranged that all components are accessible for inspection, testing, or removal without unnecessary disassembly of other equipment. Each item of equipment shall be identified by labels or other means to facilitate maintenance or testing. Metallic labels may be used only on major components, i.e., transformer shells, chassis, subassemblies, etc. Where metallic labels are used, they must be affixed by rivets or other means to ensure against inadvertent dislocation.

e) The windings of inductive components shall be encased or conformably coated to protect windings; however, such encasement or coating shall not restrict air flow over core lamination. Sufficient space is to be provided between inductive components and enclosure to avoid inductive heating.

f) Lifting eyes shall be provided, if necessary, together with sufficient additional permanent or temporary removable bracing and stiffening, to permit lifting, skidding, or rolling the assembly without deformation or damage. Two grounding pads with compression-type lug for SFC Contractor’s No. 4/0 AWG copper ground cable shall be furnished.

4. Auxiliary and Control Connections

All auxiliary wires and control cables shall be numbered at each end and cross-referenced to wiring diagrams to facilitate construction. Ring type or approved alternatives shall be used for all control connections.

5. Alarm Annunciation


An annunciator panel shall be provided for the local and remote control (via SCADA) equipment to give a visual alarm when an item of equipment has reached dangerous operating conditions or has been tripped out. The annunciator panel shall enable an easy identification of the faulted equipment. A point count for this equipment shall be submitted for approval.

K. Control Unit Enclosure and Assembly

1. Control cabinets shall be complete assemblies ready for installation. They shall be constructed to withstand normal shipping and installation handling. Appropriate provisions to mitigate the deleterious effects of RF and electromagnetic fields on the control system shall be incorporated.

2. Interconnecting cabling between shipping sections shall be furnished by the SFC Contractor. All control cabinet equipment shall be mounted or otherwise located to be easily accessible for maintenance or replacement.

3. Sufficient circuit breakers, fuses and disconnect switches shall be supplied for equipment protection due to faults and to ensure ease of equipment maintenance.

4. All components mounted on or within control cabinets shall be permanently marked in a conspicuous place to minimize maintenance errors. Marking shall not be placed on removable covers or interchangeable parts.

5. Removable covers shall be permanently marked so that they may be identified with their corresponding panel or piece of equipment.

6. All panelboard front nameplates shall be white with black lettering and shall be screwed to the cabinet with stainless steel screws. Nameplates for devices mounted inside panels shall be the manufacturers’ standard

7. Furnish and install the necessary control components for forced cooling of the enclosure where necessary.

L. Losses

1. No-Load Loss

No-Load Loss shall be defined as the total input power to the SFC equipment, including ac power of any frequency and dc power, with the three-phase, 60 Hz and single-phase, 25 Hz systems connected to the SFC equipment (input and output transformer breakers closed), all auxiliary equipment on-line, and no converter power flow from the 60 Hz to 25 Hz system or vice-versa. This definition of No-Load Loss includes the excitation currents drawn by the input and output transformers.

2. Load Loss

Load Loss shall be defined as: Total Losses minus No-Load Loss. Total Loss shall be defined as the total input power minus total output power from the SFC equipment with the three-phase, 60 Hz and single-phase 25 Hz systems connected to the SFC equipment (input and output transformer breakers closed), all auxiliary equipment on-line, and full rated power flow through the SFC equipment at nominal input and output voltage.

3. Back-to-Back Operation

“Back-to-back” operation shall be defined as the connection of two (2) SFCs such that one (1) acts as the load to the other. SFC #1 transmits power in the forward


direction (60 Hz to 25 Hz) and SFC #2 is connected to SFC #1 operating in the regenerative mode, transmitting power back to 60 Hz (25 Hz to 60 Hz). In this configuration, one (1) SFC is used as a power source in the forward direction while the other is used as a load (or a source in the reversed direction), both converters shall be connected together on the 25 Hz bus and isolated from 25 Hz network. This type of test may be used to measure the total losses of two SFCs operating at 30 MVA without actually using the full power of 30 MVA from the utility or traction power network.

4. Guaranteed Loss Reporting

The SFC Contractor shall state in its proposal the No-Load Loss and Load Loss for two (2) circumstances: (1) with the converters absorbing the fundamental and non-fundamental currents from the railroad network that shall be experienced in service, and (2) with only those fundamental and non-fundamental currents that the converters will experience when one onverter is used in 25 to 60 Hz conversion mode as a load for the converter whose losses are being evaluated. For both of these circumstances, the No-Load and Load Losses shall be stated at a 25 Hz lagging power factors of 0.70, 0.75, 0.80, 0.85, and 0.90. The no-load losses shall be measured within nominal input and output voltage ranges and shall include all auxiliary power required to maintain the equipment at no-load output.

5. Loss Values

The Load Loss and the No-Load Loss shall be stated in kilowatts for each converter system. The system shall be designed for minimum No-Load losses.

6. Loss Penalties

For evaluating the overall cost of the converter system during final commissioning, the following US dollar per kilowatt values shall be utilized:

Table 15 - Loss Penalties

Type of Loss Loss Penalty Load Loss $2635 / kW

No-Load Loss $5525 / kW

7. Revenue-Class Metering

Revenue-class metering equipment shall be permanently installed on the 60 Hz feeds to each converter unit and the 25 Hz outputs from each converter unit by the SFC Contractor as part of the this project. This equipment shall be used to measure the primary energy to and 25 Hz energy from the converter units during the loss evaluation tests described below. Factory calibration certificates shall be furnished by the SFC Contractor for the revenue-class metering equipment described herein prior to the Loss Evaluation test described in this Section. Portable instruments of equal or better accuracy and precision, subject to SEPTA’s approval, shall be furnished by the SFC Contractor to measure auxiliary power (ac and dc) required by each converter unit. The certified accuracy of these instruments shall be taken into account during the Loss Evaluation Test and damages as described below shall be owing to SEPTA only to the extent that the measured losses are in excess of the certified instrument errors. Multipliers and scaling factors of the revenue-class metering equipment may be temporarily adjusted by SEPTA or the SFC Contractor for the benefit of the Loss Evaluation test described herein. SEPTA will provide


written explanation of any such adjustments to the SFC Contractor.

8. Loss Evaluation Test

A Loss Evaluation Test of each converter shall be conducted in the field by the SFC Contractor to verify that the guaranteed losses of each SFC have not been exceeded. SEPTA reserves the right to witness testing unless this right is waived by SEPTA in writing. During the test, the converters shall be subjected to the following:

a) No-Load Loss shall be evaluated on each unit with the unit under test energized from the three-phase power source and the 25 Hz system, with NO power flow from the 60 Hz to 25 Hz system or vice-versa. The No-Load Losses Test shall be conducted over a period of no less than two (2) hours, but at least long enough for the energy meters described in section 0 to accumulate two-hundred (200) counts, and the Measured No-Load Loss for each converter unit shall be the total energy input to the converters from all sources (expressed in kilowatt-hours) divided by the elapsed time of the test expressed in hours.

b) The Total Loss shall be measured on each converter within nominal input and output voltage ranges, at 15 MVA, 25 Hz load and power factor held as close as practical to 0.80 with filters and appropriate power factor correction equipment in service and shall include the increase in auxiliary power over no-load auxiliary power required. This test shall be run for no less than twenty-four (24) hours, but at least long enough for the energy meters described in section 0 to accumulate two-hundred (200) counts. The Measured Total Loss shall be the difference between the total energy input to the converters and the total energy output from the converters, expressed in kilowatt-hours, divided by the elapsed time of the test expressed in hours. All sources of energy to the converter unit shall be included in this measurement.

c) At the option of SEPTA, the Total Loss Test may be done by either furnishing 25 Hz power to the railroad, or by circulating current between the converter under test while connected in a back-to-back arrangement. If the Total Loss Test is made by furnishing power to the railroad, then the Guaranteed Losses for circumstance (1) described in paragraph 2.02.L.4 shall be used for comparison with the realized losses and determination of damages if any, as described in paragraph 2.02.L.6. If the Total Loss Test is made by circulating current between two converters, one acting as a 60 to 25 Hz converter and the other acting as a load, then the Guaranteed Losses for circumstance (2) described in paragraph 2.02.L.4 shall be used for comparison with the realized losses and determination of damages, if any. SEPTA shall inform the SFC Contractor which of these two methods shall be used at the time the SFC Contractor informs SEPTA that he is ready to perform the test.

d) The Measured Load Loss for each unit shall be the difference between the Measured Total Loss and the Measured No-Load Loss.

e) The Load Power Factor at 25 Hz for the Measured Total Loss shall be: 𝑘𝑘𝑘𝑘

√𝑘𝑘𝑘𝑘2 + 𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘2


f) The Load Power Factor during Total Loss Test shall be held to as near 0.80 as railroad circumstances permit.

g) Load loss testing shall be conducted on each unit, using the SFC Contractor’s control system configured to hold the converter unit under test to a constant 25 Hz power of 15 MVA at the output of the SFC transformer or reactor.

h) The Measured No-Load Loss of each unit shall be compared to the SFC Contractor’s guaranteed No-Load Loss stated as shown in section 4. If the Measured No-Load Loss exceeds the guaranteed No-Load Loss, then the SFC Contractor shall pay damages to SEPTA in the amount of the number of kilowatts that the Measured No-Load Loss exceeds the guaranteed No-Load Loss, times the dollar value per No-Load Loss kilowatt shown in paragraph 6. This determination of damages shall be made for each converter unit furnished and the No-Load Loss damages owing to SEPTA shall be the sum of the No Load Loss damages for each converter unit. If the Measured No-Load Loss for any converter unit is equal to or less than the guaranteed No-Load Loss stated as shown in paragraph 4, then no No-Load Loss damages for that converter unit shall be owed by the SFC Contractor to SEPTA.

i) The Measured Load Loss of each unit shall be compared to the SFC Contractor’s guaranteed Load Loss stated as shown in paragraph 4. The Load Power Factor shall be determined as defined in section e).

1) If the Load Power Factor is equal, to two (2) decimal places, to any of the power factors for which guaranteed Load Loss values have been stated by the SFC Contractor, then the Measured Load Loss shall be compared to the guaranteed Load Loss at that power factor. If the Measured Load Loss exceeds the guaranteed Load Loss at the Load Power Factor, then the SFC Contractor shall pay damages to SEPTA in the amount of the number of kilowatts that the Measured Load Loss exceeds the guaranteed Load Loss, times the dollar value per Load Loss kilowatt shown in section 6. This determination of damages shall be made for each converter unit furnished, and the Load Loss damages owing to SEPTA shall be the sum of the Load Loss damages for each converter unit. If the Measured Load Loss for any converter unit is equal to or less than the guaranteed Load Loss stated as shown in paragraph 4, then no Load Loss damages for that converter unit shall be owed by the SFC Contractor to SEPTA.

2) If the Load Power Factor, expressed to two (2) decimal places, is between Power Factors for which guaranteed Load Losses have been stated, then by interpolation, Interpolated Guaranteed Load Losses for a power factor equal to the Load Power Factor shall be determined from the data furnished by the SFC Contractor as required by paragraph 4. If the Measured Load Loss exceeds the Interpolated Guaranteed Load Loss at the Load Power Factor, then the SFC Contractor shall pay damages to SEPTA in the amount of the number of kilowatts that the Measured Load Loss exceeds the Interpolated Guaranteed Load Loss, times the dollar


value per Load Loss kilowatt shown in paragraph 6. This determination of damages shall be made for each converter unit furnished, and the Load Loss damages owing to SEPTA shall be the sum of the Load Loss damages for each converter unit. If the Measured Load Loss for any converter unit is equal to or less than the Interpolated guaranteed Load Loss stated as shown in paragraph 4, then no Load Loss damages for that converter unit shall be owed by the SFC Contractor to SEPTA.

9. Opportunity to Repair or Replace Equipment

If the test described above shows that any damages are owing to SEPTA for excess losses, SEPTA shall afford the SFC Contractor a reasonable opportunity to repair or replace equipment in order to meet the guaranteed No-Load and Load Loss values, including repeats of the Loss Evaluation described in this section, subject to the operating needs of SEPTA. However, if more than two (2) attempts on any converter unit are made by the SFC Contractor, then the SFC Contractor shall pay SEPTA’s direct expenses of the repeated tests, including but not limited to personnel costs for witnessing the excess tests, personnel costs for dispatching power and/or arranging SEPTA’s electrical system to facilitate the test, and excess cost of electric energy and demand during the repeated tests. Repeated Loss Evaluation Tests shall not be an excusable delay.

10. Portable Instruments

During any informal preliminary evaluation of losses, and during all attempts at the Loss Evaluation Test described herein, SEPTA may install or have installed any portable instruments he desires for purposes of monitoring the tests, and SEPTA may make use of instruments permanently installed as part of the Converter Station by either the SFC Contractor or the SFC Contractor for the same purpose. The SFC Contractor shall reasonably accommodate SEPTA’s instruments.

11. Copies of Data

Copies of all data accumulated by the SFC Contractor during the Loss Evaluation Test and any informal, preliminary loss evaluations shall be deliverable to SEPTA no later than five (5) days after the data is accumulated, at no additional expense to SEPTA.

2.03 SINGLE AND THREE-PHASE FILTER BANKS

A. Basis for Design

The equipment shall be rated to complement the converter ratings.

The power factor correction equipment on the three-phase input side shall correct the power factor to within the limits required by PECO. The single- and three-phase harmonic frequency filters shall be designed to limit the input and output voltage waveform distortion to the specified values contained herein.

The equipment shall be designed and constructed to achieve the specified performance under the described service conditions without overheating or shortening the life of the equipment.

B. Standards

The SFC Contractor shall assure that the reactors, capacitors and resistors comply with the


latest issue of the applicable equipment standards.

C. Switching Devices

The minimum design life (before replacement) for switching devices employed in the filter control shall be ten (10) years for vacuum switches or twenty (20) years for circuit breakers. Sample 60 Hz and 25 Hz load profiles shall be considered in the selection of a suitable switching device for the output filter. Static switching is also an acceptable alternative.

D. Capacitors

The capacitors forming part of the power factor correction equipment and harmonic filters shall be manufactured in accordance with the latest revision of IEEE 18. They shall be the open-rack substation type and be individually fused with a current limiting fuse. The assembled structures shall be supported and insulated from ground using properly rated insulators. The stack height shall be kept to a minimum using horizontally mounted capacitor units. Capacitors shall be supplied with an unbalance protection scheme. Nameplates shall list style, serial number, kvar, rated voltage, frequency, number of phases and BIL. Connectors shall be clamp, parallel groove type accommodating one (1) or two (2) conductors, copper or aluminum. Internally connected discharge resistors shall be sized to reduce the residual voltage to 50 V within five (5) minutes. Bushings shall utilize wet process porcelain coated with a non-tracking glaze and shall be solder sealed to the capacitor case.

Spare capacitors shall be provided for each capacitor bank. Three (3) are required per bank on the 60 Hz side and one (1) per bank on the 25 Hz side. These spare capacitors units shall be installed in the stack rack (one (1) per phase), but not energized at this time. The capacitor units shall be energized following failure of the other capacitor units or if harmonic tuning requirements dictate unit energization.

The SFC Contractor shall provide the actual capacitance in microfarads obtained by measurement or test for each capacitor unit, including the spare capacitors. The SFC Contractor shall provide the location data by phase for each unit in each bank.

Each capacitor can shall be labeled with its position and keyed to a permanent nameplate on the cap rack so that the electrical position of any capacitor can be determined.

E. Reactors

The reactors for the harmonic filters shall be the dry-type comprised of fiberglass encapsulated winding groups. The reactors shall be equipped with bushings of an insulation class not less than the transformer winding terminal to which they are connected. The reactor winding design shall take into account the high voltage stresses caused on the insulation system due to lightning and switching surges. The winding insulation of series reactors shall be adequate to withstand the effects of harmonics and high thermal and mechanical stresses which may be caused due to fluctuating and sustained overloads during emergency conditions or by short circuits. Winding bracing shall be designed to withstand shocks and severe mechanical forces which may occur during transport, switching, or overload and fault conditions without causing excessive stress on the core bolt insulation.

Reactor rating shall be based on the self-cooled type cooling system and selected to operate in the linear portion of the magnetic characteristic curve.

Reactors shall be suitably sized taking into account ambient conditions, be rated for continuous operation at 105% of rated voltage at a frequency of 60 Hz (or 25 Hz as applicable), be manufactured with no more than a 5% tolerance, and taking into account the worst case harmonics anticipated in the installation.


Reactors shall be manufactured and tested in accordance with IEEE Standards C57.16 and/or IEEE C57.21

Consideration shall be given to specifying taps on the reactors to compensate for manufacturing tolerances and field tuning with capacitor banks. The reactor “continuous current rating” shall be selected such as to provide the required power output. Harmonic currents and voltages shall be accounted for in determining stray losses, turns insulation and coil height.

The SFC Contractor shall provide actual inductance in ohms and X/R ratio at fundamental frequency as obtained by measurement or test for each reactor at all tap positions. The SFC Contractor shall provide a fundamental frequency I2t thermal heating limit capability curve for the design supplied for the filter.

F. Protection

Each capacitor in a bank shall be protected by an easily replaceable current limiting fuse.

In the event that two (2) or more capacitor banks are required, a suitable sensitive differential type protection shall be provided

The fans, if used, of forced air cooled reactors shall be adequately protected against internal faults and overheating.

The capacitors in any series filters shall be protected by an overvoltage type protection.

G. Bussing and Connectors (For Outdoor Application)

The busbars shall be of adequate continuous and short-time rating for the application described herein. The busbars and busbar joints shall be capable of withstanding the mechanical forces experienced during frequent fault currents expected on the system. The design shall avoid any sharp corners on the busbar. Exposed busbar in the converter housings is not permissible. The connection between the thyristor cubicles and low voltage terminals of the transformer shall be via enclosed busbar or insulated cables installed in cable tray and shall enter the thyristor cubicles at the top.

1. Bussing

Material shall be rigid non-breech drawn seamless aluminum tubing, alloy 6063-T-6, meeting ASTM specification B241.

2. Loadings

Fault current force is determined by formula:

F = KI2/(d x 107) where:

F = force (in pounds) per foot,

I = RMS amperes, asymmetrical, short circuit current

d = phase spacing in inches, and

K = 8.694

Ice and wind force, use 1/2” ice and 4 pound per square foot wind at 0°F plus a constant (0.30 lb/ft for all conductors) added to the resultant of loading as specified by NESC.

Fault current force is assumed to occur simultaneously with ice and wind loading.

3. Deflection


Maximum allowable vertical deflection of conductor with 2” ice loading shall be equal to or less than vertical dimension of conductor.

4. Fiber Stress

Maximum allowable fiber stress

a) Loading including fault current = 18,000 lbs./sq.in.

b) Loading without fault current = 15,000 lbs./sq.in.

Point of application of coupler connectors shall fall within 1/4 span of a support point where practicable.

5. Thermal Expansion

a) The temperature range of -5°F to 195°F (-20°C to 90°C) is used for calculating expansion of conductors. When expansion connectors are used, expansion of conductor shall be limited to the capability of available approved expansion connectors.

b) Expansion connectors shall be installed only at support points, such as at bus supports or switch terminals.

H. Instrument Transformers

1. Potential and current transformers shall be provided on the 3-phase side upstream of the input filter and on the 1-phase side downstream of the output filter for performance monitoring. Additional potential and current transformers shall be provided, as necessary, for the control and protection of the SFC units.

2. The potential transformers (PT) shall supply SFC protective relays, metering, and control equipment. The PT rating, ratio, and accuracy shall be stated in the data sheets which shall be included in the maintenance manual.

3. Both windings of potential transformers shall be protected by easily replaceable fuses. Current limiting fuses are required for the high voltage winding.

4. Ring-type current transformers (CT) shall be supplied for relays with C400 accuracy class for metering and control equipment. It shall be possible to remove CTs with a minimum of disturbance to other components. The CT rating, ratio, and accuracy shall be stated in the data sheets which shall be included in the maintenance manual.

2.04 60 HZ, 3-PHASE FILTERS

A. Harmonic and power factor correction filters shall be installed on the 60 Hz three-phase input side of the converter, as required, to reduce harmonic currents fed into the supply system and to generate reactive power in order to compensate for reactive power consumption in the converter.

B. The filters shall be classified by their location, connection to the main circuit, sharpness of tuning, and the number and frequencies of their resonances.

C. The three-phase input filter shall provide voltage damping, surge suppression, harmonic suppression and power factor correction.

D. The capacitors forming part of the power factor correction equipment and harmonic filters shall be manufactured in accordance with the latest revision of IEEE 18. They shall be the open-rack substation type and be individually fused with either a current limiting or


expulsion fuse. Capacitors shall be supplied with discharge resistors, connectors, and an unbalance protection scheme. Spare capacitors shall be provided for each capacitor bank.

E. Reactor rating shall be based on the self-cooled type cooling system and selected to operate in the linear portion of the magnetic characteristic curve.

F. The 60 Hz filter banks shall be connected to a tertiary winding of the SFC isolation transformer.

2.05 25 HZ, 1-PHASE FILTERS

A. Harmonic filters may be required on the 25 Hz single-phase output side of the converter to reduce harmonic currents fed into SEPTA’s traction power system.

B. The filters shall be classified by their location, connection to the main circuit, sharpness of tuning, and the number and frequencies of their resonances.

C. The single phase output filter shall provide voltage damping, surge suppression and harmonic suppression.

D. The capacitors forming part of the harmonic filters shall be manufactured in accordance with the latest revision of ANSI/IEEE 18. They shall be the open-rack substation type and be individually fused with a current limiting fuse. Capacitors shall be supplied with discharge resistors, connectors, and an unbalance protection scheme. Spare capacitors shall be provided for each capacitor bank.

2.06 SFC INPUT AND OUTPUT TRANSFORMERS

A. Basis of Design

The SFC 60 Hz three-phase input transformers and the 25 Hz single-phase output transformers shall be designed specifically for single phase converter service. The design shall provide for essential service under the loadings, system capabilities, and environment defined elsewhere in this specification, including ambient temperatures, weather, and other conditions usually associated with outdoor installations. The SFC Contractor shall size these transformers to meet the requirements of the static frequency converters.

B. Conditions of Service

Service conditions shall be “usual” as defined in IEEE C57.12.00 (ambient air does not exceed 40°C maximum, and the average for any twenty-four (24) hour period does not exceed 30°C maximum).

C. Standards

The SFC Contractor shall assure that the input and output transformers comply with the latest issue of the applicable equipment standards identified in this specification.

D. System Grounding

1. Three-Phase System Grounding

The three-phase SFC input transformer shall provide a means for 60 Hz system grounding via a solidly grounded neutral.

2. Single-Phase System Grounding

The 24/12 kV, 25 Hz traction power system is presently supplied by three cycloconverter output transformers that have the 36 kV output side tapped at 2/3 winding length to make up a 12 kV trolley and 24 kV feeder system. The tapped


connection is solidly grounded to the rail return system.

E. Sound

The audible sound level shall not exceed 71 dBA, consistent with IEEE C57.12.90, when the transformer is operating at full-load, rated tap voltage, rated frequency, and with all auxiliary cooling equipment functioning.

F. Oil Preservation System

The transformers shall be furnished with a constant pressure type oil preservation system utilizing an air conservator where the oil is sealed from atmosphere by an expandable bladder which is allowed to expand or contract as the oil volume changes due to temperature. The system shall include a gas detector relay and a sampling valve located at ground level. The System shall be suitable for operation over an ambient temperature range of -18°C to +40°C.

G. Impedance

Measured impedances from primary to each secondary winding of the three-phase transformer shall be within 7 ½ percent of the SFC Contractor specified value. Similarly, the impedance of the primary to secondary winding of the single-phase transformer shall be within 7 ½ percent of the SFC Contractor specified value.

H. Temperature Rise

The temperature rises shall be separately guaranteed and measured for the high voltage and each low-voltage winding. All temperature rises shall be shown on the test report. The temperature rise of the transformers based on the nominal MVA rating shall not exceed 65°C by resistance measurement and 80°C for hot spot winding temperature above a 40°C ambient when operating at the specified continuous rating to assure a normal life expectancy of forty (40) years. The hot spot temperatures shall not be exceeded during the rating duty cycle.

The transformer shall be designed to permit loading in accordance with IEEE C57.91.

I. Short-Circuit Capability

The transformer shall, as a minimum, have the short-circuit capability described in IEEE C57.12.00.

J. Taps

The transformers shall have a manual tap changer suitable for operation from ground level when the transformers are de-energized only. Full kVA taps shall be provided as shown under the transformer rating.

Two (2) 2.5% taps above nominal and two (2) 2.5% taps below nominal shall be provided. The SFC Contractor shall ensure that the converter receives adequate voltage based on the voltage swing criteria described this specification.

The tap changer handle shall have provisions for padlocking, and visible indication of tap position shall be provided. The position of the tap changer shall be visible to a person standing on the ground. The number “1” or the letter “A” shall be assigned in accordance with IEEE C57.12.00.

K. Windings

The transformer winding design shall take into account the high voltage stresses on the insulation system due to lightning and switching surges on the system.


The winding insulation shall be adequate to withstand the effects which may be caused by harmonics and high thermal and mechanical stresses due to fluctuating and sustained overloads during emergency conditions or by short circuits. The SFC Contractor shall include in his bid drawings showing the winding construction, end packing, support arrangements, and the winding damping structure proposed. The high voltage and low voltage windings shall be capable of withstanding full and chopped-wave impulse voltage tests detailed in the test section.

Winding bracing shall be designed to withstand shocks and severe mechanical forces which may occur during transport, switching, or under overload and fault conditions without causing excessive stress in the core bolt insulation.

Tapping shall be arranged at such positions on the winding so as to preserve as far as possible the electromagnetic balance of the transformer at all voltage ratios.

L. Insulating Oil

The SFC Contractor shall furnish a sufficient quantity of insulating oil, which, as delivered, conforms to the requirements of ASTM D3487. The oil also shall conform to any additional or more stringent requirements imposed by the transformer vendor in order that the oil be completely compatible with the transformer insulation system.

M. Tank Design

The transformer tanks and grounding terminals shall be as recommended in IEEE C57.97.

The transformer cover shall be designed so that bushings and other top-mounted equipment is attached to elevated sections of the cover to prevent the accumulation of water under this equipment.

As far as practicable, gaskets, below oil level shall be eliminated, unless isolating valves are provided to permit replacement of gaskets during operation.

After completion of factory assembly and testing, the equipment shall be thoroughly cleaned. Except for match marking, all nonpermanent marks and coatings shall be removed, and the finish shall be clean and undamaged.

The transformer tanks and any attached compartment that is subjected to operating pressures shall be designed to withstand, without permanent distortion, pressures 25% greater than the maximum operating pressure resulting from the system of oil preservation used. The maximum operating pressures (positive and negative) which the transformer tank is designed to withstand shall be indicated on the nameplate. Either bolted or welded main cover construction shall be considered.

One or more manholes shall be provided on the transformer top. As a minimum, manholes shall be located above side-mounted bushings, and above no-load tap changers. Opening and covers shall be designed to prevent water or snow entering the transformer.

The center of gravity lines of the tank and assembled transformer shall be clearly marked or etched on all sides.

The base shall permit rolling in the directions of both major centerline (front to back and side to side) of the transformer and provision shall be made for pulling the transformers in these directions. The transformer, as normally prepared for shipment, shall not fall outside the base support members when the base is tilted 15 degrees from the horizontal, with or without oil in the transformer.

Jacking aids shall be located near the extreme ends of the junctions of the segments. There shall be a minimum of four (4) jacking lugs in accessible positions to enable the


transformer, complete with oil, to be raised or lowered using hydraulic or screw jacks. The minimum height of the lugs above the base shall be 20”.

Means shall be provided for lifting each complete transformer. The bearing surfaces of the lifting means shall be free from sharp edges. Methods shall be provided for guying the transformers. Means shall also be provided for untanking the transformers, which would be an in-shop process.

The SFC Contractor’s outline drawing shall show recommended support locations for jacking and lifting the transformer. These support locations shall be indicated on the transformer base by painting or otherwise

N. Core

The transformer cores shall be carefully assembled and clamped to ensure adequate mechanical strength to support the windings and to minimize movement during handling, transport, and to reduce vibration to a minimum under operating conditions. The design shall also inhibit movement of the core due to forces caused by traction system currents.

The prime consideration in the design of the magnetic circuit shall be the prevention of:

1. Static discharge development and short circuit to the grounded coupling structure.

2. Flux component at right angles to the plane of lamination, which may cause local heating.

O. Equipment Grounding

Two (2) grounding pads shall be furnished, located diagonally opposite on the transformer case or frame. Each pad shall have two holes on 1.75” centers, drilled and tapped 0.5” - 13NC. Grounding pads shall be made of copper-faced steel or stainless steel without copper facing.

P. ACCESSORIES

1. Liquid Indicator

Dial-type liquid level indicator (two stage) with separate alarm and trip contacts. The indicator shall have provisions for resetting. The indicator shall indicate below normal oil level and, if constant oil pressure system is used, damaged air cell. The indicator shall have a dark face dial with light indicating hand and light markings, which shall indicate maximum level, minimum level and 25°C level.

2. Dissolved Gas Analysis Monitor (Hydran Monitor)

Each of the converter transformers shall be equipped with a continuous, on-line, real-time, dissolved gas-in-oil monitoring system for use in the detection, monitoring and alarming of composite values of fault gases (hydrogen, carbon monoxide, acetylene and ethylene) dissolved in the transformer dielectric oil. The monitor shall be Syprotecs® HYDRAN 201R Model I system or SEPTA approved equivalent.

Each monitoring system (one (1) per transformer) shall consist of an intelligent transmitter and a one-channel controller. The one-channel controller shall link with one (1) transmitter, and shall provide a remote display of the dissolved gas level, alarm relay contacts, local alarm indicators and analog outputs.

An intelligent transmitter shall be provided:


a) The transmitter shall contain the sensor assembly and all electronics and any associated software necessary for stand-alone operation as a gas-in-oil monitor. The transmitter shall provide the following:

1) Local display and controls to display measured data and allow for parameter set-up.

2) RS-232 port for local computer access.

3) Supervisory RS-485 or Ethernet link port for connection to one (1) of the before mentioned controllers.

4) One (1) isolated 4-20 mA output.

5) Gas alarm and system fault relays.

6) Capability for remote upgrade of any embedded software.

b) The transmitter software shall enable the following:

1) Real-time display of gas level in PPM.

2) Displays of twenty-four (24) hour and thirty (30) day gas trends (user adjustable periods).

3) System date and time and alarm messages.

4) Multiple levels of alarming with adjustable delays on gas level.

5) Gas trends and sensor temperature.

6) Password-protected menu-access to alarm settings.

7) Set-up parameters and historical data.

8) Automatic sensor test.

9) Thermal enclosure control.

10) Software calibration of analog inputs and outputs.

c) The SFC Contractor shall install the intelligent transmitter at a readily accessible location on the transformer per the Vendor’s instructions. The SFC Contractor shall provide 120 V ac, 60 Hz power to the transmitter.

d) The transmitter shall have a one-channel controller:

1) The one-channel controller shall provide a supervisory link with one (1) transmitter. The controller shall have the capability of being networked with multiple controllers. The controller shall provide the following:

• Display of the dissolved gas level.

• Gas alarm indicators with acknowledge.

• One (1) non-isolated, configurable analog output (4-20 mA or 0-10 V)

• One (1) isolated, configurable analog output (4-20 mA or 0-10 V) for connection to the SEPTA’s SCADA system.

2) The SFC Contractor shall locate and install the controller.

3. Thermometry System


The SFC input and output transformers shall have a 4-channel fiber optic thermometry system that provides temperature measurements of the transformers similar to Luxtron Fluoroptic thermometry system or SEPTA approved. A minimum of four (4) probes shall be installed in each winding of each phase of the transformers. For the transformer to be considered acceptable, at least three (3) of the probes in each winding of each phase must survive manufacturing and be operable on the finished transformer during commissioning.

All the probe leads shall be brought outside of the transformer tank and terminated appropriately in a single location. A minimum of six (6) sensors per transformer shall be telemetered to SCADA via 4-20 mA, 0-10 V or equivalent SEPTA approved analog signal.

The instrumentation package shall be mountable in a standard 19” rack mount. The high voltage transformer winding monitoring system shall have, as a minimum, the following features:

a) Measurement of the transformer winding temperature shall be by direct reading fiber optic probe.

b) The monitor shall be modular and have the capability to display temperature readings on a minimum of four (4) independent channels.

c) The monitoring probes shall be electrically isolated from the monitor (electronics unit).

d) The monitoring system shall include a temperature display for each channel consisting of a three (3) digit LCD.

e) The minimum temperature measurement range shall be from 0°C to 200°C.

f) Temperature resolution of the LCD display shall be 1°C.

g) The monitoring system shall have a temperature accuracy of 2°C or better.

h) The monitoring system shall have the capability to communicate temperature readings to SEPTA’s SCADA system and/or remote indicating displays.

i) The maximum temperature measurement update rate shall be ten (10) seconds or less.

j) Each monitor output channel shall include a user selectable temperature alarm output limit with relay and monitoring system status indicators.

k) The temperature probes shall function properly when completely immersed in hot transformer oil.

l) The probes shall withstand exposure to hot kerosene vapor during the transformer insulation drying process.

m) System shall come complete with instrumentation (electronics unit), fiber optic temperature probes, tank wall penetrators, tank wall adapter plate, external fiber optic extension cables, and all other require hardware and equipment.

n) Tank wall penetrators, extensions, and under-oil connectors shall be of a leak free design.


o) The electronics unit shall be protected against the surge conditions specified in IEEE C37.90.1

Provide dial-type liquid thermometer with alarm and trip contacts for indication the top oil temperature. The indicator shall have provisions for resetting and be mounted in a thermowell as shown in IEEE C57.12.00 for indicating the top oil temperature. The thermometer shall have a dark face dial with light markings, a light colored indicating hand and an orange/red maximum indicating hand with provisions for resetting.

4. Upper and lower filter connection

5. Drain valve

6. Oil sampling valve

NOTE: If drain and sampling valves are furnished combined in one (1) unit, the sampling device shall be on the discharge side of the main valve, and a pipe plug for the valve shall be furnished.

7. Nameplate

A diagram nameplate shall be furnished and shall be located near eye level above the base of the transformer. The information furnished shall be in accordance with nameplate C of Section 5.12.2 of IEEE C57.12.00. Zero- and negative- sequence impedances shall be shown on transformer nameplates.

8. Pressure test valve

9. Pressure vacuum relief device

A pressure vacuum relief device shall be located on the cover. Electrical alarm contacts shall be provided for indicating operation of the pressure vacuum relief device.

10. Breather

If a constant oil-pressure system is provided, a breather enabling a passage of air in and out of the air cell as it inflates or deflates shall be provided.

11. Temperature gauge

Dial type hot spot winding temperature gauge (including associated current transformer) with four (4) single pole normally open contacts. The dial face shall be similar to that of the liquid indicator. Gauge shall include a resettable maximum temperature reading indicator.

Q. Cooling Equipment

Forced air cooling (FA) shall be provided as required and shall include as a minimum the current carrying parts sized for the forced air rating, fans, and control cabinet. The cooling system shall be by removable radiators, fitted with valves, which can be easily shipped and fitted on site. The fan motors shall have individual thermal protection. Fans shall be readily replaceable.

Terminals shall be provided in the control circuit for connecting contacts to trip the fans automatically on operation of the transformer protective relays.

If forced air cooling is required, each transformer shall be equipped with at least two (2) separately controlled fan groups. The control shall be so arranged that any group may be manually selected as the initial group or a subsequent group. The control shall be so


arranged that both groups of fans can be started manually and run continuously if desired.

Fans shall be automatically controlled from winding hottest-spot temperature by a dial hot-spot indicating relay. This relay shall have a scale with a range of at least 0-180°C and shall be provided with an alarm contact set to close at 115°C on rising temperature. Ready means shall be provided for externally checking and calibrating the entire internal thermal assembly, and shall include provisions for inserting test ammeters in any current transformer secondary circuits, for inducing test current in the current transformer secondary circuits without using the primary winding, and necessary calibrating information. Data of ultimate temperature gradient above top oil temperature vs. test current in the current transformer circuit shall be furnished. Fan wiring shall be in conduits suitable for outdoor service.

R. Connections

All terminals and interconnecting wiring for sudden pressure relays, winding temperature indicator, and fan control switches shall be located in a vermin-proof, ventilated, weatherproof control cabinet mounted on the transformer tank. The wiring used shall be copper, insulation type XHHW, 600 V insulation and be of suitable gauge. It shall have markings indicating maximum voltage, identification letters or numbers, and manufacturer’s name or trademark. The cabinet shall contain switches for auxiliary supply, space heaters with thermostat and a lamp.

All live terminals and components contained in the control cabinet shall be suitably screened and labeled to prevent inadvertent contact and provide safe working space. All alarms shall be individually wired to an easily accessible terminal block. A removable bottom drill plate shall be supplied with the cabinet to accommodate cables of various sizes.

Cover mounted bushings shall be provided on the primary side of the SFC input transformer to accommodate connection by overhead rigid bus. Provisions shall be provided on the secondary (low-voltage) side of the SFC input transformer for connection of non-segregated bus duct.

An air-terminal chamber shall be provided on the input side of the SFC output transformer for connection to cable or bus. Cover mounted bushings shall be provided for connections to 12 kV trolley, 24 kV feeder, and rail return terminals on the output side of the SFC transformer.

Fan wiring shall be in conduits suitable for outdoor service.

2.07 TRANSFORMER FACTORY TESTS

A. General

All transformers shall be subjected to manufacturer’s standard factory and quality control tests and all applicable tests required by IEEE C57.12.00. The tests shall be carried out in the manner described in IEEE C57.12.90 and IEEE C57.12.00 unless otherwise specified below. The SFC Contractor shall submit a complete Certified Test Report containing of all factory test results.

B. Standard Tests

Tank welds shall be given a pressure test by filling the tank with dry nitrogen, dry carbon dioxide, or dry air to the highest pressure for which the tank is designed and exploring all welded seams with a suitable leak detector.

C. The following tests identified in IEEE C57.12.90 shall be included:


1. Resistance measurement

2. Ratio

3. Polarity and Phase Relation

4. Excitation Current

5. Impedance, Voltage and Load Loss

6. No-Load Loss

7. Applied Voltage

8. Induced Voltage

9. Temperature Rise

10. Impulse test

D. In addition to the standard tests identified above, the following shall apply:

1. Ratio and Regulation Tests

Ratio tests for full windings and for all taps of each type of transformer shall be made. The transformer vendor shall calculate and record regulation for each type based on impedance voltage and impedance power corrected to a temperature equal to the limiting winding temperature rise by resistance covered in Table 14 of IEEE C57.12.00 plus 20°C. The SFC Contractor shall be responsible for providing the required test to SEPTA.

2. Impedance Characteristics

The impedance characteristics of the complete tapping range shall be determined by measurement of values of impedance voltage between the high voltage and low voltage winding on every tap position.

3. Highest Total Loss Test

Total losses of the input and output transformers shall be measured on each tapping position so as to identify the tapping having the highest total loss. These losses shall be guaranteed by the manufacturer within a tolerance of 7.5% of the stated losses.

4. Temperature Rise Test

Temperature rise test shall be made on one (1) completely assembled oil-immersed transformer. The tap selected shall be the one (1) which produces the highest temperature rise. The ambient temperature shall be taken as that of the surrounding air, which shall not be less than -18°C or more than 40°C.

5. Impulse Test

Complete applied impulse test sequence is required for all outdoor transformers.

2.08 SFC INPUT TRANSFORMERS (3-PHASE, 60 HZ)

A. The SFC isolation transformer shall be a multi-winding transformer designed to step down the 13.2 kV power source voltage to the proper utilization voltage required for the SFC power block input.

B. The high voltage primary of the transformer shall be solidly grounded and a tertiary winding shall be provided for the SFC 60 Hz, 3-phase filter connection, if required.


C. Surge protection shall be provided for each incoming 13.2 kV line on the transformer bushings.

D. As a minimum, the input transformer protective relaying shall include the following protection schemes as depicted on project drawings:

1. Phase Overcurrent

2. Standard transformer accessories

3. Differential

4. Ground Overcurrent

2.09 OUTPUT TRANSFORMERS (1-PHASE, 25 HZ)

A. Each Wayne Junction SFC shall operate through its own output transformer at the rated output fundamental frequency of 25 Hz and supply 15 MVA, 24/12 kV at its output terminals.

B. Surge protection shall be provided on the 24/12 kV side of the SFC output transformers.

C. The single phase output transformer shall isolate the dc component of currents generated by the static frequency converter from the 1-phase distribution system and serve as a means to step-up the SFC output voltage to the required 24/12 kV level.

D. As a minimum, the output transformer protective relaying shall include the following protection schemes as depicted on project drawings:

1. Phase Overcurrent

2. Standard transformer accessories

3. Differential

4. Ground Overcurrent

2.10 NON-SEGREGATED PHASE BUS (BUS DUCT)

A. General

1. This section describes the electrical and mechanical requirements for metal-enclosed 60 Hz and 25 Hz bus if required. Alternative methods of connecting the SFC equipment shall be submitted for approval and the SFC Contractor shall be responsible for the development and safety of the alternative design. The bus system described is to be suitable for outdoor installations, with nominal current ratings maintained in ambient temperatures to 40°C.

2. This specification covers the general requirements for the bus duct assemblies. The general requirements for the assembly (plan, arrangement, dimensions, and components) shall be developed by the SFC Contractor and approved by SEPTA. This drawing shall form the basis for detailed manufacturing and installation drawings to be developed by the SFC Contractor.

3. The assemblies shall be constructed, wired, and tested in accordance with all applicable sections of the latest standards and codes.

4. It shall be the SFC Contractor’s responsibility to be, or to become, knowledgeable of the requirements of these standards and codes. Any changes or alterations to the equipment to make it meet standards and codes requirements shall be at the expense of the SFC Contractor.


B. Installation and Operating Instructions

Installation specifications and operating instructions shall be provided covering all the equipment furnished (including, but not limited to: bus duct sections and connection details, support structures details and equipment termination details).

C. Housing

1. The bus duct shall be non-ventilated. Housing and accessory flanges, terminal enclosures, etc, shall be primed and of corrosion-resistant aluminum construction. All outdoor hardware shall be 316 stainless steel.

2. Aluminum housings shall be nominal 1/8” thickness material minimum throughout. Top covers shall be sloped to shed water.

3. Totally enclosed, non-ventilated housings shall be fitted with screened breathers and space heaters in sufficient quantity and rating to minimize condensation. Space heaters shall be completely factory wired with no exposed wiring inside the bus housing. Heaters shall be thermostatically controlled. Heater wiring shall be terminated in an octagonal box at designated end of bus housing and wired into switchgear power source by the SFC Contractor. Heaters shall be rated at 240 V and operated at 120 V (2 voltage) to maintain low heater surface temperature, and shall be designed for easy removal without requiring opening of the bus housing.

4. All housing and flange gasketing shall be closed-cell neoprene rubber, or other noncorrosive material, and shall be completely concealed for protection against deterioration.

5. The temperature rise at any point on the housing shall not exceed 30°C above an ambient temperature of 40°C.

6. A wall flange shall be provided at the point where the bus duct extends through all building and transformer fire walls.

7. Housings shall be phosphate treated and be applied with two coats of oven-baked corrosion-resistant ANSI 61 gray acrylic enamel paint.

D. Phase Bus Bars

1. Phase bus bars shall be of the non-segregated phase type, completely metal enclosed.

2. Bus bars shall be full round-edge rectangular 98-percent IACS copper of sufficient cross section to ensure full current rating without exceeding a hot spot temperature rise of 65°C in an ambient air temperature of 40°C. Joints between bus bar sections and at terminal connections shall be designed for a maximum rise of 65°C in a 40°C ambient.

3. Phase bus bars shall be mounted and secured against movement during short circuits in high-tracking-resistant, high-impact-resistant, flame-retardant, bus bar supports, spaced along the bus run as required to meet the short-circuit current rating. The support blocks shall be ribbed to provide long creepage paths and fitted with corona suppressors, consisting of silicone rubber inserts between the insulated bus bars and support blocks.

4. Phase bus bars, at 5 kV class and above, shall be insulated with extruded Noryl tubing, rated for continuous operation at 130°C.


5. Contact surfaces of copper bus bars shall be silver plated. All bus bar connections shall be bolted. Bolts shall pass through the bus bar conductors, and shall be capable of being properly torqued and locked in place, to provide and maintain full and uniform pressure under all operating conditions. (Torque requirements in ft-lb shall be furnished by Vendor.) Temperature rise of bus bar joints shall not exceed bus bar rise by more than 5°C and in no case shall such bus bar joint temperature rise exceed 65°C.

6. A ground bus shall be furnished which shall electrically connect together all equipment connected to the bus duct. The ground bus shall be copper and have suitable terminating pads for connections to station ground system.

7. Flexible connections shall be provided for connecting bus to porcelain transformer bushings, switchgear bus risers and SFC equipment. All necessary adapter bars and spacers, bolting hardware, and insulating materials, for connection to transformer and switchgear terminals, shall be provided and the proper coordination of connections between bus and terminal equipment shall be the responsibility of the SFC Contractor. A phase transposition shall be incorporated to account for difference in phasing (where required).

E. Supports

Bus duct supports shall be outdoor column type with base plates for attaching to foundations furnished and installed by the SFC Contractor. Column supports, anchor bolts, etc, shall be hot-dipped galvanized materials.

F. Ratings

1. The maximum hot-spot temperature rise at any point in the bus duct at continuous rated load shall not exceed 65°C above an ambient temperature of 40°C.

2. The ratings of the bus duct shall be defined by the Vendor based on the requirements for his equipment.

G. Installation

The SFC Contractor shall install the busway and accessories in accordance with vendor’s instructions.

H. Tests

The SFC Contractor shall furnish the vendor’s Certified Test Reports for the bus. Tests shall be performed in accordance with the latest issue of IEEE Standard C37.23 and shall include the following:

1. Power Frequency Withstand Test Report

2. Impulse Voltage Withstand Test Report

3. Continuous Current Rating (Heat Run) Test Report

2.11 WIRING REQUIREMENTS

The SFC Contractor shall provide all power, control, signal wire and any special cable assemblies, i.e., cables with plug connectors, etc., required to interconnect the SFC Contractor’s equipment in accordance with the requirements of Section 16120, Conductors and Cables.

2.12 INSPECTION

Shop fabrication shall be subject to inspection and approval by SEPTA and/or its representatives,


who shall have free access to the SFC Contractor’s and the Vendor’s shops for inspection of fabrication and for observing shop tests. All tests required for certification of equipment shall be made at the SFC Contractor’s expense.

2.13 SFC COMPONENT FACTORY TESTS

A. Factory tests in accordance with the requirements of the technical specifications shall be performed by the SFC Contractor on the equipment specified herein and may be inspected, verified, or witnessed by the SEPTA or representative as noted below. The test procedure shall be developed by the SFC Contractor and submitted for review and comment prior to performing the testing. For those items listed below, the SFC Contractor shall give the SEPTA twenty-four (24) days’ notice before the start of any test. A copy of the factory test procedures shall be submitted to SEPTA prior to commencement of the test program. SEPTA reserves the right to witness any factory tests.

B. The factory tests on all equipment shall be performed in the manufacturer’s plant and shall be arranged to represent the working conditions as closely as possible. The tests shall be carried out in accordance with the approved test plans and procedures to ensure that satisfactory operation is obtained at rated frequency, voltage and power.

C. The SFC Contractor shall submit complete test plans and procedures for review and approval at least thirty (30) days prior to the desired testing date. The plans and procedures must include detailed information on the test type, identify what is being tested, how the test shall be performed, all necessary prerequisites, the pertinent codes and standards that apply, the anticipated results, as well as the pass/fail criteria for the test. The submittal shall include proposed test record forms.

The following sections indicate the minimum tests required.

D. Factory Inspection and Tests

1. Prior to the start of manufacture, the SFC Contractor shall provide a list and schedule, of all proposed tests and inspections. SEPTA shall be notified at least ten (10) working days in advance of the actual tests and the inspections. SEPTA reserves the right to witness testing unless this right is waived by SEPTA in writing. SEPTA may photograph, or video-tape the work-in-progress and under test in the SFC Contractor’s or subcontractors’ facilities. Alternatively, the SFC Contractor or the subcontractor may furnish the photographs at no cost to SEPTA.

2. The SFC Contractor shall provide SEPTA with five (5) certified copies of all factory test data.

E. Power Block Electronics Shop Tests

The following tests shall be performed on the power block conversion equipment and their auxiliaries in accordance with the applicable IEEE Standards.

1. Dielectric Test - Dielectric tests shall be performed in the Vendor’s plant and in the field on the main circuit, auxiliary circuits and fan motor supply to demonstrate the adequacy of the insulation, the creepage distances and clearances between device terminals and elements.

2. Load Tests - The power electronics shall be subjected to rated voltage and rated current tests in the Vendor’s plant. The mode of operation during the testing shall be substantially the same as in regular service. The power electronics shall withstand, without injury, the continuous and short time loadings described in this


Specification Section. Test results must include the verification of thermal calculations.

3. Efficiency and Losses

a) The efficiency shall be determined by calculation based on separately measured losses in the various components of the power electronic unit for rated voltage, current and frequency and for the normal mode of operation obtained with the proposed input and output transformer connection.

b) The loss calculation shall include the power electronics losses, transformer losses and all the auxiliary loads such as fan motors, auxiliary power transformers, protective relaying, metering and other devices.

4. Voltage Regulation and Power Factor - The voltage regulation and power factor shall be calculated in accordance with the applicable IEEE Standards.

5. Control Equipment - The control equipment shall be checked and tested to ensure the performance as specified. The tests shall include, but not be limited to:

a) Control of power electronic current sharing

b) Tests of supply voltages to individual control units

c) Checking of measuring circuits

d) Test of protective equipment operation

e) Test of control pulse units

f) Test of control oscillator amplitude and phase position

g) Test of synchronizing, load sharing and current limiting functions

h) Test of blocking unit operation

6. Converter Unit - The SFC Contractor shall provide certification of the no-load distortion measurements of the converter unit.

PART 3 - EXECUTION

3.01 PROJECT INTEGRATION

A. The project integration requirements are summarized as follows:

1. The final project configuration with have four 15 MVA SFCs with ratings given in this specification.

2. The new frequency converters shall be required to operate both independently and in parallel with each other under either manual or automatic load sharing control.

3. Always keep two SFC units in operation (live) with a third in stand-by (de-energized, but ready to start when needed).

4. Minimize disruption to existing SFC station operations during design, construction, testing, and commissioning.

5. Accommodate concurrent infrastructure improvement projects.

6. Minimize adverse operational, aesthetic, and environmental impacts.


7. The spare 13.2 kV, 60 Hz, 3-phase circuit breaker in the 230 kV control building (contains 13.2 kV switchgear) will be used for powering the new SFC #4.

8. The spare 480 V, 60 Hz, 3-phase circuit breakers in the 230 kV control building will be used for supplying auxiliary power to the new SFC #4.

9. Existing filter equipment in the 60 Hz filter yard will be removed. The foundations for these filters will remain in place. Any new reactors, charging transformers/circuit breakers, or heat exchangers can be located in these areas.

10. A new duct bank will be constructed from the 230 kV control building to the new SFC #4 open-air bus to be constructed in the 60 Hz filter yard. Another duct bank will be constructed from the open-air bus to the SFC #4 input transformer, with a portion extended to the basement of the SFC #4 building. The duct banks will contain power and control cables. The existing 60 Hz filter yard duct banks will be re-used for SFCs #1, #2, and #3.

11. The new SFC #4, 60 Hz open-air bus will utilize a manually-operated grounding switch similar to SFCs #1, #2, and #3. The open-air bus will also have a set of PTs and CTs for use with the new SFC #4 protective relaying, metering, and/or control scheme.

12. The existing 60 Hz, 13.2 kV, 1000 kcmil cables will be replaced between the 13.2 kV switchgear and open-air bus. The existing 60 Hz, 13.2 kV, 500 kcmil cables to SFC #1, #2, and #3 input transformers will be replaced as required by the new SFC design.

13. All duct banks associated with SFCs #1, #2, and #3 will remain in place in the 60 Hz filter yards in order to minimize risks and operational impact during construction.

14. The existing grounding switches, PTs, and CTs will remain connected to the existing 60 Hz open-air bus for SFCs #1, #2, and #3. Based on the accuracy class, the PTs and/or CTs may be replaced if required by the SFC vendor.

15. New input transformers must fit into the existing 60 Hz transformer areas.

16. New SFC equipment must fit into the existing converter rooms with sufficient working space to meet all building and electrical codes and standards.

17. New SFC equipment will be transported into the existing SFC rooms through doorways that are approximately 6 ft wide and 13 ft-4 in high (182.9 cm x 406.4 cm).

18. The new SFC #4 building addition will have the same overall dimensions as the SFC #3 room.

19. The existing and new converter rooms are approximately 45 ft-8 in long, 28 ft wide, and 19 ft-1 in high to lowest overhead beam (13.9 m x 8.5 m x 19.1 m).

20. New SFC heat exchangers shall be located on the roof of the converter buildings. These heat exchanges will share room with roof top units used for building heating and cooling.

21. New output transformers must fit into the existing 25 Hz transformer areas.

22. The existing filter equipment in the 25 Hz filter yard will be removed. The foundations for these filters will remain in place.


23. A new duct bank will be constructed from the output of the SFC #4 building basement, joining a new duct bank from the 25 Hz output transformer to the 25 Hz yard cable riser. The duct bank will contain power and control cables. A new open-air bus will be constructed to terminate the SFC #4, 24/12 kV cables from the 25 Hz output transformer. The new open-air bus will contain surge arresters, PTs, CTs, disconnect switches, grounding switches, and a circuit breaker. An exposed rail return bus will be constructed near the SFC #4 output breaker, similar to the SFC #1, #2, and #3 rail return buses, in order to bond the transformer rail return cable to station ground.

24. A new duct bank will constructed from the SFC #4 output circuit breaker to the 25 Hz traction power substation. The duct bank will contain power and control cables.

25. All duct banks associated with SFC #1, #2, and #3 will remain in place in the 25 Hz filter yards in order to minimize impact during construction.

26. The existing 25 Hz, 12 kV, 24 kV, and rail return cables will be replaced between the 25 Hz traction power substation and the SFC disconnect switches located next to the SFC output circuit breakers.

27. The existing SFC output circuit breakers will be replaced for each SFC. The new circuit breakers are ABB model FSKII. Each is supplied with a CT on both line and load side of each pole. These CTs will replace the existing CTs.

28. The existing 25 Hz disconnect and grounding switches next to the cable riser on the load side of the circuit breaker will be replaced.

29. The 25 Hz disconnect and grounding switches, PTs, and surge arresters on the SFC side of the circuit breaker will be relocated and replaced, as required, based on the size of the new ABB FSKII circuit breakers.

30. SFC #2 60 Hz input and 25 Hz output transformers do not presently have oil containments. If the new SFC design requires oil-filled transformers, new oil containments will be required for SFC #2 and SFC #4. The existing SFC #1 and SFC #3 both have existing transformer oil containments.

3.02 CONSTRUCTION SEQUENCE

A. The main priority in developing a construction sequence will be to keep at least two SFCs in operation at all times with a third in stand-by.

B. The second priority is to avoid construction traffic exposure to any unit while in operation. Presently, the SFC rooms function strictly to contain power block equipment and associated buswork. Walking through a room while the SFC is functioning, is kept to a minimum. However, during construction, it is strongly discouraged to keep SFC room doors open or allow construction materials to be transported through the room while the SFC is operating. In order to avoid exposure to construction traffic, a wall and doors will be constructed in front of the SFC power block equipment in order to isolate the sensitive equipment from dust and debris, as well as personnel.

C. With these two main concepts in mind, the following general sequence will be followed:


2. Construct the new SFC #4 building, including 60 Hz and 25 Hz power feeder duct banks, 25 Hz output circuit breaker, and make connections to the existing Wayne Junction 25 Hz traction power substation. The new SFC #4 converter room will


have a wall with doors between the SFC power electronics and the power distribution/control equipment.

3. Establish a new station computer in the existing Control room. Depending on SFC Contractor options, the existing computer equipment will need to be removed one unit at a time or it can be left in place until the final new SFC is commissioned.

4. Demolish the SFC #3 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz open-air bus and duct banks, as required. Modify 25 Hz and 60 Hz filter yards.

5. Install a new wall and doors in the SFC #3 building. Install the new SFC #3 equipment, 25 Hz transformer, 60 Hz transformer/reactors, 25 Hz circuit breaker, and route all new power feeders in new and/or existing duct banks. Commission the new SFC unit.

6. Demolish the SFC #1 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz open-air bus and duct banks, as required. Modify 25 Hz and 60 Hz filter yards. Note that the reason that SFC #1 is selected to be demolished after the construction of SFC #3 is so that all debris to be carried from SFC #2 demolition will only occur after constructing a wall in front of SFC #1 power electronics equipment.


8. Demolish the SFC #2 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz open-air bus and duct banks, as required. Modify 25 Hz and 60 Hz filter yards.


10. After all new SFCs are commissioned, the existing computer system can be removed. The final Control room will either have a complete new computer system or a HMI interface that coordinates control of all new SFCs. The SFC Contractor shall provide a wall-mounted master local/remote switch with a yellow flashing beacon to switch from local to remote control for the SFC system. The beacon shall flash when the system is in local control.

3.03 SURFACE PREPARATION AND PAINTING

A. All metal parts of outdoor equipment, such as transformer tanks and radiators, circuit breaker enclosures, capacitor, reactor and resistor enclosures shall be protected against corrosion. All surfaces shall be grit blasted to clean textured metal for ideal paint adhesion and primed with a rust inhibiting coat. Two (2) coats of ANSI Standard 61 Gray pigment topcoat shall be used unless otherwise indicated.

3.04 SFC FIELD TESTS

A. General Field Tests


1. Field acceptance tests shall be conducted by the SFC Contractor after installation is complete.

2. As part of the 60% design submittal, the SFC Contractor shall submit a list of any and all field tests which must be performed during installation and initial start-up of the equipment.

3. Detailed test and startup procedures shall be submitted to SEPTA for approval no less than three (3) months prior to the proposed start of test date.

4. Detailed test and startup procedures shall include pass/fail criteria.

5. SEPTA and Design Consultant shall be the sole judge as to whether or not a test has passed.

6. These tests shall be conducted in accordance with the latest applicable ANSI, NEMA, and IEEE standards, to demonstrate the ability of the equipment furnished to operate under the conditions specified and to meet the guaranteed performance. If the results of the tests conducted indicate that the equipment does not meet its guaranteed performance, the SFC Contractor shall at his expense make all necessary adjustments or changes required to meet the guaranteed performance. After the required adjustments and/or changes are made, the equipment shall be retested at the SFC Contractor’s expense.

7. Sound pressure level data shall be measured in decibels, referenced to 0.0002 microbars, using a sound level meter conforming to ASA S1.4, Type 1 tolerance limits. The nine (9) preferred octave band filter sets shall conform to ASA S1.11, Class 2, Type E tolerance limits.

B. Thirty (30) Day Reliability Field Test (Burn in Period)

1. The Performance Tests shall not take place until all major plant systems and equipment are mechanically complete and the plant has demonstrated reliability by running automatically for a thirty (30) day period. For a period of thirty days, the converter station shall be operated by SEPTA personnel under the guidance of the SFC Contractor. Operations shall be continuous, subject to on-off actions required by SEPTA’s 25 Hz Network. The converter station shall be operated in every possible mode, both locally and remotely via the SCADA system, and in such a manner as to demonstrate that the continuous, overload, and tripping capabilities of the station as a whole, and each converter individually, have been met.

2. During the thirty (30) day period the SFC Contractor shall conduct on-site training of SEPTA’s operations and maintenance personnel.

3. The burn-in period shall be deemed successful if no false alarms are received either locally or via SCADA and, during the thirty (30) day period availability has been 99.98% or better, meaning that all control functions requested within the specified response time, that all indications work as intended, that all metering circuits give accurate values, that all apparatus works in the intended manner, that power is delivered to the railroad in the quantity required, that all temperatures are within specification and within design limits, and that the station auxiliary systems perform as they should. Total downtime may not exceed (1-0.9998) times the thirty (30) days times twenty-four (24) hours/day in order for this test to be successful.


4. If the thirty (30) day burn-in test is not successful, the SFC Contractor shall promptly make repairs, and the entire test shall be run again. The Facility Acceptance Test shall not commence until the thirty (30) day burn-in test has been passed to the satisfaction of SEPTA.

C. Facility Acceptance Field Test (Performance Test)

1. As a condition of acceptance, the supplied equipment shall successfully pass the facility acceptance test conducted by the SFC Contractor and witnessed by the Design Consultant and SEPTA. The SFC Contractor shall develop such test plan and shall address the following:

a) Converter controls and indications, demonstrating that all controls and indications associated with the converters work as intended in both local and remote modes.

b) The function and accuracy of each telemetry circuit in the station related to the Vendor’s equipment including signal conditioning devices, SCADA and metering devices.

c) Doble test and high potential test of all transformers, capacitors and inductors.

d) Full gas analysis of all oil-filled equipment.

e) Load-Sharing Test

2. Testing of the completed converter station shall be developed along the lines outlined below. The SFC Contractor’s personnel shall operate the equipment under direction of SEPTA’s Load Dispatcher during these tests.

a) A twenty-four (24) Hour Test demonstrating the general functionality of the station during which time the converter station shall be operated feeding power to the railroad, locally for that length of time.

b) Following the twenty-four (24) hour test, staged fault tests shall be made in order to demonstrate the capability of each converter unit to supply the specified short circuit current for the required period. Each converter shall be subjected to three (3) short circuit events over a ten (10) minute period. Each event shall involve driving the converter to the rated short circuit output power and verification that this output is maintained for the required period without tripping of or damage to the converter.

c) A thirty (30) Day Endurance Test, following the Staged Fault Test, shall have the converter station operate in MW load-sharing mode with SEPTA’s 24/12 kV traction power system. Operations during this test period are intended to demonstrate the ability of the plant to accomplish load sharing between the individual converters and the 24/12 kV network. The Station shall follow a MW reference signal which shall vary in accordance with the railroad system time of day load demand. Voltage/reactive power support shall follow the 24/12 kV system demand up to the rated capability of the converters as indicated in this Specification. Load sharing capabilities and functional requirements contained in this specification shall be demonstrated during this period.

d) A black start demonstration test. This test shall demonstrate the SFC Station’s ability to energize a dead section of the 24/12 kV, 25 Hz, single-phase system.


e) A load-sharing test shall be performed to test the capability of each SFC to operate in parallel and share load with other frequency converters including the existing rotary frequency converter at Wayne Junction. During operations, record load-sharing characteristics of each frequency converter in parallel operation. Record the following data, as a minimum:

1) Converter output current (before and after load changes).

2) Converter output voltage (before and after load changes).

3) Power division and exchange between converters.

4) Real power (watts) and reactive power (vars) on each frequency converter.

5) System frequency (60 Hz and 25 Hz).

f) Verify that all frequency converters have appropriate droop characteristics and share real and reactive load proportionally in a stable manner. Document the active power division, active power exchange, reactive power division and transient response in the following steps for each combination.

1) Divide the load proportionally between the frequency converters and operate in parallel for 15 minutes.

2) Increase the load in steps until each frequency converter is loaded in accordance with SEPTA’s requested power output.

3) Decrease the load in steps until each frequency converter is loaded in accordance with SEPTA’s requested power output.

4) Transfer load in accordance with SEPTA’s direction between frequency converters.

5) Dispatch the new Wayne Junction SFCs and existing cycloconverters to share load. Without any manual adjustment, operate in load sharing mode for 24 hours. Monitor and record station operation. Both the new SFCs and existing cycloconverters shall operate in a stable manner without oscillating while sharing load proportionally and following the required droop characteristics and loading characteristics.

3.05 SITE SUPPORT PERSONNEL

A. The SFC Contractor shall provide commissioning services as follows:

1. Inspection and checkout of the equipment after installation.

2. Performance tests required by the specification.

3. Adjustment and calibration of devices as required, to avoid start-up damage and for safety prior to start-up.

4. Participation as the equipment and system are placed into service to demonstrate satisfactory operation and specified performance. This shall include on-site surveillance, over-view and assistance by the Vendor’s qualified Service Engineer for a period of sixty (60) days following SEPTA’s complete acceptance.

5. Technical advice as necessary for the proper maintenance of the equipment.


B. The SFC Contractor shall provide the services of a field service engineer (FSE) to give technical direction for the installation and startup of equipment. Technical direction does not include any supervision, management, regulation, arbitration, or measurement of work capability of site personnel.

C. The FSE responsibilities include the following:

1. Incoming inspection of the material for:

a) conformity/completeness according to dispatch notes;

b) transport damages;

c) appropriate storage.

2. Assembly of the materials according to:

a) design plan, layout, and assembly drawings;

b) operation instructions of sub-suppliers;

c) internal assembly and mounting instructions;

d) VDE, DIN, ANSI, NEMA guidelines

3. Supervising the assembly and mounting processes.

4. Establishing the assembly and mounting flowchart.

5. Coordination of the third party companies according to the progress of works.

6. Supervision of third party companies by means of schedules, working reports, and checklists.

7. Checking the execution of assembly and mounting works including:

a) visual inspections, comparison with drawings;

b) verification of cable and wiring connections;

c) initial functional tests of subsystem or components.

8. The SFC Contractor shall provide, as a part of this Contract, the following site support personnel:

a) A qualified person, eight (8) hours/day, five (5) days/week for the next ninety (90) days after final completion of the project to provide assistance during operation. Salary, transportation and other expenses shall be included in the Contract Price. This person shall also be on-call twenty-four (24) hours/day for emergencies and shall respond in one (1) hour.

b) A qualified person on call for the remainder of the warranty period for emergencies. They shall respond to the site in three (3) hours. Time spent by the Service Engineer on Vendor’s standard tests, tests outlined elsewhere, correcting manufacturing mistakes, and/or replacing faulty equipment in the field shall not be considered as part of assistance outlined above.

3.06 TRAINING

The SFC Contractor shall conduct a comprehensive training course for SEPTA’s personnel. The SFC Contractor shall provide a training person to perform a comprehensive Task and Skill analysis of the SEPTA employees, who shall operate and maintain the Converter Station and develop a


formal training program based on that Task and Skill analysis. Training shall be provided as specified in accordance with Specification Section 01822.

END OF SECTION



Wayne Junction SFC 16262A-1 60% Design Submittal Rehabilitation Project November 29, 2016

SECTION 16262 - APPENDIX A

SFC TECHNICAL FILL-IN DATA SHEETS

PART 1 - GENERAL


A. Section 16262 - Static Frequency Converter

PART 2 - PRODUCTS

2.01 TECHNICAL FILL-IN DATA SHEETS

The SFC Contractor shall fill-in the following data sheets and submit to SEPTA with the Request for Proposal Bid Documents and update at each of the following points in the project, as required:

A. Request for proposal

B. 30% design stage

C. 60% design stage

D. 90% design stage

E. 100% design stage

2.02 CONVERTERS

Converter Rating

Output apparent power rating (MVA) a) Continuous, rms b) 1 hour c) 6 minutes d) 30 seconds e) 2 seconds f) time before next overload cycle

Continuous real power rating (MW) (SFC Contractor shall provide capability curves)

Power Factor

For rated operation (range)

Three-phase network

Single-phase network

Converter Input Current Rating

@ 100% 3-Phase Input Voltage




Converter Output Current Rating

@ 100% 1-Phase Output Voltage



Short-Circuit Current Delivery Capability

Three-phase, 60 Hz Magnitude (kA)

Three-phase, 60 Hz Duration (sec)

Single-phase, 25 Hz Magnitude (kA)

Single-phase, 25 Hz Duration (sec)

Converter Voltage Rating

Input Voltage:

Rated Voltage

Maximum Voltage

Minimum Voltage

Output Voltage:

Rated Voltage

Maximum Voltage

Minimum Voltage

Losses

No-load losses (kW)

Load Losses (kW @eff)

@ 50% output

@ 60% output

@ 75% output

@ 90% output

@ 95% output

@ 100% output

Semiconductors

Semiconductor Device Types

Three-phase Module Type

Voltage rating


Current rating

Single-phase Module Type

Voltage rating

Current rating

Converter Cooling

Power electronic component temperature for worst case thermal duty

Max. Junction Temp. at Full Load

Amperes continuous

Ambient air temperature, °C or °F

Maximum Temperature Junction

Thermal Safety Margin

Noise Data

Outdoor dBA @ 100’-0”

Indoor Equipment dBA @ 3’-0”

Coolant (by weight)

Deionized water %

Ethylene glycol %

Coolant freeze point

Cooling Fans

Electrical Characteristics

Voltage

Single/Three Phase

Frequency

No. of Cooling Fans

Fan motor horsepower

Fan motor speed

Fan motor enclosure

Fan motor service factor

Circulation Pumps

Electrical Characteristics

Voltage


Single/Three Phase

Frequency

No. of Circulation Pumps

Pump motor horsepower

Pump motor speed

Pump motor enclosure

Pump motor service factor

Converter Module Characteristics

Three-phase, 60 Hz Module

Voltage across module

Three-phase current

Single-phase, 25 Hz module

Voltage across module

Short-circuit current through module

Module output current at rated power (rms)

DC Link Characteristics

Voltage

Current

Harmonic Limitations

Single-phase Side:

Voltage distortion at 24/12 kV, 25 Hz

IFD

THD

Current Distortion at 24/12 kV, 25 Hz

IFD

THD

Three-Phase Side:

Voltage Distortion at 230 kV level, 60 Hz

IFD

THD

Current Distortion at 230 kV level, 60 Hz

IFD


THD

Voltage Distortion at 13.2 kV level, 25 Hz

IFD

THD

Current Distortion at 13.2 kV level, 25 Hz

IFD

THD

Control Panels

Quantity

Dimension of each panel (width x length x height), ft-in

Weight of each panel (lbs)

Heat rejection of each panel (W)

Physical Parameters

Dimensions required for complete SFC power electronic block installation (width x length x height), ft-in

Weigth of SFC power block equipment (lbs)

2.03 INPUT TRANSFORMERS

Manufacturer

Electrical Parameters

Rated Power (MVA)

Rated Voltage (kV)

No-Load Loss at 100%, 105% and 110% of rated voltage

Full-Load Guaranteed Losses at OA, FA, FOA ratings

Cooling System Losses

Impedance (HV/LV/Diff/Comp)

Impedance at OA rating


Reactance at OA rating

Resistance at OA rating

Exciting current in % of full load current at rated current and 60 Hz

Three-phase capacitance to ground, HV side

Three-phase capacitance to ground, LV side

Noise Data

Audible sound level @ OA rating

Loading Capability

With the loss of one-half of the cooling auxiliaries,% load xfmr shall carry continuously w/o exceeding hot spot temp

Weights

Core and Coils

Tank and Fittings

Oil (Gal)

Total Weight

Shipping Weight

Materials

Tank

H.V. Winding

L.V. Winding

Dimensions

Overall Height

Width

Depth

Height Over Cover

Untanking (plus slings)

Minimum clearance of jacking lugs to base (inches)


Transformer Oil

Oil Grade

Shipment

Fault Pressure Relay

Fault Pressure Relay type

Forced Cooling Equipment

Cooling fans

Cooling pumps

2.04 OUTPUT TRANSFORMERS

Manufacturer

Electrical Parameters

Rated Power (MVA)

Rated Voltage (kV)

No-Load Loss at 100%, 105% and 110% of rated voltage

Full-Load Guaranteed Loss, exclusive of cooling system at OA, FA, and FOA rating of transformer

Cooling System Losses

Impedance at OA rating

Reactance at OA rating

Resistance at OA rating

Exciting current in % of full load current at rated current and 25 Hz

Capacitance to ground, HV side

Capacitance to ground, LV side

Noise Data

Audible sound level @ OA rating

Loading Capability


With the loss of one-half of the cooling auxiliaries, percent load transformer shall carry continuously w/o exceeding hot spot temp

Approximate Weights

Core and Coils

Tank and Fittings

Oil ( Gal)

Total Weight

Shipping Weight

Materials

Tank

H.V. Winding

L.V. Winding

Approximate Dimensions

Overall Height

Width

Depth

Height Over Cover

Untanking (plus slings)

Minimum clearance of jacking lugs to base

Transformer Oil

Oil Grade

Shipment


Fault Pressure Relay


Forced Cooling Equipment

Cooling Fans

Circulating Pumps


2.05 INPUT FILTERS

A. Filter Reactor

Manufacturer

Style

Type

Rated Ohms @ 60 Hz

Tolerance, %

Rated Inductance

Tolerance, %

Taps

Rated Voltage

BIL

X/R Ratio @60 Hz

Weight

Short-circuit current rating, sym. amperes

Center unit compensated, yes/no

Center unit reverse wound, yes/no

Dimensions (including structure)

a.) Max. height

b.) Max. width

c.) Max. depth

d.) Recommended horizontal spacing

Continuous Current Requirements (Filter reactor duty requirements in amperes per phase at the following frequencies)

@60Hz

@300Hz

@420Hz

@660Hz

@780Hz

@1380Hz

@1500Hz

Short-Circuit Withstand Requirements

Nominal Operating Requirements

Maximum Operating Voltage


Total operating weight

Special foundation requirements, yes/no

Dist. to metallic parts forming closed loops

No. of terminal blades per terminal

B. Filter Resistor

Manufacturer

Style No.

Resistance in ohms

Continuous Current Rating

Voltage Rating

BIL Rating

Temperature Rise (continuous)

Weight


a.) Max. height

b.) Max. width

c.) Max. depth

C. Filter Capacitor - individual

Manufacturer

Style No.

Nominal Can kvar Rating

Nominal Voltage Frequency Rating

Nominal Capacitance Rating

Number of Cans

Number of Bushings per Can

Capacitor Fusing

D. Filter Capacitor - capacitor bank

Total capacitance per Phase

Number of Cans per Phase

Capacitor Bank Connection / BIL

Normal Bus Operating Voltage


Capacitor Operating Voltage due to Reactor Voltage

Total kvar @ Capacitor Rated Voltage

Effective Total kvar at Capacitor Operating Voltage (0% tol)

Effective Total kvar at Capacitor Operating Voltage (+/- 5% tol)

Expected Bank kvar (Less Reactor kvar loss)

Continuous Capacitor Current Duty Requirements Filter reactor duty requirements in amperes per Phase (fundamental at maximum bus operating voltage) Provide frequency, amps, and L-N voltage in a table.

Specify the total rms filter voltage duty requirements in a table.

Total rms filter current duty requiremen

Sum of I(h)/H filter duty requirement

Sum of rms voltage across capacitor per phase

Equivalent voltage across capacitor bank in each phase

Weight


2.06 OUTPUT FILTER

A. Filter Reactor

Manufacturer

Style

Type

Rated Ohms @ 60 Hz

Tolerance, %

Rated Inductance

Tolerance, %

Taps

Rated Voltage

BIL

X/R Ratio @60 Hz

Weight:

Short circuit current rating, sym. amperes

Center unit compensated, yes/no


Center unit reverse wound, yes/no

Dimensions (including structure):

a.) Max. height

b.) Max. width

c.) Max. depth

d.) Recommended horizontal spacing

Continuous Current Requirements (Filter reactor duty requirements in amperes per phase at the following frequencies)

@25Hz

@125Hz

@175Hz

@275Hz

@325Hz

@575Hz

@625Hz

Short Circuit Withstand Requirements

Nominal Operating Requirements

Maximum Operating Voltage

Total operating weight

Special foundation requirements, yes/no

Dist. to metallic parts forming closed loops

No. of terminal blades per terminal

B. Filter Resistor

Manufacturer

Style No.

Resistance in ohms


Voltage Rating

BIL Rating

Temperature Rise (continuous)

Weight


a.) Max. height

b.) Max. width


c.) Max. depth

C. Filter Capacitor - Individual

Manufacturer

Style No.

Nominal Can kvar Rating

Nominal Voltage Frequency Rating

Nominal Capacitance Rating

Number of Cans

Number of Bushings per Can

Capacitor Fusing

D. Filter Capacitor - Bank

Total capacitance per Phase

Number of Cans per Phase

Capacitor Bank Connection / BIL

Normal Bus Operating Voltage

Capacitor Operating Voltage due to Reactor Voltage

Total kvar @ Capacitor Rated Voltage

Effective Total kvar at Capacitor Operating Voltage (0% tol)

Effective Total kvar at Capacitor Operating Voltage (+/- 5% tol)

Expected Bank kvar (Less Reactor kvar loss)

Continuous Capacitor Current Duty Requirements filter reactor duty requirements in amperes per Phase (fundamental at maximum bus operating voltage) Provide frequency, amps, and L-N voltage in a table.

Specify the total rms filter voltage duty requirements in a table.

Total rms filter current duty requirement

Sum of I(h)/H filter duty requirement

Sum of rms voltage across capacitor per phase

Equivalent voltage across capacitor bank in each phase

Weight


Dimensions (including structure): a.) Max. Height b.) Max. Width c.) Max. Depth

2.07 NON-SEGREGATED BUS DUCT

Manufacturer:

Electrical Parameters Three-Phase, 60 Hz Single-Phase, 25 Hz

Voltage Class

Nominal Voltage Rating

Number of Phases

Operating Frequency


Short Circuit Rating: (Momentary Current Amps)

Basic Insulation Level (BIL)

Structural Requirements

Maximum Non-braced support span

2.08 ELECTRICAL PANELS

For each electrical panel supplied with the SFC unit, provide the following information. Table may be duplicated as required.

Nominal voltage rating, volts

Phases (1-ph, 3-ph)

Main Circuit Breaker

Manufacturer

Type

Interrupting rating, amps

Type certification (e.g., UL, NEMA, etc)

Branch Circuit Breakers

Manufacturer

Type

Number of Circuits


Interrupting rating, amps

Type certification (e.g., UL, NEMA, etc)

Main Horizontal Bus

Material

Continuous current rating, amps

Short circuit withstand rating, amps

Main Vertical Bus

Material

Continuous current rating, amps

Short circuit withstand rating, amps

Physical Data

Enclosure and trim

NEMA type enclosure

Type material

Sheet metal thickness, inches

Paint, color & type

Dimensions (HxWxD), inches

Weight, lbs.

END OF SECTION



Wayne Junction SFC 16262B-1 60% Design Submittal Rehabilitation Project November 29, 2016

SECTION 16262 - APPENDIX B

SFC DOCUMENT SUBMITTAL SCHEDULE

PART 1 - GENERAL



B. Section 16262 – Static Frequency Converter

C. Section 16262 Appendix A – SFC Technical Data Sheets

1.02 DOCUMENT SUBMITTAL SCHEDULE

The following tabulation identifies the minimum requirements for document submittals. Refer to individual specifications for other requirements:

Bid 30 60 90 100

Fab

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g DOCUMENT DESCRIPTION

X X QA Program

X X Special Procedures and Safety Program

X X Project management manual

X X Project control procedures

X X Project planning, scheduling & cost control procedures

X X Project team organization

X X

Resumes of key personnel

X X

Project specific milestone schedule

X X X X X X X X X Engineering schedule

X X X X X Fabrication schedule

X X X X Procurement schedule

X X X X X X Testing schedule

X X X X X Inspection schedule

X X X X X Shipping and delivery schedule

X X X X X X X Installation schedule

X X X X X Warranties and guarantees

X X Document control procedures (naming, revision control)

X X X X X X Document list and submittal schedule

X X X X Equipment test plans and reports

X X X X X Factory inspection and plan

X X X X X Site testing and commissioning plan


Bid 30 60 90 100

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DOCUMENT DESCRIPTION

X X X X X Equipment protection during shipping and installation

X

X X X Inspection/records check

X X X X X

SFC system overall description

X X X X X

System interface and integration design

X X X X X

Operating description of control system

X X X X X

System performance parameters and requirements

X X X X Operating modes

X X X X X Basis for equipment ratings

X X X X System description of digital control system description of operation

X X X X X Design considerations

X X X X X Output capability diagram over full operatign range

X X X X 60 Hz system analysis (harmonics, voltage, loading)

X X X X 25 Hz system analysis (harmonics, voltage, loading, short-circuit)

X X X X 24/12 kV transient simulations (magnitude, duration, waveforms)

X X X X Cable sizing

X X X X X Auxiliary power system ac/dc load demand

X X X

Relay protection study (incl. select/set/curves/interfaces)

X X X Instrument transformer sizing

X X X Insulation coordination study

X X X Surge arrester sizing

X X X X Special requirements for 13.2, 60 Hz kV circuit breakers

X X X X Special requirements for 24/12 kV, 25 Hz circuit breakers

X X X X Environmental conditions

X X X X Equipment heat rejection

X X X X Reliability/maintainability analysis

X X X X Life expectancy analysis

X X X X Thermal performance of power electronic equipment


Bid 30 60 90 100

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X X X X Definition of performance guarantees (losses, harmonics, full-load power output , power factor, short-circuit capability)

X X X

Noise level study X X X

Electromagnetic compatibility study

X X X X

SFC power block equipment specification

X X X 60 Hz input transformer specification

X X X 60 Hz reactor and filter specification

X X X Precharging circuit breaker specification

X X X Padmount transformer specification

X X X 25 Hz output transformer specification

X X X 25 Hz reactor and filter specification

X X X X Grounding and bonding specification

X X X Protection and control specification

X X X X Heating, ventilation, and air-conditioning specification

X X X SFC cooling system specification

X X X Power distribution equipment specification

X X X UPS/Battery system specification X X X

Station control network specification (SCADA, RTU)

X X X Sequence of events recorder specification

X X X Transient fault recorder specification

X X X Cable specifications

X X X X X Overal system single-line diagram

X X X X X ac system single-line diagram

X X X X X dc system single-line diagram

X X X X X SFC equipment-to-station interface drawings

X X X Relay logic diagrams

X X X X Digital control logic diagrams

X X X X Protective relaying and metering diagrams (full-line)

X X X Protecitve relaying and control schematics

X X X Power and control schematics


Bid 30 60 90 100

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X X X Block diagrams (cables, wire IDs between equipment)

X X X

Interconnection wiring diagrams X X X

Internal equipment wiring diagrams

X X X X

Estimated number of external terminations (pwr/cont.)

X X X X X

Cable numbering scheme X X X

Cable schedules

X X X Power panel layouts

X X X Relay cabinet layouts

X X X SER cabinet layout

X X X SCADA cabinet layout

X X X Converter system control panel layouts

X X X X X SCADA point count

X X X SCADA point list

X X X X X Annunciator panel point count

X X x Annunciator point list

X X X X X General site layout drawings

X X X X X General equipment layout drawings

X X X X X Equipment dimensional drawings

X X X X X Equipment clearance requirements

X X X X X

Equipment electrical interfaces

X X X X X

Equipment mechanical and structural interfaces

X X X X Equipment front views

X X X X Equipment section views

X X X Bus duct drawings

X X X Converter assembly drawings

X X X Converter busbar arrangements

X X X Converter potential equilization

X X X Converter physical protection and covers

X X X Converter transducer arrangements

X X X X Foundation loading drawing

X X X Equipment anchoring drawings

X X X Equipment supporting structure drawings

X X X Process and instrumentation diagrams (P&IDs)


Bid 30 60 90 100

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X X X X Field piping specification for heat exchangers

X X X

Equipment nameplate schedule (lines, size, letter height)

X X X X X

List of all equipment provided by SFC vendor

X

X X X

Equipment weights

X X X X X

Equipment ratings

X X X X X SFC rating

X X X X X Completed technical data sheets

X X X Relay technical data

X X X X Equipment reliability data

X X X Thermal heating limit capability curve for filters

X X X Bill of materials (comprehensive, categorized)

X X X Spare parts recommendations

X X X Special tools

X X X Construction/installation documents

X X X X X Detailed installation/erection/mounting drawings and details

X X X X Operation training

X X X X Maintenance training

X

X X

Recommended inspection/maintenance schedule

X X X Operation and maintenance requirements

X X Operating manuals

X X Maintenance manuals

X X Certified test reports

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION

NOT USED

END OF SECTION



Wayne Junction SFC 16262C-1 60% Design Submittal Rehabilitation Project November 29, 2016

SECTION 16262 - APPENDIX C

SFC CONTRACTOR QUESTIONNAIRE

PART 1 - GENERAL


A. Section 16262 – Static Frequency Converter

B. Section 16262A – SFC Technical Fill-In Data Sheets

C. Section 16262B – SFC Document Submittal Schedule

PART 2 - PRODUCTS

2.01 TECHNICAL FILL-IN DATA SHEETS

The SFC Contractor shall complete the following questionnaire and submit to SEPTA with the Request for Proposal Bid Documents.

Note that the numbering of the questions follows those presented in the 15% Scope Definition Report. Some questions have been deleted, some revised, and a few new questions have been added.


No. Question Response 1. Converter system - existing equipment 1.a Are you able to rehabilitate the existing cycloconverter

power block equipment? This would involve refurbishing all thyristor-controlled power equipment to restore the system to like-new performance, with an expected lifetime of no less than forty years. Please describe how equipment would be refurbished.

1.b Are you able to rehabilitate the existing control room equipment? This would involve refurbishing all control room equipment, including converter computers, load sharing equipment, and converter protection relays, to restore the system to like-new performance, with an expected lifetime of no less than forty years. Please describe how equipment would be refurbished.

1.c If proposing new SFC power-block equipment (the latest technology), are you able to use the existing SFC input and output power transformers? If technically compatible, would you be able to refurbish in order to achieve an expected lifetime of no less than forty years?

2. Converter system - new equipment 2.a Are you able to provide a new SFC system that will be

technically and functionally compatible with SEPTA's existing 60 Hz-to-25 Hz power supply system? In other words, can you provide a replacement converter system that will meet SEPTA's requirements?

2.b What type of converter system do you propose, e.g., dc-link, cycloconverter?


No. Question Response 2.c What type of power electronics is used in your converter

system, e.g., IGBT, IGCT?

2.d Is there inherent redundancy with your design? For example, if one module fails, will the converter keep functioning and supply real and reactive power to the 25 Hz system?

3. Converter system operation 3.a.1 The existing cycloconverters are rated as follows:

Each can supply 15 MVA continuously, then supply an overload of 18 MVA for 1 hour, 24 MVA for 6 minutes, 30 MVA for 30 seconds, and 4000 A for 2 seconds at 12 kV, followed by 15 MVA for 1 hour before next overload cycle. Please confirm your equipment will meet these ratings: 15 MVA continuous power 18 MVA for 1 hour 24 MVA for 6 minutes 30 MVA for 30 seconds 4000 A for 2 seconds at 12 kV followed by 15 MVA for 1 hour before next overload cycle Input power factor: ≥0.95 lagging Output power factor: ≥0.7 lagging

3.d Are your proposed converters a standard design or do you propose to modify your standard design (either increase ratings or decrease ratings) in order to meet the SFC continuous and overload power requirements?

3.e What are the benefits of your proposed technology over the other available vendor equipment on the market today?


No. Question Response 3.f Please provide electrical single-line and schematic drawings

for the proposed system to assist with bid evaluation.

3.g Please provide an estimated value and duration of short-circuit current that each converter will supply during a fault on the 60 Hz system or a fault on the 25 Hz system. Assume that the short-circuit is on the supply side of the 60 Hz circuit breaker or the load side of the 25 Hz circuit breaker. As a minimum, the 12 kV, 25 Hz side shall supply 4000 A for 2 seconds.

3.h With the converter step-down transformers supplied from a 13.2 kV, 60 Hz, three-phase system, what is the minimum and maximum required short-circuit current, voltage regulation, voltage transients, and voltage harmonics permissible from the utility or railway system in order for your SFC system to operate correctly?

3.i The present Wayne Junction SFC station transmits power from 60 Hz to 25 Hz only. Can your converter system operate with power flowing in either direction? Can the converter supply power from SEPTA's 25 Hz system to PECO's 60 Hz system?

3.j Are there any special requirements for your proposed converters to operate in parallel with SEPTA's existing three 15 MVA cycloconverters on the same 24/12 kV, 25 Hz, single-phase bus?


No. Question Response 3.k Describe how the new SFC units will share real and reactive

power load with the existing cycloconverters. In order to share real and reactive power equally, will the new converter equipment need to interface with the existing loading sharing equipment at Wayne Junction? Note that the existing load sharing equipment was designed for the addition of a fourth unit. Please address whether you will need to perform a field test to determine the existing SFCs' droop curves (real power vs. load angle, reactive power vs. bus voltage).

3.l Are there any issues with operating new SFC technology in parallel with existing cycloconverters? For example, the existing cycloconverters have filters on both 60 Hz and 25 Hz sides. Will this impact the design or operation of new SFCs, considering that the existing filters will most likely be removed if four new SFCs are provided?

3.m Describe the startup and shutdown operating sequence and instructions for your equipment. For example, are there any special synchronizing requirements or procedures required for your equipment? How are the 60 Hz and 25 Hz circuit breakers controlled?

3.n What are the operating modes of the converters, e.g., startup (black start), power operation, reactive power operation?

3.o Can the converters operate during a momentary loss of 60 Hz utility power? What is the time of the longest allowable momentary loss of 230 kV, 60 Hz supply voltage that the converters can withstand before they need to be automatically separated from the 60 Hz system?


No. Question Response 3.p Can the converters operate during a continuous loss of 13.2

kV, 60 Hz, 3-phase utility power to function as a source of reactive power to SEPTA's 25 Hz system, given that 480 V auxiliary power is still available?

3.q What are the no-load losses and full-load losses of each (15 MVA) converter unit operating separately? What are the no-load losses and full-load losses of all four converter units operating together? Please provide a graph of losses as a function of loading from 0% load to 100% load. The losses shall be for a single converter unit between the 13.2 kV terminals of the input transformer to the 24/12 kV terminals of the output transformer or reactor. Losses shall include all auxiliary power system components.

3.r What are the harmonic currents expected from the converter system during normal operation? During full-load operation, what are the typical values of the fundamental and harmonic currents? Provide the values for current in amperes for the fundamental and each harmonic.

3.s How is harmonic current control designed into your system? For example, are the input and output transformers specially designed to reduce harmonics or sound? Are filters required to reduce harmonics?

3.t Are there any special electromagnetic interference mitigation requirements? For example, do the converters require a Faraday cage or special screens around the converter buildings?

3.u What are the noise levels associated with the converter in full power production?


No. Question Response 3.v What is the highest normal operating voltage of the SFC

power block? If you are using open-rack equipment with exposed energized parts, this will determine clearance space around equipment per NFPA 70, The National Electrical Code. Please note that this project plans on requiring that the room housing the SFC power block is automatically de-energized as soon as a door is opened to the room - no person will be allowed to work on or near energized SFC equipment.

4. Layout, Dimensions, and Weights 4.a Based on the site dimensions provided on RFP drawings,

will your proposed converter system equipment fit within the available areas, e.g., filter yards, input and output transformer areas, SFC rooms, control room, roof? What are the major components that will be placed in these areas?

4.b What are the minimum clearances required to bring your SFC equipment into the SFC rooms? Are the doorways and corridors wide enough to bring your new equipment into the building? Are doorway heights sufficient? Are SFC room heights sufficient?

4.c What are the minimum clearances required around the completed SFC equipment after installation?

4.d Describe the typical building requirements for your complete converter system, e.g., control room, converter room, pump and water conditioning, air cooling and ventilation, fire protection.

4.e Can any of the equipment be designed for multi-story construction so that physical layout space can be reduced? For example, can the heat exchangers be placed on the SFC building roof?


No. Question Response 4.f Please provide typical layout drawings with dimensions and

labeled components. Provide the overall converter system dimensions, i.e., area required for input transformers, filters, converters, cooling system, output transformers, and reactors. Note that equipment must fit within the designated areas on RFP drawings.

4.g Provide the 60 Hz input transformers dimensions and weights, including tank, radiators, and conservator.

4.h Provide the 60 Hz filter and/or reactor dimensions and weights.

4.i Provide the SFC power block dimensions and weights.

4.j Provide the dc filter dimensions and weights.

4.k Provide the cooling equipment dimensions and weights.

4.l Provide the 25 Hz output transformers dimensions and weights, including tank, radiators, and conservator.

4.m Provide the 25 Hz filter and/or reactor dimensions and weights.

4.m What are the foundation requirements of your equipment?

4.o The existing SFC thyristor equipment is enclosed in metal panels within the SFC rooms. Personnel are able to walk into the SFC rooms while the equipment is in operation. To access SFC #1 room, personnel walk from the control building corridor, through SFC #2 room, and into SFC #1 room without shutting down equipment. Will your proposed SFC equipment be enclosed in metal cubicles? Note that access to SFC power block equipment rooms will be prohibited when equipment is energized.

5. 60 Hz input transformers 5.a What type of input transformers are required, i.e., number

transformer tanks per converter, number of windings per tank, connection type, grounding?


No. Question Response 5.b What type of transformer cooling is provided, i.e., fans, oil,

water?

5.c How many gallons of oil per tank, radiators, and conservator?

5.d Does your design use "charging transformers"? These are typically energized prior to energizing the main transformers in order to charge the converter capacitors or power transformer magnetizing circuits, reducing the inrush current when starting the system.

5.e What type of transformer insulating oil is being offered? 6. 60 Hz filters 6.a Are 60 Hz harmonic filters required?

6.b How is filtering accomplished? Are there separate filters? Are they always in operation?

7. DC filters 7.a Are DC harmonic filters required?


8. 25 Hz filters 8.a Are 25 Hz harmonic filters required?


9. 25 Hz output transformer and/or reactors 9.a What type of output transformer is required, i.e., number

tanks per converter, number of windings per tank, connection type, grounding?

9.b What type of transformer cooling is provided, i.e., fans, oil, water?

9.c How many gallons of oil per tank, radiator, and conservator?


No. Question Response 9.d The converters are required to supply power to a 24/12 kV,

25 Hz, single-phase traction power substation. If no step-up transformers are required, will the new converters require any type of reactors?

9.e What type of transformer insulating oil is being offered?

10. Circuit Breakers 10.a Are there any special circuit breaker requirements for the

13.2 kV, 60 Hz, 3-phase side of the converters? The existing circuit breakers used for each SFC are Siemens type GM1-1000-3000-77 vacuum interrupters rated 15 kV, 3000 A. There is a spare circuit breaker of the same model that could be used for SFC #4.

10.b Are there any special circuit breaker requirements for the 24/12 kV, 25 Hz, 1-phase side of the converters?

11. Auxiliary Power System 11.a The station has 480 V, 60 Hz, 3-phase power available for

supporting the SFC auxiliary systems. What type of auxiliary power system is required to supply the converter system during shutdown, startup, and normal power operation?

11.b What is the required capacity of the ac auxiliary power system for each converter unit, including all auxiliary supporting equipment?


No. Question Response 11.c What is the required capacity of the dc auxiliary power

system, including charger size and battery amp-hour capacity?

11.d What is the longest allowable momentary loss of the 480 V, 60 Hz auxiliary power distribution system that the converter system can withstand before it stops supplying power to the 25 Hz railway system?

11.e The Project plans on supplying two independent 480 V, 60 Hz, 3-phase power feeders directly to the SFC power distribution equipment for each SFC unit (a total of eight power feeders for all four SFCs). It is assumed that each SFC power distribution panel will have a transfer switch between the two supplied 480 V power feeders. It is also assumed that each SFC power distribution system has a dry-type transformer to step voltage down to 208Y/120 V ac, or any other voltage required to operate the SFC system. Please confirm the assumptions and describe your local SFC power distribution system.

11.f The Project plans on supplying the roof mounted air-conditioning system for each SFC room from the SFC power distribution system located in the SFC room, which is fed from the two independent 480 V power feeders. This allows each SFC room to operate independently, including local power distribution to auxiliary equipment. Please confirm this method is acceptable.

12. Protection 12.a What type of converter protection systems are required?

12.b For internal faults, how does the converter trip the 60 Hz system input circuit?

12.c For internal faults, how does the converter trip the 25 Hz system output circuit?


No. Question Response 12.d* Where will the 60 Hz and 25 Hz transformer protection

relays be located, e.g., within your proposed converter control building?

13. Environmental Cooling, Heating, and Air Handling 13.a What type of cooling system is required for converter

operation?

13.b What type of heating and cooling systems are required for the buildings?

13.c How many pumps are required to operate the converter cooling system?

13.d Are there pollution limitations or filtration requirements?

13.e What are the environmental conditions required for the converter system components?

13.f Is there redundancy in the cooling, heating, and air handling equipment for the converters?

13.g Does the cooling system have a remote tank for cooling liquid level monitoring and filling?

13.h Are there any check valves or monitoring on the cooling system to stop the flow of coolant should there be a coolant rupture?

13.i How are the cooling tubes connected to the system, e.g., quick-connect, bolted?

13.j How much heat is given off of a SFC unit during full-load operation?

13.k At what temperature and humidity must the SFC room be maintained during full-load operation and when the SFC is shut down?


No. Question Response 13.l Is a moisture or humidity control system required?

14. Communications and Controls 14.a What type of computer operating system do the converters

use?

14.b What type of computer communication protocols are used?

14.c Are the communication system languages proprietary?

14.d How is the converter system operated? Can it be operated locally and/or remotely?

15. Manufacturing 15.a Describe how you can comply with "Buy America"

requirements per United States Code Title 49 (49 U.S.C.), Section 24405(a)(1), i.e., how you will use steel, iron, and manufactured goods for this project that are produced in the United States.

15.b Provide the manufacturer names and locations where the major components will be made.

16. Testing and Commissioning 16.a How will the system be tested and commissioned? The

Wayne Junction station must be kept operational at all times with a minimum of two SFCs in-service.

16.b If components of the system need to be separated or specially built to accommodate the limited space requirements at the Wayne Junction site, how will this affect the commissioning of the system?

17. Shipping


No. Question Response 17.a What is the largest item to be shipped to the site? What are

the dimensions and weight of this item?

17.b How are components shipped? Describe the contents of typical shipping sections, e.g., transformer tanks, radiators, conservator, converter power block, cooling system components, filters, etc.

17.c Will the converter power blocks be pre-assembled, tested, and installed in a final containment prior to shipping to the site, or will the power blocks be assembled, installed, and tested inside the SFC rooms after arriving at site?

18. Assembly 18.a Who will be required to assemble the equipment at the

Wayne Junction site? Will the assembly of equipment require special supervision by the SFC manufacturer?

18.b Is special training required to assemble the equipment?

18.c What is the estimated division of labor while assembling the converter system at the Wayne Junction site, e.g., 20% by the SFC vendor and 80% by others?

19. Maintenance and Support 19.a What is the normal maintenance schedule for your provided

equipment?

19.b Where are the converter maintenance facilities located?

19.c Where is "customer support" located?

19.d Where are replacement parts built?

19.e Are the maintenance and support personnel part of the same company that designed and installed the equipment?

20. Training 20.a Is special training required to maintain your equipment?


No. Question Response 20.b What type of training program is recommended? 21. Parts 21.a Are any proprietary parts requiring SEPTA to buy

replacement parts from only one vendor?

21.b Are the parts for proposed converter system used by your company in any other industry? For example, are any parts of the converter power block used in the wind generation industry or motor drive industry? Can any parts of the converter system be directly replaced by parts used in these other industries? Please provide specific examples where your converter parts are currently being used, such as the name of the product line and number of these products being used.

21.b.1* SEPTA is concerned that converter system parts may become obsolete within 20 years. Specific parts of concern are the control cards or power electronic devices. In your proposal, you confirmed that the parts used by your proposed converter system are also used by your company in any other industries. Please provide specific examples where your converter parts are currently being used, such as the name of the product line and number of these products being used.

21.c Can the parts supplied by your converter system be supplied by several vendors or are they exclusive?

21.d What are the life spans of the components?

21.e What is the designed life span of the power delivery system?

21.f What is the designed life span of the cooling system?

21.g What is the design life of the converter control system?

21.h How many major parts are in the system? Describe how they are grouped or preassembled.


No. Question Response 21.i What parts of the converters are considered modular?

21.j Are there any hazardous materials associated with your proposed system? If so, please provide references to material safety data sheet (MSDS) information.

22. Reliability

22.a What are the mean-time-between-failure (MTBF) indices for the major components of the converter system? Please provide a system availability calculation to evaluate the statistical performance of the system over a long period of observation in terms of the mean time between failure (MTBF) for components and the system.

22.b What are the failure rates?

22.c What are the repair times for various failure modes of your equipment?

22.d What is the availability of parts?

22.e How many years have the parts supplied with your system been in service in the industry?

23. Experience and References 23.a How many similar sized facilities does your company have

in operation?

23.b What is the commissioning date of the last supplied similar facility? Where is it located?

23.c Please provide references for your equipment installed in similar conditions. References shall include client name, installation date, installation location, type of system, system ratings, contact information, and cost.


No. Question Response 23.d Please provide a summary of any known failures of

operating converter systems supplied by your company. Provide a brief summary of the failure and how your company responded to the failure. For example, if your converter technology was known to recently experience high-voltage transients when an output fault was cleared, how was this deficiency corrected?

23.e Have you installed and tested a similar type of facility to Wayne Junction? For example, has your company installed new SFC units in parallel to existing older SFC units at the same substation? If so, how were the units made to share real and reactive power load?

24. Cost Proposal 24.a Provide your cost based on supply of: 60 Hz filters and/or

reactors as required; 60 Hz input transformers; the SFC power block equipment; associated cooling and control equipment; 25 Hz output transformers; 25 Hz filters and/or reactors as required; protective relays and instrument transformers; all interconnection wiring and bus work; design engineering associated with the supply of the SFCs and related equipment; factory testing; delivery; installation support; and commissioning.

25. Schedule 25.a Please provide the schedule for the design, production,

factory testing, shipping to the Wayne Junction site, assembly at the site, site testing and commissioning, training, and turnover for SEPTA operation.


No. Question Response 26. Construction Phasing 26.a There are three existing SFC units with one new unit to be

added at Wayne Junction. Two SFC units are to remain in-service, with on in stand-by, at all times during the replacement of the three existing units and addition of the new unit. The Project is planning on building the new SFC #4 building first, then replacing SFC #3, SFC #1, and SFC #2, in that order. The sequence is based on a planned method of removing equipment from each room. Each unit must be commissioned at the completion of each unit's installation. Please provide your suggested construction phasing sequence, including demolition, installation, and commissioning requirements.

26.a.1 Based on your site walkdown, do you have any suggestions for construction phasing, demolition, installation, or commissioning?

26.c The Project is planning that SFC rooms will be accessed by constructing a wall between the existing outside doorways and the SFC power block equipment. The SFCs will be accessed through double-doors from the new corridor. This will keep the SFC power block equipment free of debris. SFC power distribution equipment, controls, and pump skids would be located in this corridor area, outside of the SFC power block room. Please provide your assessment of this proposed installation arrangement.

END OF SECTION


SECTION 16290

PROTECTIVE DEVICES AND INSTRUMENT TRANSFORMERS

PART 1 - GENERAL


A. This Section specifies general requirements for application of protective relays, instrumentation, and associated devices.

B. Detailed requirements are specified in the relevant individual equipment sections. The equipment sections and the Contract Drawings describe the minimum protective scheme required and are intended to serve as an aid to the functional requirements. Components such as auxiliary relays, isolating diodes, fuses and other similar devices required for a complete installation are not individually specified, but shall be provided by the Contractor.



B. Section 01452 – Contract Quality Control – Traction Power Equipment


D. Section 01752 – Spare Parts and Maintenance Manual – Traction Power Equipment

E. Section 01822 – Demonstration and Training – Traction Power Equipment

F. Section 01832 – Operations and Maintenance Manuals – Traction Power Equipment


H. Section 16052 – General Electric Requirement – Traction Power Equipment



K. Section 16330 – Medium Voltage (2-Pole) Breakers – Switching and Protection

L. Section 16335 – Surge Arresters

M. Section 16952 – Electrical Testing – Traction Power Equipment

1.03 SUBMITTALS

A. Submit the following documents and samples for SEPTA’s review and approval:

1. Data: Provide technical product data sheets for all items of the system equipment. Include the following equipment:

a) Current transformers

b) Potential transformers

c) Protective devices

d) Auxiliary relays

e) Measuring instruments

f) Indicating devices


g) Cables and wires

h) Equipment enclosure

i) Terminal blocks and connectors

2. Product Samples

a) The Contractor shall submit samples of the following products for approval:

1) Cables and wires

2) Terminal blocks and connectors

3) Furnish relay setting software for each relay.



1. ASCII General American National Standard Code I

2. IEEE Std 242 Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems

3. IEEE C2 National Electrical Safety Code

4. IEEE C37.1 Definition, Specification, and Analysis of Systems Used for Supervisory Control, Data Acquisition, and Automatic Control

5. IEEE C37.2 Standard Electrical Power System Device Function Numbers

6. IEEE C37.90 Relays and Relay Systems Associated with Electric Power Apparatus

7. IEEE C37.90.1 Standard Surge Withstand Capability (SWC) Tests for Protective Relays and Relay Systems

8. IEEE C37.97 Protective Relay Applications to Power System Busbars

9. IEEE C37.112

10. IEEE Standard Inverse-Time Characteristics for Overcurrent Relays

11. IEEE C39.1 Requirements for Electrical Analog Indicating

12. Instruments IEEE C57.13 Requirements for Instrument Transformers

13. NEMA C1 Electrical Power Connectors for Substations

14. NEMA EI2 Fittings, Cast Metal Boxes, and Conduit Bodies

15. NEMA FB 1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies NEMA ICS4 Terminal Blocks for Industrial Control Equipment and Systems NEMA ICS6 Enclosures for Industrial Control Systems

16. NEMA LA 1 Surge Arresters

17. NEMA PB 1 Panelboards

18. NFPA 780 Lightning Protection Code

19. UL486A Lugs for Use with Copper Conductors Wire Connectors and Soldering UL 508 Electrical Industrial Control Equipment


PART 2 - PRODUCTS

2.01 PROTECTIVE DEVICES

A. Protective Relay Scheme Design. Design and provide a comprehensive protective scheme to protect the substation equipment and the overhead distribution system, as well as to provide back-up protection to the vehicle protective devices.

1. Base the protective scheme design on the load, overload and short circuit currents.

2. Select the characteristics and ranges of all protective devices to ensure satisfactory coordination of all devices and a fast fault clearance.

B. Provide sufficient hard wire connections for all protective functions to allow for all

substation equipment, including the 12 kV and 24 kV switchgear, autotransformer circuit breakers and autotransformers, to continue to be functional, via local control, in the event of failure of any bay module, local area network, gateway computer, or any part of the SCADA or communications equipment.

C. Relay Types. Select solid-state, microprocessor based, multifunction, self reset protective relays. All main functions of the relays shall be individually configurable on a computer and shall be enabled or disabled by the user by means of straightforward configuration procedure.

D. Mechanical Design. Provide high quality, utility-type, protective relays of modular design enclosed in rustproof, dustproof, metal or high-impact plastic cases suitable for flush mounting on equipment cabinets.

E. Control Panel. Provide relays with provisions for relay setting, adjustments, and testing from the front of the relay. Provide each protective relay with readily visible and accessible LCD control panel integrated with the relay. The panel shall enable entry of all data required for operation of the relay, including the following:

1. Readout and modifications of settings

2. Readout of measured data

3. Readout of operating data logs and of monitored signal logs

4. Readout of event logs, at least last 10 events

5. Support relay testing and commissioning tasks

F. Self-monitoring. Provide each relay with comprehensive and continuous self-monitoring capability ensuring that hardware and software errors are detected and do not cause malfunction of the protective device. Depending upon the fault diagnosis, the self-monitoring system shall issue alarm or block the relay operation. Provide all relays with provision to annunciate operation and failure on the relay as follows:

1. Locally, the relay operation, alarm, and failure shall be indicated by light emitting diodes (LEDs).

2. Remotely, provide each relay with a sufficient number of contacts and outputs to enable operation, alarm, and failure of the relay to be indicated on the SCADA system.

G. Relay Arrangement. All protective relays shall be arranged to be conveniently accessible, easily visible, and logically grouped. Devices of related functions shall be located in


proximity to each other. The protective relays shall be installed on the cubicle door and shall be semi-flush mounted.

H. Maintenance and testing. Provide test switches to disable all tripping circuits of the relay in the event that it is necessary to remove the relay for service or replacement or for testing the relay functions. Provide test switches so that current transformer circuits shall be short-circuited and potential transformer circuits shall be open-circuited prior to the relay removal from its case or its rack or for testing the relay functions.

I. Other Features. Provide the protective relays with the following features:

1. Internal clock for event logging capable of being synchronized to the communications protocol.

2. Silver or silver/copper alloy non-bonding contacts.

J. Approved Manufacturer: Areva, MiCom series of relays, or approved equal.

2.02 PROTECTIVE RELAY PHILOSOPHY

A. For description of the relays refer to the circuit breaker specifications 16330.

B. SFC Output transformer Faults

1. Output transformer protection shall include overcurrent relays, differential relays as well as pressure relief, temperature and low oil devices. The relays shall trip the respective transformer circuit breaker via hand reset and electrical/hand reset lockout relays.

C. Trolley-to-Ground Faults

1. Trolley-to-ground faults shall be detected by distance relays. Following a trolley-to-ground fault, only the trolley circuit breakers feeding the faulted section of the trolley system shall open.

D. Feeder-to-Ground Faults

1. Feeder-to-ground faults shall be detected by distance relays and feeder differential relays. Following a feeder to-ground fault, only the feeder circuit breakers feeding the faulted section of feeder shall open.

E. Feeder-to-Trolley Faults

1. Feeder-to-trolley faults shall be detected by the feeder distance relays, the trolley distance relays and the feeder differential relays when installed in the future. Following a feeder-to-trolley fault, the 24 kV feeder circuit breakers feeding the faulted section of feeder shall open, while all 12 kV trolley circuit breakers shall be blocked closed until the feeder circuit breakers have opened.

2. Following opening of the feeder circuit breakers, the trolley circuit breakers serving the faulted line shall open.

F. Busbar Faults

1. Busbar faults shall be detected by instantaneous bus differential relays.

2. Upon operation, a bus lockout relay shall trip all circuit breakers connected to the bus.

G. Trolley/Feeder Protection Back-up


1. No additional circuit breaker back-up relays will be necessary. Faults not cleared by the trolley/feeder protection shall be cleared by the protection of the other circuit breaker(s) connected to the bus.

H. Breaker Failure Relaying

1. Failure of trolley or feeder breakers to interrupt fault current shall be detected by breaker failure protective scheme. Following operation of trolley or feeder protective relay, fault detector relay shall pick up and two (2) timer stages shall be started.

2. If at the end of pre-selected time delay period of the first stage the fundamental of current is still above a settable threshold, this shall be an indication of a failed breaker and a re-trip signal to the second trip coil shall be issued.

3. Upon elapse of the second timer stage, a bus lockout relay shall trip all circuit breakers connected to the bus.

I. Automatic Reclosure

1. The circuit breakers shall not have automatic reclosure capability. All closing operations of circuit breakers shall be initiated locally by an operator or remotely by the power dispatcher via the SCADA system.

J. Protective Devices Wiring

1. Use copper cables for the wiring related with the protection circuits including wiring from CTs and PTs and the wiring for the trip circuits between various cubicles.

2.03 AUXILIARY, TRIPPING, AND CONTROL RELAYS

A. Provide compact, highly reliable, mechanically stable, voltage operated, self-reset, hand-reset and electrically/hand-reset auxiliary, tripping, and control relays, as required for particular application.

B. Provide each relay with flag to indicate relay operation.

2.04 CURRENT TRANSFORMERS

A. Provide current transformers (CTs) to accurately transform the system currents for metering and relaying. Select the current transformers to satisfy ANSI and IEEE requirements for metering and relaying accuracy classification under the burdens imposed by the metering and protective devices.

B. Select ring core type current transformers with toroidally wound and fully distributed secondary windings.

C. Select current transformers insulated with structural grade thermoplastic to withstand dielectric test levels of the equipment and to carry the currents occurring during rated load, overload, and short circuit currents without excessive heating or injury.

D. Provide each current transformer with a mounting frame which bolts securely to the equipment cubicle. Run secondary wiring from the current transformer terminal studs to terminal blocks. Provide the current transformer terminal blocks with covers having integral shorting bars.


2.05 POTENTIAL TRANSFORMERS

A. Provide potential transformers (PTs) to accurately transform the system voltages for metering and relaying. Select the potential transformers to satisfy ANSI and IEEE requirements for metering and relaying accuracy classification under the loads imposed by the metering and protective devices.

B. Select dry-type potential transformers with physically strong protective cases and with superior insulating properties. Contractor may propose oil-filled units for acceptance by the SEPTA Project Manager.

C. Select potential transformers with adequate insulation to withstand the dielectric test levels of the equipment and to carry their load continuously without excessive heating or injury.

D. Select the PTs with high resistance primary windings and with high knee point (not less than 1.2p.u.).

E. Protect the primary circuits of all potential transformers by means of nonrenewable cartridge-type fuses. Provide fuses with blown fuse indication. Locate the primary fuses in roll-out carriages equipped with disconnecting devices. Protect secondary circuits of all potential transformers by molded case circuit breakers mounted in the cubicle control compartment.

F. Access to the potential transformer fuses shall be prevented unless the fuses are disconnected from the primary circuit and the main secondary molded case circuit breaker is opened. Withdrawing the fuse carriage shall disconnect the primary side of the potential transformer from the power source.

G. A grounding device shall ground the fuses as the carriage is withdrawn and effectively discharge the potential transformer of any static charge.

2.06 TRANSDUCERS AND CONVERTERS

A. Select transducers and converters as required for the applications specified.

B. Choose transducers and converters with inputs compatible with outputs from CTs, PTs, and other measuring devices and outputs compatible with switchgear cubicle bay module inputs.

C. Provide compact transducers and converters to convert input variables into proportional output signals with accuracy of 0.1 % or better.

D. The transducers and converters may be stand-alone devices or may be an integral part of relays or measuring devices.

E. Install the transducers and converters in a suitable enclosure.

2.07 INSTRUMENTATION

A. Provide high quality, metal case, semi-flush, four and one-half inches (4-1/2") square, switchboard type meters with accuracy of one percent of full scale value.

B. Select all instruments to match the input signals, including fault currents.

2.08 INDICATION

A. Provide illuminated and non-illuminated indication for all key functions of the equipment as specified herein.


B. All illuminated indication shall be by LEDs located on cubicle doors. The indicators may consist of individual LEDs or clusters of LEDs, depending on the required brightness. In order to identify LED failures, each LED or group of LEDs shall have a push-to-test switch located conveniently near the LED or group of LEDs. When depressed, the test switch shall disconnect the normal circuit feed and cause the LEDs to illuminate. The LED color shall be selected by the SEPTA during shop drawing review.

2.09 TEST BLOCKS / TEST SWITCHES

A. Provide test blocks in semi-flush cases of uniform sizes suitable for panel mounting.

B. Wire the test blocks to provide a direct access to the system protection and measurement. Include the following monitoring and testing functions:

1. Recording of all instrument-measured functions

2. Monitoring of CT currents and PT voltages

3. CT short-circuiting

4. CT secondary injection testing

5. Operation of circuit breakers

6. DC auxiliary power monitoring

C. Provide a dull-black dust cover permitting covering of the test blocks when not in use.

2.10 ANNUNCIATION

A. Provide the substation with internal annunciation system consisting of convection cooled, modular design and solid-state programmable annunciator. Design the annunciator using LED indicating lamps and audible alarm. Include test, silence, acknowledge and reset switches, as well as other associated equipment. Contractor may propose alternative type of annunciator subject to approval by SEPTA. E.g. Contractor may propose a substation PLC using a HMI for annunciation and system trouble shooting.

B. Design the audible alarm to operate only when the annunciator control switch is in "Local" position.

C. Display the following functions:

1. Transformer Overtemperature

2. Transformer Low Oil Level

3. Transformer Differential Relay Operation

4. AC station power loss.

5. DC auxiliary power loss.

6. Bus differential relay operation

7. Substation air temperature high.

8. Fire alarm.

9. Intrusion alarm.

PART 3 - EXECUTION


3.01 TESTING

A. Perform applicable tests on the following equipment:

1. Indicating Instruments. Test indicating instruments in accordance with IEEE C39.1.

2. Relays and Transducers. Test relays and transducers in accordance with IEEE C37.90 and IEEE C37.90.1.

3. Instrument Transformers. Test instrument transformers in accordance with IEEE C57.13 and NEMA E121.

4. Annunciator. Test annunciator in accordance with IEEE C37.90.

END OF SECTION


SECTION 16335

SURGE ARRESTERS

PART 1 - GENERAL


A. Furnish suitable surge arresters and voltage surge protective devices (SPD) to protect substation equipment against overvoltages.






1.03 SUBMITTALS


1. Product Data: Provide technical product data for the following equipment:

a) Surge arresters

b) SPD

c) Connecting wires and cables

2. Manufacturer's certified test data. Include evidence that the arresters and transient voltage surge suppressors conform to the specified standards.



1. ANSI C.2 National Electrical Safety Code

2. IEEE C62 Surge Protection, Standards Collection

3. NFPA 780 National Fire Protection Association, Lightning Protection Code

4. UL 96 Lighting Protection Components

5. UL 96A Installation Requirements for Lightning Protection Systems

PART 2 - PRODUCTS

2.01 PROTECTED EQUIPMENT

A. Protect power equipment outside and within the substation as appropriate, including the following equipment:

1. 13.2 kV, 3 ph, 60 Hz equipment and cables between the 230 kV Control Building and 60 Hz SFC transformers/reactors

2. 12/24 kV, 1 ph, 25 Hz equipment and cables between the 25 Hz SFC transformers and 25 Hz Wayne Junction Traction Power Substation (WJTPS)


3. 60 Hz and 25 Hz transformers (by SFCC)

4. 60 Hz panelboards

B. Protect electronic equipment, including, but not limited to:

1. Power supplies and battery chargers

2. Switchgear electronic equipment including SCADA devices

3. Remote terminal unit

4. Data communication lines

5. Voice communication lines

C. Select the protective equipment voltage rating, energy dissipation rating, and other characteristics compatible with the equipment to be protected.

2.02 OVERVOLTAGE PROTECTION

A. Protect all electrical and electronics equipment. Take into account the following:

1. Possible sources of overvoltages

a) Lightning strikes in the project locale

b) Circuit breaker switching surges

c) Electrical noise level

d) Presence of high voltage overhead lines

2. Location of equipment

a) Outdoor equipment: Take into account the maximum expected overvoltage.

b) Indoor equipment: Take into account the equipment distance from the service entrance.

3. Equipment type

a) Voltage level of equipment input and output

b) AC or DC power input and output

c) Analog or digital signal input and output

d) Voice or data signal input and output

4. Ground grid resistivity at the substation location

B. Design and coordinate equipment insulation and protection at three levels:

1. Use primary level of protection at the electrical service entrance. Design the primary level devices to protect equipment against the bulk of surge energy and noise.

2. Use secondary level of protection directly in front of the protected equipment. Design the units to allow for protection against surges that pass the primary level protection.

3. Use tertiary level of protection, also called equipment withstand capability, to protect against all remaining overvoltages.


4. Coordinate all three levels of protection to ensure that, following a lightning strike, switching surge, or increase in noise energy, the protective devices clamp the voltage at the terminal of each item of equipment to safe level.

C. Provide the following:

1. A sufficient number of appropriately rated protective devices suitable for the protected circuit voltage level and functional requirement. Protect circuits using the following equipment:

a) Surge arresters with surge counters

b) Transient voltage surge suppressor (TVSS) devices

2. An adequate bonding of equipment to reduce potential differences between equipment and limit circulating currents.

3. A low resistance grounding system for the protected and protective equipment to safely shunt overvoltages to ground grid

2.03 SURGE ARRESTERS

A. Locations

1. 13.2 kV, 3 ph, 60 Hz system

a) Provide phase-to-ground and phase-to-phase arresters on the new SFC #4 open-air buses.

b) Replace the phase-to-ground and phase-to-phase arresters on the existing SFCs #1, #2, and #3 buses, if required on Contract drawings.

2. 12 kV and 24 kV, 1 ph, 25 Hz system

a) Provide one phase-to-ground surge arrester on each 12 kV and 24 kV bus in the 25 Hz Filter Yard for SFCs #1, #2, #3, and #4.

b) Provide one phase-to-ground surge arrester on each 12 kV and 24 kV bus in the 25 Hz WJTPS for SFC #4.

c) Locate the surge arresters on structures as shown on Contract Drawings.

d) Provide protective metal mesh as shown on the Contract Drawings to prevent damage to the disconnect switches due to projectiles in the event of the arrester rupture.

3. SFC transformers

a) Surge arresters shall be provided by the SFCC for each SFC input and output transformer

B. Ratings

1. Provide polymer body surge arresters with characteristics as shown in Table 1. Note that utilization voltages are single phase at 25 Hz.

2. Acceptable surge arresters: GE Tranquell XE, or approved equal.


TABLE 1 – SURGE ARRESTER RATINGS

Surge Arrester Characteristic 12 kV Circuits

150 BIL 24 kV Circuits

250 BIL

Class Station Class Station Class

Type Gapless Metal-oxide Gapless Metal-oxide

Rating 18 kV 36 kV

Maximum Continuous Operating Voltage (MCOV)

15.3 kV 29 kV

2.04 SURGE PROTECTION DEVICE (SPD)

A. Provide only UL 1449 Third Edition Listed SPD.

B. Locate the SPD in close proximity of the protected devices.

C. Ratings: Consult the protected device/equipment manufacturer about the type and rating of the most suitable transient voltage surge suppressor for protection of the device/equipment. Comply with the device/equipment manufacturer recommendation, except service entrance product shall be Type 1 with a 200 kA per phase rating.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Use only UL listed materials and UL certified installers for the work associated with surge and lightning protection system.

1. Surge Arresters

a) Install surge arresters on structures, as shown on contract drawings.

2. Surge Protection Device (SPD)

a) Install the SPD in accordance with the suppressor and the protected device/equipment manufacturers’ recommendations.

3.02 GROUNDING

A. General

1. Install each grounding connection via the shortest possible route without unnecessary bends and kinks in the grounding conductor.

2. Splices are not allowed in the grounding connections.

B. Surge Arresters

1. Ground each surge arrester to the ground bus.

2. Use the ground grid pigtails to connect the surge arrester ground bus to the ground grid.

3. Protect the conductors in a rigid metallic, non-magnetic conduit attached to the building structure.

C. Surge Protection Device (SPD)


1. Use bare stranded copper wires for connections between surge arresters and grounding busbar.

2. Use conductors and grounding techniques as recommended by the product manufacturers.

3.03 TESTING

A. Surge Arresters: Test surge arresters in accordance with ANSI C62.11.

END OF SECTION




SECTION 16411

ENCLOSED SWITCHES

PART 1 - GENERAL


A. The work specified in this Section consists of materials for furnishing, installing, connecting, energizing, testing, cleaning and protecting enclosed disconnect switches and fuses.








G. Section 16123 – Building Wire and Cable

H. Section 16950 – Testing of Electrical Equipment

1.03 SUBMITTALS

A. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card. Provide from product manufacturers a written statement indicating why an item does not have a quality assurance verification. Such statements are subject to the approval of the Project Manager.

B. Product Data and Catalog Cuts: Provide product data for all products provided. Indicate clearly the usage of each product.

C. Provide manufacturer’s instructions for all enclosed disconnect switches.


A. Provide products that are listed or labeled by Underwriters Laboratory, approved by factory mutual, or certified as meeting the standards of UL by the Electrical Testing Laboratory (ETL) for the location installed in, and the application intended, unless products meeting the requirements of these testing laboratories are not available, or unless standards do not exist for the products.

B. All work shall conform to NFPA 70, National Electrical Code.

1. Install work under supervision of licensed electricians.

C. References:

1. National Electrical Manufacturers Association (NEMA)

a) NEMA 250: Electrical Enclosures


b) NEMA KS1: Enclosed and Miscellaneous Distribution Equipment Switches


a) NFPA 70: National Electrical Code (NEC)

3. Underwriters Laboratory (UL):

a) UL 98: Standard for Safety for Enclosed and Dead-Front Switches

b) UL 198E: Class R Fuses

PART 2 - PRODUCTS

2.01 ENCLOSED DISCONNECT SWITCHES

A. Provide enclosed disconnect switches meeting NEMA Standard KS l, UL 98 and the following requirements. Horsepower, voltage, amperage, number of poles, and type shall be as indicated on the drawings.

1. Enclosure: NEMA Standard 250 Type 1, unless indicated otherwise on the drawings. Construct enclosures of code gauge (UL 98) sheet steel treated with a rust-inhibiting phosphate and finished in gray baked enamel. Enclosure furnished with manufacturer’s permanent record of switch type, catalog number, and horsepower rating.

2. Switch Mechanism: Quick-make, quick-break operating handle and mechanism forming an integral part of the box, not the cover, with positive padlocking provisions in the OFF position. Switch current carrying parts electroplated for resistance to corrosion. Switch blades visible in the OFF position when door is open. Switch lugs UL listed for copper cables and front removable.

3. Heavy Duty Type Fusible: Dead front construction with permanent arc suppressors and dual cover interlock (to prevent unauthorized opening of switch in ON position) and positive pressure fuse clips.

4. Heavy Duty Type Non-Fusible: Dead front construction with permanent arc suppressors and dual cover interlock (to prevent unauthorized opening of switch in ON position).

B. Acceptable Manufacturers:

1. Square D Company

2. General Electric

3. Cutler-Hammer


2.02 FUSES

A. Current limiting type, of voltage and amperage as indicated on the drawings. Provide one set of spare fuses for each ampere size indicated and each point of use.

1. Non-Motor Loads: Use Limitron, fast-acting, single element type, UL Class RK1.

2. Motor, Welder and Transformer Loads: Use Fusetron, dual-element, time-delay type, UL Class RK5.


B. Acceptable Manufacturers:

1. Bussman

2. Gould-Shawmut


PART 3 - EXECUTION

3.01 PREPARATION

A. Ensure that painted surfaces which will be covered by items of this section have a prime and finish coat of paint.

B. Ensure that all indoor areas are enclosed from the weather.

3.02 INSTALLATION

A. Space enclosures out from surfaces mounted on 1/4-inch (6 mm) spacers or U-Channel supports.

B. Install all disconnect switches in accordance with the manufacturer’s instructions

C. Set enclosure top 6-feet 6-inches (198 mm) above finished floor or grade unless otherwise indicated or specified.

D. Punch holes for conduit entries in the enclosures.

E. In all areas except dry areas, install conduit drain-fitting in punched hole in bottom of enclosure, conduit breather fitting in top of enclosure.

F. Interface with other work:

1. Connect conduits to enclosure with water-tight hubs except as follows:

a) The bottom of enclosures in damp locations may have a sealing locknut and interior locknut, and grounding bushing in place of a water-tight hub.

b) In dry locations, two locknuts and bushings may be used in place of a water-tight hub.

2. Connect wiring to line and load terminals with lugs provided or approved by manufacturer. Remove interior or protect interior components during wire-pulling.

3. Identify in accordance with Section 16075.

G. Protection:

1. During painting, mask all nameplates, all plastic parts, push-buttons, operating shafts and all items not to be painted.

2. Protect all items during work of other trades including welding and cutting.

3. Protect disconnect switches against overloads, short-circuits, and improper operation. Pad-lock off when work is being done on downstream circuits.


A. Site Testing:


1. Prior to energizing ensure that all load-side wiring is clear of shorts and has received and passed the insulation tests of Section 16950.

B. Perform tests in accordance with Section 16950.

END OF SECTION


SECTION 16440

PANELBOARDS

PART 1 - GENERAL


A. The work specified in this section consists of all materials for furnishing, installing connecting, energizing, testing, cleaning, and protecting wall-mounted panelboards.







F. Section 16070 – Hangers, Anchors and Supports

G. Section 16075 – Electrical Identification

H. Section 16123 – Building Wire and Cable


1.03 SUBMITTALS

A. Make all submittals in accordance with Section 01300.

B. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card.

C. Product Data and Catalog Cuts: Provide product data for all products provided. Indicate clearly the usage and designation of each product.

D. Shop Drawings: Submit shop drawings for all panelboards.

E. Provide manufacturer’s instructions for all panelboards.


A. Provide panelboards which have been design tested in accordance with NEMA PB 1.

B. Provide panelboards which have been production tested in accordance with NEMA PB 1.


D. Install work under supervision of licensed electricians.

E. References:

1. American Society for Testing and Materials (ASTM):

a) ASTM B164, Nickel-Copper Alloy, Bar and Wire.


b) ASTM B1 87, Standard Specifications for Copper Bus, Bus Bar, Rod and Shapes


a) NEMA 250, Electrical Enclosures.

b) NEMA AB 1, Molded Case Circuit Breakers and Molded Case Switches

c) NEMA AB 2, Molded Case Circuit Breakers and their Application

d) NEMA PB 1, Panelboards

e) NEMA PB 1, General Instructions for Proper Installation, Operation, and Maintenance of Panelboards


a) NFPA 70, National Electrical Code (NEC)

4. Underwriters Laboratories (UL):

a) UL 489, Molded Case Circuit Breakers and Circuit Breaker Enclosures

b) UL 50, Cabinets and Boxes

c) UL 67, Panelboards


A. Panelboards are connected to system voltages as follows:

1. 480Y/277 Volt, 3-phase, 4-wire, 60 Hz

2. 208/120 Volt, 3-phase, 4-wire, 60 Hz

PART 2 - PRODUCTS


A. Basic Electrical Materials: Those products such as conduit, wireways, wire and connectors, cable, support devices, fasteners, and similar devices as required for work of this section are as specified in other sections of these specifications.

2.02 PANELBOARDS

A. Provide dead-front panelboards as follows:

1. Accommodate bolt-on molded case circuit breakers as specified below.

2. Conform to NEMA PB 1 and NFPA 70, Article 384.

3. Consist of interiors, matching enclosures and covers of a single manufacturer as specified below.

4. Have circuit breakers of frame sizes, trip ratings, number of poles, and types as scheduled, indicated and noted.

5. Provide branch circuits phased in sequence vertically and numbered uniformly left to right, top to bottom.

B. Provide panelboards that are fully rated for a short circuit capacity as scheduled, indicated, and noted on the drawings.


C. Interiors: Provide interiors, as follows:

1. Provide tin plated main, ground and neutral copper buses conforming to ASTM B1 87 having not less than 98 percent conductivity.

2. Mount interiors on galvanized steel backplate.

3. Make provisions for future breakers and for circuit breakers in all future spaces as indicated, scheduled or noted and so that additional breakers can be mounted without additional connectors or extension of busses.

D. Provide solderless type main, sub-feed, and through feed lugs rated for copper and aluminum conductors of size, number and type, as indicated, scheduled and noted on the drawings.

E. Enclosures:

1. Provide enclosures conforming to NEMA 250 for the types as indicated, scheduled, noted, and specified. Provide NEMA 1 enclosures unless otherwise indicated on the drawings.

2. Fabricate from galvanized steel without knockouts.

3. Provide side, bottom, and top gutters of minimum 4-inch (10cm) width, of minimum 5-1/2 inch (14cm) depth, and sized as indicated, scheduled, and noted and as required by NFPA 70 Article 373 for the actual entry point.

4. Provide circuit directory of sufficient size to allow 40-characters per circuit; indicate the source of service (i.e., upstream panelboard, switchboard, motor control center, etc.) to the panelboard. Mount the directory in a transparent protective covering.

F. Doors: Provide doors as follows:

1. Provide concealed hinges and trim clamps.

2. Provide combination catch and master keyed, flat key lock with two keys for each lock and common keying throughout each building of the facility.

G. Finishes:

1. Factory finish enclosure cover completely using an electro-deposition process that deposits a complete finish coat of paint on all interior and exterior surfaces as well as bolted joints.

2. Include in the paint process cleaning, rinsing, phosphatizing, pre-paint and post paint rinses, bake-cure and cool down steps.

3. Provide overall finish capable of passing a 300-hour salt spray per ASTM B117 with less than 1/8 loss of paint from a scribed line.

H. Molded case circuit breakers:

1. Provide inverse time and instantaneous tripping characteristics.

2. Provide trip ratings, frame sizes, and number of poles as indicated, scheduled, and noted on the drawings.

3. Provide full rated circuit breakers with short circuit ratings equal to the panelboard installed as scheduled on the drawings.

4. Provide molded case circuit breakers conforming to NEMA AB 1, and UL 489.


5. Provide circuit breakers of the same manufacture and type as the panelboard installed.

I. Panelboard Types:

1. Branch Power and Lighting (208Y/120V) - Square D NQOD

2. Branch Power and Lighting (480Y/277V) - Square D NF

3. Branch Power (480Y/277V) - Square D I-Line

4. Distribution - Square D I-Line

J. Acceptable Manufacturers:

1. Square D

2. General Electric

3. Cutler-Hammer


PART 3 - EXECUTION

3.01 PREPARATION

A. Ensure that painted surfaces which will be covered by items of this section have a prime and finish coat of paint.

B. Ensure that all indoor areas are enclosed from the weather.

3.02 INSTALLATION

A. Space enclosures out from surfaces mounted on 1/4-inch (6mm) spacers or U-channel supports. Provide supports as specified in Section 16070.

B. Install all panelboards and circuit breakers in accordance with the manufacturer’s instructions and NEMA PB 1.1.

C. Set enclosure top 6-feet 6-inches above finished floor or grade unless otherwise indicated or specified.

D. Punch holes for conduit entries in the enclosures.

E. In all areas except dry areas, install conduit drain fitting in punched hole in bottom of enclosure, conduit breather fitting in top of enclosure.

F. Interface with other work:

1. Connect conduits to enclosure with water tight hubs, except in damp locations on the bottom of enclosures a sealing locknut may be used in place of water tight hubs, and in dry locations two locknuts and bushings may be used.

2. Connect wiring to line and load terminals with lugs provided or approved by manufacturer in conformance with Section 16123. Remove interior or protect interior components during wire pulling.

3. Identify in accordance with Section 16075.

G. At the end of the project update the circuit directories to reflect as-built conditions. Circuit directions shall be typed.


H. Protection:

1. During painting, mask all nameplates, all plastic parts, and all items not to be painted.

2. Protect all items during work of other trades including welding and cutting.

3. Protect panelboards against overloads, short circuits, and improper operation; padlock off when work is being done on downstream circuits.


A. Site Testing:

1. Prior to Energizing:

a) Have insulation testing and setting of overcurrent protective device adjustments made in conformance of Section 16950.

b) Ensure that all load side wiring is clear of shorts and has received and passed the insulation tests of Section 16950.

c) Open all downstream disconnects and open circuit breaker.

2. Perform tests in accordance with Section 16950.

3.04 CLEANING

A. After wiring, vacuum out interior and wipe clean of all foreign material.

B. After painting in areas, remove all over paint, drips and splashes.

END OF SECTION




SECTION 16460

LOW-VOLTAGE TRANSFORMERS

PART 1 - GENERAL


A. The work specified in this section consists of material for furnishing, installing, connecting, energizing, testing, cleaning, and protecting transformers.





D. Section 01600 – Material & Equipment

E. Section 01830 – Operation & Maintenance Data

F. Section 16010 – Basic Electrical Requirements


H. Section 16060 – Grounding and Bonding

I. Section 16075 – Electrical Identification

J. Section 16123 – Building Wire and Cable

K. Section 16130 – Raceways and Boxes

L. Section 16950 – Testing Electrical Equipment

1.03 SUBMITTALS

A. Make all submittals in accordance with Section 01300.

B. Testing Agency/Quality Verification: Provide with all product data evidence of testing agency/quality verification, listing, and labeling either by printed mark on the data or by a separate listing card. Provide from product manufacturers a written statement indicating why an item does not have quality assurance verification. Such statements are subject to the approval of SEPTA and the Project Manager.

C. Product Data:

1. List of transformers and accessories to be furnished and installed.

2. Catalog cuts of all transformers and accessories.

D. Shop Drawings: Provide shop drawings for the following:

1. Complete outline drawing in English Units, showing overall length, width, and height and including ratings of equipment, impedance, and installation restrictions.

E. Factory Tests: Submit factory test reports as specified in this section.

F. Installation Certificates: Submit Installation Certificates for transformers.


G. Project Closeout: Submit record drawings, shop drawings, product data, and Operation and Maintenance Manuals.


A. All work shall conform to regulatory requirements of all state, local, and national governing codes and requirements.

B. All work shall conform to the latest edition of NFPA 70, National Electrical Code.

C. Install work under supervision of skilled licensed electricians.

D. References:

1. Institute of Electrical and Electronic Engineers/American National Standards Institute (IEEE/ANSI)

2. National Electric Manufacturer's Association (NEMA)

3. National Fire Protection Association (NFPA): 70 - NEC


A. Design Criteria:

1. Provide transformers with ratings as indicated on Contract Drawings.

2. Provide transformers designed for the following conditions:

a) 40 degrees C. maximum ambient temperature

b) -20 degrees C. minimum ambient temperature

c) 100 feet above sea level

d) Indoor unless otherwise indicated or specified

B. Provide transformers for connecting to systems with a let-through fault capability up to the limits of IEEE/ANSI C57.12.59.

1.06 QUALIFICATIONS


1.07 DELIVERY, STORAGE & HANDLING

A. Protect items from damage during delivery, storage, and handling in accordance with Section 01600.

1.08 OPERATION & MAINTENANCE DATA

A. Submit Operation and Maintenance Manual in binder form with indexes and tabs for each Section. Conform to Section 01830.

PART 2 - PRODUCTS


A. Square D

B. General Electric


C. Cutler-Hammer

D. Or Approved Equal

1. Request for substitutions shall be made in conformity with Section 01600 and in addition the following must be included with each request:

a) Guaranteed performance data for each size including sound level, losses at full load, impedances, and size and number of taps

b) Overall dimensions for each size

c) Capacitance between windings for each shielded isolation transformer.

2.02 SECONDARY TRANSFORMERS

A. Provide general purpose, indoor, double-wound, ventilated, dry-type transformers conforming to NEMA Standards ST-20, ANSI C89.2 and NEMA TP-1.

B. Design transformer for continuous operation at rated kVA, 24 hours a day, 365 days a year, with normal life expectancy, without exceeding 150° C temperature rise above 40° C ambient.

C. The maximum temperature of the top of the enclosure shall not exceed 35° C rise above a 40° C ambient.

D. Provide 220C insulation systems. Provide final insulation treatment of total immersion in an insulating varnish that provides superior bond strength, high dielectric strength, and outstanding power factors at temperatures. Cure at normal operating temperatures for sufficient time to complete curing of the varnish and drive off all volatile elements in the varnish solvent. Provide sufficient air ducts to prevent any undesirable hot spots in the winding.

E. Wind secondary low voltage winding next to the core, for step-down service; wind secondary high voltage winding next to the core for step-up service.

F. Construct transformer core of a high quality, non-aging, low loss silicon steel with high magnetic permeability, and low hysteresis and eddy current losses. Design and size core to keep flux density well below the saturation point. Clamp core laminations securely with heavy gauge steel angles.

G. Mount core on rubber, vibration-absorbing mounts and securely bolt the core to the base. Provide design to conform to NEMA ST-20 standards according to kVA rating.

H. Provide mechanical bracing to brace the cores and coils to withstand short circuit currents established by IEEE/ANSI C57.12.59.

I. Provide wall mounted transformers with wall brackets adequate for the supporting weight and seismic loads.

J. Provide transformer materials that are flame retardant and that shall not support combustion as defined in ASTM Standard Test Method D635.

K. Provide terminals marked in accordance with IEEE/ANSI C57.12.70.

L. Provide taps in accordance with Table 16460-1.


Table 16460-1 Transformer Taps

Phase: Rating:

Full Capacity Above Nominal (FCAN)

Full Capacity Below Nominal (FCBN)

Number Size Number Size

Single 15 through 100 kVA Two (2) 2.5 % Four (4) 2.5 %

M. Enclosures:

1. Provide transformers with NEMA 1 code gauge sheet metal enclosures with removable front and back panels.

2. Provide screens or grills for all ventilation openings. Design screens and grills to prevent accidental access to electrified parts.

3. Degrease, clean, phosphatize, prime coat and finish coat with an ANSI Z55.1 number 61 gray baked enamel

PART 3 - EXECUTION

3.01 PREPARATION

A. Ensure that ground cable of proper size is installed in floor or wall as required in conformity with Section 16060.

B. Check conduit stub-ups for correct type, size and location.

C. Correct any and all defects.

3.02 INSTALLATION

A. Install, set level and plumb. Shim as required at each support point with shims on all sides of anchor bolts. After leveling, replace multiple shims with a single machined plate and no more than two small shims at each location. Unless otherwise noted, set transformer level to within 1/16-inch from end to end and side to side.

B. Provide 4-inch steel platforms for all floor mounted transformers. Extend platform to wall if the wall is less than 8-inches from the transformer and extend platform 2-inches beyond the transformer.

C. Provide through bolts with 1/8-inch thick galvanized steel backing plates for all wall-mounted transformers mounted on masonry walls when the wall opposite the transformer is an unfinished masonry wall. On masonry walls that are exterior walls or interior walls with finish, grout in mounting bolts as wall is constructed. For wall-mounted transformers mounted on wood walls, provide 4-inch x 6-inch wood blocking in the wall during construction of wall.

D. Provide sufficient anchor bolts to restrain transformer movement against tipping.


E. Connect transformer to conduit system in accordance with Section 16130 and as follows:

1. Use liquid-tight flexible metal conduit formed into a J-hook shape with sufficient slack to prevent transmission of vibration or provide bottom entry of conduit without direct connection to enclosure. Use insulating grounding bushing and two locknuts on all conduit entries.

F. Make electrical connections as follows and in accordance with Articles 300 and 450 of the NEC and Section 16123. Make electrical connections with compression lugs approved by manufacturer. Leave sufficient slack to allow for remaking connections twice and also allow for any expansion and contraction and limit the transmission of vibration.

G. Grounding:

1. Ground neutral of all three-phase transformers with wye-connected secondaries

2. Ground transformer to closest equipment ground bus bar.

H. Protection:

1. Protect against short circuits and overloads. Replace any transformer subjected to a short circuit exceeding the allowable magnitude and time limits of IEEE/ANSI C57.12.59.

2. Protect against painting splash.

3. Protect against damage during work of other trades.


A. Perform the initial start-up under the direct supervision of a licensed electrician in the presence of Owner’s representative.

B. Prior to Startup/Energization:

1. Perform insulation tests in accordance with Section 16950 prior to energization. Dry out all transformers with low readings and retest.

2. Insure that all wiring connected to the transformer is free of shorts.

3. Insure that the proper size of overcurrent protective device is installed and set to the proper settings.

C. Conduct field tests in the presence of authorized representative of the Owner.

D. Perform tests in accordance with Section 16950.

E. Correct all defects found and retest after correction of defects.

F. Submit a certified report of the test.

END OF SECTION




SECTION 16791

COMBINED RELAY AND CONTROL SWITCHBOARD

PART 1 - GENERAL


A. This Section specifies the requirements for the design, modifications, installation and testing of an existing switchboard for relay and control apparatus as specified herein and indicated on the Contract Drawings.

B. The term “Combined Relay and Control Switchboard” as used herein shall mean an assembly of control, metering, protective and regulatory apparatus mounted and wired on panels, and their supporting structure.

C. The existing switchboard shall be modified, wired and tested in the field.

D. The unmanned substation shall be locally and remotely controlled and monitored by SEPTA via Supervisory Control and Data Acquisition (SCADA) as specified and as shown on the Drawings.


A. Section 16050 – Basic Electrical Materials and Methods

B. Section 16052 – General Electric Requirement – Traction Power Equipment

C. Section 16060 – Grounding and Bonding

D. Section 16330 – Medium Voltage (2-Pole) Breakers – Switching and Protection

E. Section 16910 – Electrical Systems Control (SCADA)

F. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 REFERENCES

A. Controls and instrumentation shall comply with the following:

1. American National Standards Institute (ANSI):

a) C37.90 Relays and Relay Systems Associated with Electric Power Apparatus

b) C39.1 Electrical Analog Indicating Instruments


a) 250 Enclosures for Electrical Equipment (1,000 Volts Maximum)

b) ICS 6 Enclosures for Industrial Control and Systems


A. Subject to compliance with requirements of the Contract Documents, vendors offering product and services which may be considered for control and instrument panels for this project include, but are not limited to the following:

1. Balfour Beatty Rail, Denver, Colorado

2. Controlled Power Ltd. (CPC), Lafayette Hill, Pennsylvania


3. Electrical Power Systems, Inc., Tulsa, Oklahoma

4. PACS Industries, Inc., Great Neck, New York

5. Powercon Corporation, Severn, Maryland

6. Relay & Power Systems, Conshohocken, Pennsylvania

7. TPS Co./Powell Industries (Traction Power Systems), California

1.05 SUBMITTALS

A. Submit the following for approval in accordance with the General Requirements.

1. Type of Switchboard as Defined Herein

2. Overall Dimensions and Approximate Weight

3. Number and Size of Panels

4. List of Switches, Instruments, Relays and Other Devices Included on Each Panel

5. Description of Switchboard Construction

6. For Devices in Item No. 4 (above), Manufacturers Catalog Data, Shop Drawings and Product Information, Including Model Numbers or Item Identification, Ratings, and Characteristics for a Complete Product Description

7. Front View, Section Views, Rear View and Floor Plan Drawings, locating all Switchboard Devices

8. Manufacturer’s installation instructions and recommendations

9. Manufacturer’ operation and maintenance manual

10. Complete Schematic and Panel wiring Diagrams

11. Internal Wiring Diagrams, Outline Dimensions and drilling Plans for all separately furnished Devices

12. Manufacturing and factory test schedule.

13. Field Test Procedures.

PART 2 - PRODUCTS

2.01 GENERAL

A. Relay and Control panels shall be provided for the local and remote control and data acquisition of all substation equipment, including circuit breakers and motor operated disconnect switches, and will interface with the SCADA system as specified in Section 16910. Protective relays shall be as specified in Section 16290.

1. Types of panels shall be as follows:

a) Combined Relay and Control panels for the 25 Hz, single-phase, electrification system

2.02 CONTROL PANELS

A. Relay and Control Panels


1. The existing relay and control panels are located as shown on the Drawings. All modifications to the existing relay and control panels shall matched the existing relay and control panels. The existing relay and control panel specifications are stated below.

2. Relay and control panels shall be enclosed on the top, the bottom and all sides, designed for free-standing installation with brush-grommet and/or gland plates on the top for cable access. Provide gasketed access plate on bottom and top with the required number of openings sealed with hole-plugs. Doors shall be located on the rear of the control panel. Doors shall be fully gasketed standard projection doors with lift-off hinges and provisions for locking (per NEMA 12). Suitable door stops shall be provided to prevent damage to hinges.

3. Relay and control panels shall be constructed from highest quality hot-rolled, pickled and oiled sheet steel equal to ANSI C1010. Front and rear panels shall be constructed from No. 11 gauge steel minimum. Side sheets and top members shall be constructed from No. 13 gauge steel minimum. Suitable stiffeners shall be used to prevent warping. The control panel shall be NEMA 12.

4. Adequate ventilating openings complete with filters located behind each opening to retard the entrance of dust, foreign matter, insects, and rodents shall be provided.

5. Relay and control panel wiring shall be factory installed, Type SIS cross-linked polyethylene, 600 Volt, tinned copper. Control wiring and voltage transformer circuit wiring shall be stranded No. 12 AWG minimum. Current transformer circuit wiring shall be stranded No. 10 AWG minimum. Indication wiring shall be stranded No. 14 AWG minimum. Wiring shall be firmly fixed in place with clamps of a type which will not damage insulation. Wiring shall be neat, with all wires grouped as much as possible and kept organized utilizing a pre-fabricated cable management system. Ring type solder-less terminal connectors of the heavy duty insulated type shall be used on all control wiring. Wiring associated with meters and transducers shall be arranged to permit the testing and calibration of the associated devices through built in or panel mounted test blocks without disturbing the protective devices. Terminal blocks shall have screw type terminals capable of receiving two solid copper wires. Twenty percent spare unassigned terminals are required. All terminal blocks shall be furnished with marking strips for wire identification. All devices shall be identified on the rear of the panel with device number. All incoming wires to the control panels shall terminate on terminal blocks whereon a separate terminal suitable for No. 10 AWG wire shall be provided for each incoming wire and shall be plainly marked with an approved wire designation. Terminal blocks shall be located conveniently for connections to incoming control cables and shall be provided with a suitable locking device for all connections. Test blocks shall be GE Type PK-2 or equal, with potential and/or current terminals as required.

6. Fuse blocks shall be kept toward the tops of these cabinets.

7. Equipment associated with a particular bus shall be on the respective side of the relay and control panel.

8. A 1”x1/8” high conductivity (99% copper or better) copper ground bus shall be installed near the base of the combined relay and control switchboard extending the entire length of the switchboard. A mechanical connector for #2 AWG wire


shall be provided at each end of each ground bus for connection to the substation ground system.

9. All relay device nomenclature, wiring nomenclature, wire tags and name plates shall conform to SEPTA standards.

10. Panel interiors shall be high visibility white. Panel exteriors shall be ANSI 61 Gray.

B. Nameplates:

1. Nameplates shall be provided and mounted for all relays, switches, push buttons, instruments and other devices on the front of the panels. Switchboards shall include suitable painted mimic buses with arrangement and color as indicated on the Drawings.

2. Nameplates shall be fabricated from 1/8 inch thick laminated plastic (heat resistant plastic lamicoid nameplates) with white letters on a black background. The lettering shall be accurately aligned and engraved into the black core. Nameplates shall be attached with screws or rivets.

3. Size of nameplates shall be 1 inch by 2-1/2 inches minimum. Letters shall be minimum 1/4 inch high normal block lettering, unless otherwise indicated.

C. Painting:

1. Prior to assembly and before shop painting, all surfaces of the panels shall be thoroughly cleaned of rust, oil, grease, dirt, and mill scale and painted both exterior and interior with one coat of rust-inhibiting primer.

2. The exterior of the panels shall be given two or more finish coats of light gray enamel (equal to ANSI 61). The minimum total primer and finish dry film thickness shall be five mils. Interior of cubicles shall be white.

2.03 CONTROL OF SUBSTATIONS

A. Control Switches and Indicating Lamps:

1. Control Switches shall be Series 24 as manufactured by Electroswitch, or equal, in addition to those listed below. By the use of a suitable double-throw, control-selector switch located on the combined relay and control switchboard, control from either the local point or the remote point, as selected, shall be permitted but simultaneous control from both points shall be prevented.

a) Voltage Transfer handles shall be three-position, multi-deck with knurled handle – Electroswitch #24202B or equal

b) Breaker Control handles shall be G.E. #16SB1DB4I66SPR39 or equal

c) Lock-out Relay handles shall be high-speed multi-contact electric trip.

2. Two LED indicating lamps shall be provided with each control switch; a red lamp indicating the “closed” position and a green lamp indicating the “open” position of the controlled apparatus. Each control switch shall have a locked-out position in which the red and green lamp circuits and all other circuits connected to the control switch are interrupted. The Indicating lamps shall be General Electric ET-16 LED’s, rated voltage 125 Vdc or approved equal.


B. The Contractor shall verify the existing protection system power supplies and switching and maintain the same in the new relay and control switchboard.

C. All substation relays that are required for accomplishing the required functions shall be furnished, mounted and wired on the combined relay and control switchboard by the Manufacturer.

D. Suitable test switches shall be included with each switchboard. Test switches shall be mounted on the front of the panels unless otherwise approved and shall be provided with suitable covers that leave no live parts exposed. Test switches shall provide for the following operations:

1. The disconnection of each instrument, meter, and relay current element from its current transformer secondary circuit so as to be available for connection to a test circuit, without interrupting the circuit from which it is removed.

2. The insertion of a portable ammeter or other current element in each current transformer secondary circuit without interrupting the circuit and without short-circuiting or disrupting any circuit element that normally is connected in the circuit. In the case of differential relays this requirement shall mean the insertion of different ammeters in series with the operating coil and in series with each restraining coil.

3. The short circuiting of each current transformer secondary, and, in the case of each current transformer used in a differential circuit, the isolation of this current transformer secondary from the secondary wiring of the other current transformers of the same differential circuit.

4. The disconnection of each instrument, meter, and relay potential element so as to be available for connection to the test circuit.

5. The disconnection of all dc connections from each relay or unit of relays.

E. The following items shall be included on the Combined Relay and Control Switchboard:

1. One control switch, with red and green indicating lamps, for each circuit breaker and each electrically operated switch to be controlled

2. One Voltmeter, 200 Vdc for control battery voltage

3. One Voltmeter, 150 Vac, scale 0 – 15 kV, for trolley bus voltage

4. One Voltmeter, 150 Vac, scale 0 – 28 kV, for trolley bus voltage

5. One Voltmeter switch, for selecting the potential bus

6. Instrument switches for potential buses

7. One ac Ammeter for each SFC in feed. Scale 0 – 1200 Amperes. To include suitable devices for short circuiting the ammeter when not in use, and for plugging in a portable recording ammeter when desired.

2.04 RELAY PROTECTION

A. Protective relays are identified on relay and meter diagrams per IEEE Standard C37.2-1 987 “IEEE Standard Electrical Power System Device Function Numbers”. All relays are subject to approval by SEPTA. The selection of correct range of operation of the relay shall be the responsibility of the Contractor. The relays shall be single phase unless


otherwise noted. All relays shall be capable of communicating with the RTU. All Areva relays shall be IEC61850 compliant. Types and typical equipment are as follows.

1. 25 Hz relay for 24 kV feeder circuits:

a) Refer to Specification Section 16290.

2. 25 Hz relays for 12 kV trolley circuits:

a) Refer to Specification Section 16290.

2.05 EQUIPMENT

A. Instruments:

1. Instruments shall meet the requirements of ANSI C39.1 for electrical indicating switchboard instruments, accuracy class 1. Meters shall be of the solid state digital monitor design for switchboard application, Single Channel Transducer display as manufactured by Bitronics or approved equal. Units associated with analog input to an RTU may include the transducer outputs in lieu of separate transducers. Meter characteristics shall be as follows:

2. Maximum continuous input voltage – 150 Volts, phase to neutral

3. Maximum continuous input current – 10 Amperes (programmable to any CT ratio)

4. Maximum burden for current circuit – 0.5 VA

5. Maximum burden for voltage circuit – 0.5 VA

6. Surge withstand capability per IEEE/ANSI C37.90.1

7. Operating temperature – 20° C to 70° C

8. Control power requirement – 6 VA max at 120 Vac

9. Construction - metal housing with standard switchboard dimensions and cutout per ANSI 39.1

B. Transducers:

1. Transducers shall be rated 5 Amperes and 120 Volt input, suitable for switchboard mounting or alternately integral components of the associated panel mounted meter. Associated current transformer and potential transformer ratios shall be as shown on the Drawings. Output shall be 0-1 mA. Output range related to primary input shall be in accordance with the RTU point list. Transducers shall be by Ametek Power Instruments, Models VT110A2-25 and CT510A2-25 or approved equals. Transducer characteristics shall be as follows:

2. Accuracy: +/- (0.15% reading, +0.1% rated output)

3. Maximum continuous input voltage – 150 Volts, phase to neutral

4. Maximum continuous input current – 10 Amperes

5. Maximum burden for current circuit – 0.25 VA

6. Maximum burden for voltage circuit – 2.2 VA

7. Surge withstand capability per ANSI 037.90.1

8. Minimum input/output isolation – 1500 Vac, 60 Hz


9. Construction - metal housing with standard switchboard dimensions and cutout per ANSI 39.1.

10. All wiring of instrument transformer circuits to transducers shall be through approved instrument transformer test switches.

2.06 FACTORY AND FIELD TESTING

A. Factory testing shall be performed on each piece of equipment. Factory test plans and procedures shall be submitted in advance to the SEPTA Project Manager.

B. Testing of the completely wired Switchboard shall be performed.

C. Where necessary, input, output and proof of correct wiring of field terminals shall be performed by applying the appropriate operating voltages to each circuit in lieu of the remote equipment being made available.

D. The complete Switchboard shall be given visual inspection, wiring checks and operational, continuity, and electrical tests for each circuit in accordance with the latest standards of IEEE, NEMA and ANSI, in order to assure completeness, adequacy and proper functioning of equipment.

E. The SEPTA Project Manager shall be notified at least two weeks in advance of factory testing for witnessing by an SEPTA representative.

F. Field Tests:

1. Upon installation equipment at the site and prior to acceptance of the Combined Relay and Control Switchboard, tests of all systems shall be required to demonstrate functional and operational requirements. All tests shall be conducted at a mutually approved time. Provide all instruments, facilities and labor required to properly conduct the tests.

2. Adjust and set all relay trip devices, shunt trip devices, alarm devices and calibrate the transducers in accordance with required values.

3. All control circuits shall be given continuity tests and operational tests from the supply source for which they were designed. This shall include normal breaker operation three times from each control point, relay trips and activation of associated alarm devices. Operation of breakers and motor operated disconnect switches shall be simulated.

4. All protective relays shall be tripped (electrically) to determine whether the proper breaker has functioned as intended and any device or devices (including alarms) have also operated correctly. Functioning of breakers shall be simulated by a suitable test board.

5. Voltmeters shall be checked against potential transformer ratios. Pointers shall be set on zero scale, with no voltage, then after energizing, voltmeter reading shall be checked with test voltmeter.

6. All test results shall be in accordance with these Specifications and the Manufacturer’s recommendations and subject to approval by SEPTA.

7. All equipment shall be given operational tests. These tests shall include mechanical operation as well as operation by control circuits, relays and tripping devices. Operating voltage at closing and tripping coils shall be checked to determine that voltage is of proper value.


8. Test Reports: Record and submit reports in accordance with Section 01300.

9. Field test plans and procedures shall be submitted in advance to the SEPTA Project Manager.

2.07 SHIPMENT

A. All relay and control panels shall be installed and secured within the Substation Control Building and shall be shipped in accordance with the Manufacturer’s recommendations

B. Each shipment shall be monitored for damage during transport by the application of “Shockwatch” labels, or equivalent.

PART 3 - EXECUTION

3.01 INSTALLATION

A. The equipment shall be installed in accordance with the Contract Drawings and these specifications.

END OF SECTION


SECTION 16910

ELECTRICAL SYSTEMS CONTROL (SCADA)

PART 1 - GENERAL


A. This section specifies the requirements for furnishing and installing a Supervisory Remote Terminal Unit (RTU) in the Static Frequency Converter building at Wayne Junction, which shall be compatible with the existing Master Station equipment. SEPTA Regional Rail Division (RRD) has a supervisory system for remote control and indication of the circuit breakers and for monitoring equipment and auxiliary circuits at all its substations. The existing Master Station of the supervisory system is located at the control center at 1234 Market Street, 19th Floor, which are all TDMS-Plus units manufactured by QEI, Inc.

B. The RTU designs shall not require any changes to the QUICS IV Master Station SCADA System. Prepare all databases required for the SCADA system. The RTU shall be capable of being installed in a 19-inch standard communication rack.

C. Furnish and install in the SFC building control room a free-standing NEMA 12 cabinet for the remote terminal unit (RTU). In the SFC control room, the SCADA RTU shall interface with the SFC main controller equipment for all indication and control points, as required.

1. Furnish and install control and indication cable(s) from the SFC main controller cabinets to the remote terminal unit (RTU). The following equipment requires SCADA control, supervisory and/or alarm indications:

2. Circuit breakers and breakers of the 13.2 kV, 12 kV and 24 kV switchgear line-ups require close/open operation control, closed/open status indication, various alarm/trip signals, and telemetry signals as shown on the drawings and as specified.

3. Route all control, alarm, status, and telemetry functions from the switchgear and circuit breakers via the SFC vendor control system equipment. Coordinate the routing method with the switchgear and circuit breaker suppliers.

4. Each of the four SFC units requires one Master (Local/Remote) Switch.

5. Substation 43 device (Local/Remote) requires control and indication functions (Refer to each SCADA Points Table to determine which cubicles require this device). In Local position, the Power Dispatcher shall only be able to trip any SCADA-controlled circuit breaker. The Power Dispatcher shall have full control of all traction power circuit breakers when 43 device is in the Remote position.

6. Intrusion alarm system requires supervisory and alarm functions including door bypass switch indication status.

7. Fire alarm control panel (FACP) requires supervisory and alarm indication, both the SFC building and the adjacent 230 kV Substation.

8. There are additional I/O control, supervisory, and indication functions that will be communicated via the switchgear network server directly.

D. The existing SFC building controls and indications for supervisory control are listed as reference in the SCADA Points Tables, which are provided in Part 2 - PRODUCTS.

E. The contractor shall interface indication and control points for the spare 13.2 kV and 480 V circuit breakers that are being utilized for this project with the existing QEI RTU cabinets


located in the 230 kV Substation. Additionally, the contractor shall interface indication points from the proposed fire alarm control panel for the 230 kV Substation.

F. Assume responsibility for providing and testing end-to-end control, supervisory, and data acquisition functions for all equipment, from SEPTA Operation Control Center at 1234 Market Street, Philadelphia, PA.






E. All other sections of Division 16

1.03 SUBMITTALS

A. Shop drawings including complete points listing, product description, catalog data, wiring details, interconnection diagrams, microprocessor details, instructions manual, operating and maintenance manuals, details of Interface with existing systems, software documentation, test programs for detailed testing, and database preparation and completion

B. Step-by-step installation instructions

C. Recommended list of test equipment and spare parts

D. Operation and Maintenance Manual

E. Test plans and procedures for the factory, field, and end-to-end tests


A. Applicable portions of the latest editions of the publication referenced shall form a part of this Specification.

1. ANSI - American National Standards Institute

2. NFPA - National Fire Protection Association

3. IEEE - Institute of Electrical and Electronic Engineers

4. NEMA - National Electrical Manufacturers Association

B. The installation shall be performed by workmen with established skills in the type of work covered by this section.


A. Before a request for final payment is made, compile and deliver sets of complete Operating and Maintenance manuals, all securely bound and enclosed in suitable, hard cover binders, on all of the equipment specified herein. All manuals shall be the most recent and up-to-date releases.

B. The material required shall include, but not be limited to, the following:

1. Equipment:


a) Manufacturer's Specifications and Descriptions

b) Handling Instructions

c) Step-by-Step Installation Instructions

2. Operating Manuals:

a) Equipment Ratings

b) Operating Instructions

c) Outline Drawings

d) Wiring and Schematic Drawings, including circuit board schematics

3. Software:

a) Description

b) Documentation

4. Maintenance Manuals:

a) Maintenance Instructions

b) Equipment Troubleshooting

c) Replacement Parts List

5. Miscellaneous Bulletins and Information

1.06 INSPECTION

A. Inspection of the material/equipment will be made at the point of delivery. However, the SEPTA Project Manager reserves the right to make any tests or inspection that it may deem necessary at the Contractor's plant. In the event inspection is made at the plant, grant the SEPTA Project Manager free entry at all times while work under this specification is being performed, to all parts of the plant which concern the manufacture of the concerned material/equipment.

1. Render all facilities to satisfy the SEPTA Project Manager that the material/ equipment is being furnished in accordance with this Specification. If you are not the manufacturer of the material/ equipment, impose these conditions in your contract with the manufacturer. In all cases, notify the SEPTA Project Manager when the finished material/equipment is ready for shipment in order that plant inspection of the material/equipment may be made if desired.

1.07 WARRANTY

A. Provide standard warranty against defective materials and workmanship, from the date 0f Substation acceptance by SEPTA.

1.08 MAINTENANCE SERVICE AND EXTRA MATERIAL

A. Spare Parts

1. To insure inclusion with contract orders, submit for approval, a recommended list of spare parts.


2. Furnish, prior to the system being placed in service, two (2) each of the active printed circuit boards that are utilized on this Project, as required by SEPTA (latest Board revisions should be provided).

3. The intent of this clause is that a complete set of spare material is furnished to insure the continued operation of the system, considering the long delays which may be inherent in future replacement and predicted usage rates.

4. Specifically highlight any equipment which has unduly long delivery time exceeding 12 weeks and/or where there is likelihood that spares may become unavailable within the next ten years.

PART 2 - PRODUCTS


A. Provide the necessary relays, indication contacts, interface cables, and transducers in the various power equipment enclosures, and in the substation, for connection to the supervisory system, as described herein and as shown on the drawings.

1. Supervisory “indication” power shall be 24 Vac or 120 Vac from the supervisory RTU cabinet through normally open or normally closed contacts in the equipment, then back to the supervisory device point.

2. Control power to operate circuit breakers shall be 130 Vdc from the device being operated to the supervisory interposing relay then back to the device point.

3. Supervisory interposing relays for control of circuit breakers shall have a minimum rating of 130 Vdc, 20 Amps continuous with closing pulse duration of 500 milliseconds. If the equipment current requirements are greater than 20 A or if the pulse required is longer than 500 milliseconds, provide interposing relays in the equipment to accomplish the desired close or trip operation.

4. Analog inputs for ac and dc voltage and current shall be 4-20 ma from transducers.

a) Transducers:

1) AC voltage and current transducers shall be Ametek Power Instruments Electronic Models or equivalent.

2) DC voltage transducers shall be Ametek Power Instruments or equivalent.

5. Name plates shall be 1” x 3” laminated black plastic and shall be engraved with 1/2” white lettering “Remote Terminal Unit”. Name plate shall be mounted on surface of the RTU.

B. Provide 20 percent spare wires in each cable with a minimum of two spares per cable.

C. Control cables shall be as specified in Section 16120 of the Specifications.

D. Wire terminals shall be insulated, compression type, ring tongue lugs such as manufactured by T & B or Sta-Kon or approved equal. Spade type terminals are not acceptable.

2.02 SUPERVISORY REMOTE TERMINAL UNIT

A. Supervisory RTU shall be of a micro-processor type design. Panel shall contain all necessary subsystem equipment to provide a complete operating system. Note: This style


RTU requires external voltage and current transducers. Subsystems shall include, but not be limited to, the following:

1. Power distribution subsystem

2. Communications subsystem

3. Micro-processor subsystem

4. Status input subsystem

5. Control output subsystem

6. Interposing relay subsystem

7. Digital to analog subsystem for four-wire analog data transmission

8. Multiport Data Modems (Universal Data Systems) or approved equals.

B. All input and output terminals shall be capable of meeting and withstanding the requirements of the ANSI C37.90(a) Surge Withstand Capability (SWC) Test.

C. The RTU shall be totally enclosed in a NEMA 12, twist handle, 3 point latch, gasketed, vented, free-standing enclosure, UL listed, and pad lockable (3/8-inch shank minimum). The enclosure shall be front accessible only, allowing placement of enclosure against a wall. Color shall be ANSI 61 light gray.

D. Communications between the remote terminal unit and the Master Station equipment shall be over SEPTA's existing fiber optics communication system. The RTU shall also be capable of communicating over Ethernet LAN using TCP/IP protocol. Termination options for Ethernet connections shall include 10/100 BaseT as well as single mode fiber optics.

E. A micro-processor with programmable read-only memories shall be provided for future changes in the station.

1. All programs shall be stored in programmable read-only memory that is not electrically erasable.

2. Program reloading shall not be required due to power surges, dips or outages.

3. Random access memory may be used to store temporary raw data prior to transmission.

F. Optical isolators shall be provided on all status or alarm inputs. A digital filter shall be employed on all inputs to eliminate contact bounce. All optical isolator components shall be installed in opto-isolator sockets.

G. All status, alarm, potential, etc., indications from the substation equipment to the remote terminal unit shall be digital type from electrically isolated normally open or normally closed contacts.

H. Interposing relays for control of substation equipment shall have two Form C heavy-duty contacts. Contacts shall be rated for a 20 A (resistive) load at 130 Vdc and have adjustable close time up to 500 milliseconds, and shall be Potter & Brumfield (P&B) catalog number PRD1 1 DJ0-24V or equal. All control and status circuit boards shall include LED indications on every point. The circuit boards shall be installed via board sockets.

I. Make all connections from external equipment that are connected to the remote terminal unit, shall be made to terminal blocks provided in the RTU.


J. All connections from the remote terminal unit to external equipment shall be made to terminal blocks provided in the remote terminal unit.

K. All connections from I/O relays on circuit boards shall be made to terminal blocks. Direct connections to circuit board relay I/O are not permitted.

L. The RTU shall obtain 120 Vac power from the substation AC Panel.

M. Provide a sealed 12 Vdc maintenance free battery back-up to sustain remote operation for minimum of one hour.

N. Dimensions shall not exceed 60 inches high, 36 inches wide and 48 inches deep. Small unit sizes are acceptable if approved in advance by the SEPTA Project Manager.

O. The supervisory unit shall be based upon the ePAQ-9410 Multifunction Gateway or SEPTA approved equal and shall operate from and be thoroughly and fully compatible with an existing substation master supervisory system, TDMS-Plus, manufactured by QEI, Inc., Springfield, New Jersey.

1. The unit shall be programmed to respond to the QEI QUICS IV System Communication Protocol.

2. No modification to the QEI, TDMS-Plus Alpha Master Station Servers will be accepted.

3. Licensing Agreement Fee for QEI, QUICS IV protocol must be included in the bid.

4. The proposed RTUs shall support multiple protocols and be capable of DNP3 communications with Intelligent Electronic Devices (IEDs) over RS-232 serial port, RS-485, or Ethernet link.

5. The number of serial communications ports shall be expandable up to no less than eight usable ports. One serial port shall also be provided for RTU configuration and testing purposes.

6. RTU configuration shall be accomplished via software. The configuration software shall provide a simple, logical, user-friendly graphical interface.

7. The unit shall be sized for the required status points, control points and analog points as per the plans.

8. Provide all equipment required for full interface of the RTUs with the Master Station at no additional cost to SEPTA.

P. Communications between the network server and the RTU shall be accomplished using single mode fiber optic cable.

Q. Furnish one multi-port Data Modem (Universal Data Systems or approved equal) to be installed by SEPTA at Master Control Center at 1234 Market Street, Philadelphia, Pennsylvania. Multiport Modem must match one in RTU.

R. Provide 20-percent spare control and indication points, completely wired to terminal blocks in the SFC building RTU.

S. Provide a switchable work light and 120 Vac duplex convenience receptacle within the RTU.


2.03 EXISTING SCADA RTU POINTS

SFC Building RTU Control Points Description Function Point Address

SFC 1 Control Open, Trip, Stop, Block, Off 0 Close, Run, Start, Reset, Off

SFC 1 DEBLOCK Control

Not Used 1 Close, Run, Start, Reset, Off


SFC 2 DEBLOCK Control Not Used 3 Close, Run, Start, Reset, Off


SFC 3 DEBLOCK Control Not Used 5 Close, Run, Start, Reset, Off

Auto Start Auto/Manual Control Open, Trip, Stop, Block, Off 6 Close, Run, Start, Reset, Off

Spare Not Used 7 Not Used





SFC Building RTU Status Points – panel A7 Description Sta Name Function Point No.

SFC 1 Control SFC1 Status 0 SFC 1 DEBLOCK Control SFC1 Status 1



Spare Status 6 Spare Status 7 Spare Status 8 Spare Status 9 Spare Status 10 Spare Status 11 Spare Status 12 Spare Status 13 Spare Status 14 Spare Status 15


SFC Building Status Points – Panel A6 Description Sta Name Function Point No.

WL1-Q17 Ground Switch SFC1 Status 0 C1-Q16 Ground Switch SFC1 Status 1

L1-Q1 Joslyn Switch SFC1 Status 2 C2-Q16 Ground Switch SFC1 Status 3

C2-Q1 Joslyn SFC1 Status 4 WL11,12 Q16 Ground Switch SFC1 Status 5 WL11,12 Q17 Ground Switch SFC1 Status 6

WL11,12-Q1 “E BKR” SFC1 Status 7 WL11,12-Q11 Disconnect Switch SFC1 Status 8

Auto Start on Indication SFC1 Status 9 Over Voltage Alarm SFC1 Status 10 Over Current Alarm SFC1 Status 11 Negative Sequence SFC1 Status 12

14 MVAR (C2) Unbalance SFC1 Status 13 Fault (C2) 14 MVAR SFC1 Status 14 Fault (L1) 7 MVAR SFC1 Status 15

SFC Building RTU Status Points – Panel A5 Description Sta Name Function Point No.

Breaker Fail (L1) 7 MVAR SFC1 Status 0 Unbalance (C2) 10 MVAR SFC1 Status 1

Fault (C2) 10 MVAR SFC1 Status 2 Breaker Fail (C2) 10 MVAR SFC1 Status 3

MCB PT 13.2 kV SFC1 Status 4 3 Phase Transformer Alarm SFC1 Status 5

3 Phase Transformer Lockout SFC1 Status 6 Single Phase Transformer Alarm SFC1 Status 7

Single Phase Transformer Lockout SFC1 Status 8 DC/DC Converter Fault SFC1 Status 9

Single Phase Filter unbalance SFC1 Status 10 Reverse Power 12 kV SFC1 Status 11 Over Current 12 kV SFC1 Status 12

Reverse Power 24 kV SFC1 Status 13 Over Current 24 kV SFC1 Status 14

Low pressure single phase breaker SFC1 Status 15

SFC Building RTU Status Points – Panel A4 Description Sta Name Function Point No.

AC Distribution Alarm SFC1 Status 0 DC Distribution Alarm SFC1 Status 1

MCB PT U111 SFC1 Status 2 Converter Alarm SFC1 Status 3

Converter Lockout SFC1 Status 4 No pressure single phase breaker SFC1 Status 5

Current Limit SFC1 Status 6


Cooling air temperature SFC1 Status 7 Reduced current limit 1 alarm SFC1 Status 8 Reduced current limit 2 alarm SFC1 Status 9

First fan out alarm SFC1 Status 10 Long start sequence alarm SFC1 Status 11

Sync alarm SFC1 Status 12 DC supply fail SFC1 Status 13 25 Hz MCB PT SFC1 Status 14

Battery ground Fault SFC1 Status 15

SFC Building RTU Status Points – Panel B1 Description Sta Name Function Point No.

Auxiliary power supply fail SFC1 Status 0 Stall alarm SFC1 Status 1

WL1-Q17 Ground switch SFC2 Status 2 C1-Q16 Ground switch SFC2 Status 3

L1-Q1 Joslyn switch SFC2 Status 4 C2-Q16 Ground switch SFC2 Status 5

C2-Q1 Joslyn SFC2 Status 6 WL11, 12 Q16 Ground switch SFC2 Status 7 Wl11, 12 Q17 Ground switch SFC2 Status 8

WL11, 12-Q11 “E BKR” SFC2 Status 9 WL11, 12-Q11 Disconnect switch SFC2 Status 10

Auto start on indication SFC2 Status 11 Over voltage alarm SFC2 Status 12 Over current alarm SFC2 Status 13 Negative sequence SFC2 Status 14

14 MVAR (C2) unbalance SFC2 Status 15


Fault (C2) 14 MVAR SFC2 Status 0 Fault (L1) 7 MVAR SFC2 Status 1

Unbalance (C2) 10 MVAR SFC2 Status 2 Fault (C2) 10 MVAR SFC2 Status 3





Reverse Power 24 kV SFC2 Status 13 Over Current 24 kV SFC2 Status 14

Low Pressure single phase breaker SFC2 Status 15






Current Limit SFC2 Status 6 Cooling air temperature SFC2 Status 7

Reduced current limit 1 alarm SFC2 Status 8 Reduced current limit 2 alarm SFC2 Status 9


Sync alarm SFC2 Status 12 DC supply fail SFC2 Status 13 25 Hz MCB PT SFC2 Status 14

Battery ground Fault SFC2 Status 15


Auxiliary power supply fail SFC2 Status 0 Stall alarm SFC2 Status 1

WL1-Q17 Ground switch SFC3 Status 2 C1-Q16 Ground switch SFC3 Status 3

L1-Q1 Joslyn switch SFC3 Status 4 C2-Q16 Ground switch SFC3 Status 5

C2-Q1 Joslyn SFC3 Status 6 WL11, 12 Q16 Ground switch SFC3 Status 7 Wl11, 12 Q17 Ground switch SFC3 Status 8

WL11, 12-Q11 “E BKR” SFC3 Status 9 WL11, 12-Q11 Disconnect switch SFC3 Status 10

Auto start on indication SFC3 Status 11 Over voltage alarm SFC3 Status 12 Over current alarm SFC3 Status 13 Negative sequence SFC3 Status 14

14 MVAR (C2) unbalance SFC3 Status 15


Fault (C2) 14 MVAR SFC3 Status 0 Fault (L1) 7 MVAR SFC3 Status 1

Breaker fail (L1) 7 MVAR SFC3 Status 2 Unbalance (C2) 10 MVAR SFC3 Status 3

Fault (C2) 10 MVAR SFC3 Status 4 Breaker fail (C2) 10 MVAR SFC3 Status 5






Reverse Power 24 kV SFC3 Status 15


Over Current 24 kV SFC3 Status 0 Low pressure single phase breaker SFC3 Status 1




Current Limit SFC3 Status 8 Cooling air temperature SFC3 Status 9

Reduced current limit 1 alarm SFC3 Status 10 Reduced current limit 2 alarm SFC3 Status 11


Sync alarm SFC3 Status 14 DC supply fail SFC3 Status 15

SFC Building RTU Status Points – Panel B7

Description Sta Name Function Point No. 25 Hz MCB PT SFC3 Status 0

Battery ground Fault SFC3 Status 1 Auxiliary power supply fail SFC3 Status 2

Stall alarm SFC3 Status 3 DC Feed to RTU alarm SFC Status 4

RTU local/remote SFC Status 5 Spare Status 6 Spare Status 7

SFC Control in Local SFC Status 8 Spare Status 9 Spare Status 10

SFC Entry Door Alarm SFC Status 11 Spare Status 12 Spare Status 13 Spare Status 14 Spare Status 15

SFC Building RTU Analog Points – Panel A9


Description Input Eng Unit Span Sta Name Point No. 230 kV 60 Hz MWatts 0-10 ma 0/30 MW SFC1 0 230 kV 60 Hz MVARS 10-0-1 ma 30/0/30 MW SFC1 1 230 kV 60 Hz kVolts 0-10 ma 0/15 kV SFC1 2

230 kV 60 Hz Amperes 0-10 ma 0/4 kV SFC1 3 230 kV 60 Hz Power Factor 10-0-1 ma 0.5/1/0.5 SFC1 4

230 kV 60 Hz Frequency 0-10 ma 50/70 Hz SFC1 5 12 kV, 25 Hz MWatts 0-10 ma 0/30 MW SFC1 6 12 kV, 25 Hz MVARS 10-0-1 ma 30/0/30 MW SFC1 7 12 kV, 25 Hz kVolts 0-10 ma 0/15 kV SFC1 8

12 kV, 25 Hz Amperes 0-10 ma 0/2 KAMPS SFC1 9 12 kV, 25 Hz Power Factor 10-0-1 ma 0.5/1/.05 SFC1 10

12 kV, 25 Hz Frequency 0-10 ma 20/30 Hz SFC1 11 24 kV, 25 Hz Watts 0-10 ma 0/30 MW SFC1 12

24 kV, 25 Hz MVARS 10-0-1 ma 15/0/15 MW SFC1 13 24 kV, 25 Hz kVolts 0-10 ma 0/30 MW SFC1 14

24 kV, 25 Hz Amperes 0-10 ma 0/600 AMP SFC1 15

SFC Building RTU Analog Points – Panel A8 Description Input Eng Unit Span Sta Name Point No.

24 kV, 25 Hz Power Factor 10-0-10 ma 0.5/1/0.5 SFC1 16 230 kV 60 Hz MWatts 0-10 ma 0/30 MW SFC2 17 230 kV 60 Hz MVARS 10-0-1 ma 30/0/30 MW SFC2 18 230 kV 60 Hz kVolts 0-10 ma 0/15 kV SFC2 19


230 kV 60 Hz Frequency 0-10 ma 50/70 Hz SFC2 22 12 kV, 25 Hz MWatts 0-10 ma 0/30 MW SFC2 23 12 kV, 25 Hz MVARS 10-0-1 ma 30/0/30 MW SFC2 24 12 kV, 25 Hz kVolts 0-10 ma 0/15 kV SFC2 25

12 kV, 25 Hz Amperes 0-10 ma 0/2 KAMPS SFC2 26 12 kV, 25 Hz Power Factor 10-0-1 ma 0.5/1/.05 SFC2 27

12 kV, 25 Hz Frequency 0-10 ma 20/30 Hz SFC2 28 24 kV, 25 Hz Watts 0-10 ma 0/30 MW SFC2 29

24 kV, 25 Hz MVARS 10-0-1 ma 15/0/15 MW SFC2 30 24 kV, 25 Hz kVolts 0-10 ma 0/30 MW SFC2 31


Description Input Eng Unit Span Sta Name Point No. 24 kV, 25 Hz Amperes 0-10 ma 0/600 Amp SFC2 50

24 kV, 25 Hz Power Factor 10-0-10 ma 0.5/1/0.5 SFC2 32 230 kV 60 Hz MWatts 0-10 ma 0/30 MW SFC3 33 230 kV 60 Hz MVARS 10-0-1 ma 30/0/30 MW SFC3 34 230 kV 60 Hz kVolts 0-10 ma 0/15 kV SFC3 35


230 kV 60 Hz Frequency 0-10 ma 50/70 Hz SFC3 38 12 kV, 25 Hz MWatts 0-10 ma 0/30 MW SFC3 39 12 kV, 25 Hz MVARS 10-0-1 ma 30/0/30 MW SFC3 40


12 kV, 25 Hz kVolts 0-10 ma 0/15 kV SFC3 41 12 kV, 25 Hz Amperes 0-10 ma 0/2 KAMPS SFC3 42

12 kV, 25 Hz Power Factor 10-0-1 ma 0.5/1/.05 SFC3 43 12 kV, 25 Hz Frequency 0-10 ma 20/30 Hz SFC3 44

24 kV, 25 Hz Watts 0-10 ma 0/30 MW SFC3 45 24 kV, 25 Hz MVARS 10-0-1 ma 15/0/15 MW SFC3 46


Description Input Eng Unit Span Sta Name Point No. 24 kV, 25 Hz kVolts 0-10 ma 9/30 kV SFC3 47

24 kV, 25 Hz Amperes 0-10 ma 0/600 Amp SFC3 48 24 kV, 25 Hz Power Factor 10-0-1 ma 0.5/1/0.5 SFC3 49

Spare 51 Spare 52 Spare 53 Spare 54 Spare 55 Spare 56 Spare 57 Spare 58 Spare 59 Spare 60 Spare 61 Spare 62 Spare 63

25 HZ TPSS RTU Status points – Panel 3 Description Sta Name Function Point No.

System Alarm 230 KV Substation Alarm 0 System Trouble 230 KV Substation Alarm 1

Detection Battery Room 1 230 KV Substation Alarm 2 Thermal Detection 1 230 KV Substation Alarm 3 Thermal Detection 2 230 KV Substation Alarm 4

Detection Battery Room 2 230 KV Substation Alarm 5 Manual Pull Battery Room 230 KV Substation Alarm 6 Manual Pull Control Room 230 KV Substation Alarm 7

Control Room Halon 1 230 KV Substation Alarm 8 Control Room Halon 2 230 KV Substation Alarm 9

Water Flow 1 230 KV Substation Alarm 10 Water Flow 2 230 KV Substation Alarm 11

Switch Gear Zone 1 Detect 230 KV Substation Alarm 12 Switch Gear Zone 2 Detect 230 KV Substation Alarm 13

Battery Room Detect Zone 1 230 KV Substation Alarm 14 Battery Room Detect Zone 2 230 KV Substation Alarm 15

25 HZ TPSS RTU Status points – Panel 4

Description Sta Name Function Point No. System Alarm SFC2 Alarm 0


System Trouble SFC2 Alarm 1 Deluge #1 SFC2 Alarm 2 Deluge #2 SFC2 Alarm 3

Deluge #1 Water Flow SFC2 Alarm 4 Deluge #2 Water Flow SFC2 Alarm 5

Halon Manual #1 SFC2 Alarm 6 Halon Manual #2 SFC2 Alarm 7 Halon #1 Zone #1 SFC2 Alarm 8 Halon #1 Zone #2 SFC2 Alarm 9 Halon #2 Zone #1 SFC2 Alarm 10 Halon #2 Zone #2 SFC2 Alarm 11 Halon #2 Zone #3 SFC2 Alarm 12 Halon #2 Zone #4 SFC2 Alarm 13 Halon #2 Zone #5 SFC2 Alarm 14 Halon #2 Zone #6 SFC2 Alarm 15


Description Sta Name Function Point No. Fire Alarm Zone #1 SFC2 Alarm 0 Fire Alarm Zone #2 SFC2 Alarm 1

Halon 1 SFC2 Alarm 2 Halon 2 SFC2 Alarm 3

System 1 & 3 Alarm SFC1 Alarm 4 System 1 & 3 Trouble SFC1 Alarm 5 Thermal Detector T3A SFC3 Alarm 6 Thermal Detector T3B SFC3 Alarm 7

Water Flow T3A SFC3 Alarm 8 Water Flow T3B SFC3 Alarm 9

Building 1 Zone 1 SFC1 Alarm 10 Building 1 Zone 2 SFC1 Alarm 11 Building 3 Zone 1 SFC3 Alarm 12 Building 3 Zone 2 SFC3 Alarm 13

Halon Manual Building 1 SFC1 Alarm 14 Halon Manual Building 3 SFC3 Alarm 15


Description Sta Name Function Point No. Thermal Detection T1A SFC1 Alarm 0 Thermal Detection T1B SFC1 Alarm 1

Water Flow T1A SFC1 Alarm 2 Water Flow T1B SFC1 Alarm 3

Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9 Spare 10 Spare 11


Spare 12 Spare 13 Spare 14 Spare 15

PART 3 - EXECUTION

3.01 PREPARATION

A. Thoroughly review the drawings and specifications in preparation for installation of the materials and equipment. Materials shall be procured, stored, and planned for use which minimizes waste, and substitutions, and maximizes installation efficiency and quality of end product.

B. Examine all contract and reference drawings, to verify and properly coordinate the work; check all relevant drawings including civil, mechanical drawings and shop drawings.

C. Prepare all databases required for the SCADA system.

3.02 INSTALLATION

A. Control Cable Installation

B. Install control cable in tray or conduit utilizing the SFC control room raised floor where applicable.

C. SCADA RTU Cabinet

1. Connect all wires from the substation equipment terminal blocks to the supervisory RTU terminal blocks.

2. Provide tape pothead where cable jacket is removed on both ends of each cable. Bundle and tie neatly all wiring inside equipment.

3. Neatly bundle spare wires inside equipment.

4. Identify each cable by device name and number.

5. Identify each wire including spares with wire markers.

D. Securely fasten the SCADA RTU cabinet to the floor in accordance with seismic zone 2b requirements.

E. Use a single point grounding method. Provide a grounding bus in the RTU cabinet to terminate the drain wires from all control and indication cables.

F. Install a 120 Vac receptacle in the RTU cabinet, and supply power to the receptacle from the ac distribution panel.

G. Install loosely-shipped current and voltage transducers in the associated equipment and connect the transducer outputs to the remote terminal unit.

3.03 TESTING AND ACCEPTANCE

A. Perform and successfully pass factory tests and field Commissioning tests prior to the equipment being accepted by SEPTA.

B. Factory Tests


1. Refer to Section 16950 – Testing of Electrical Equipment

2. Furnish SEPTA with certified copies of the results of all tests and measurements made to determine the quality and serviceability of the equipment manufactured in accordance with this Specification. Such results shall show compliance with all the requirements of this Specification. SEPTA approval at actual acceptance test shall be contingent upon prior receipt and approval of these certified tests. During the actual acceptance test, minimum of 10% of all points shall be tested. If problems arise, SEPTA may specify that more or all points within the questionable remote terminal unit be re-tested.

3. The factory acceptance test shall be witnessed by a minimum of two (2) representatives of SEPTA.

C. Field Tests

1. Perform the Field testing according to the SEPTA-approved SCADA System Test Plan

2. Perform the specified field tests including end-to-end tests on all points to the satisfaction of SEPTA including:

a) End-to-end tests for all new SFC equipment and associated switch gear, breakers and relays via designated communication lines.

b) End-to-end tests for Intrusion Alarm System via designated communication lines.

c) End-to-end tests for Fire Alarm and Detection via designated communication lines.

D. Submit to SEPTA the test results.

END OF SECTION


SECTION 16950

TESTING OF ELECTRICAL EQUIPMENT

PART 1 - GENERAL


A. This section specifies the requirements for factory and field-testing, on electrical equipment furnished and installed under this Contract. This section also includes testing of existing auxiliary power transformers.

B. The following equipment and/or material shall be tested in accordance with the requirements of this Section:

1. SCADA System

2. Medium voltage cables

3. Composite Copper/Fiber Optic Cable

4. Battery, Battery Charger, and DC Distribution System

5. Auxiliary Power Transformers

6. Vacuum Circuit Breakers

7. Disconnect and Grounding Switches (non-load break)

8. Automatic Transfer Switches as integrated with the indoor switchboards

9. Panelboards

10. Fuse Cutouts

11. Receptacles

12. Motor Starters

13. Enclosed Switches

14. Panelboards

15. Lighting System

16. Fire Alarm

17. Intrusion Detection and Alarm

18. Thermo-graphic testing of the Auxiliary Power Equipment







1.03 SUBMITTALS

A. Provide a detailed testing program for the equipment in accordance with the test procedures described in Section 01300 and the referenced industry Standards organizations.

B. Submit a Factory Test plan and a Field Test Plan to SEPTA 60 days prior to performing the tests. Describe the overall test process, including the responsibilities of individuals and documentation of the test results. Demonstrate that a complete, safe and operable power system has been provided and that as a minimum, the following data:

1. A flow diagram indicating the logical sequence of tests starting with material receiving tests and inspections and concluding with system demonstration tests

2. Test Schedules

3. Record-keeping assignments, procedures, and forms

4. Procedures for monitoring, correcting and re-testing variances

5. Procedures for controlling and documenting all changes made to the hardware after the start of testing

6. Block diagrams for the hardware test configuration including external data transmission interfaces, and detailed descriptions of any and all test and/or simulation equipment

7. Estimated duration of each test

8. Software version numbers, CRC check sums, date and time for every module

9. Calibration and the traceability to known standards of hardware, software, simulation tools and test equipment to be used for testing

C. Test procedures and reports, for tests specified, shall conform to the requirements herein.

1. Detailed test procedures will not be required if such procedures are adequately described in ANSI, IEEE, or NEMA Standards, or standards reviewed by the Resident Engineer, and copies of the standards are submitted with the related test. Include the following in all detailed test procedures (minimum requirement):

a) Test purpose

b) Applicable standards or code including specific paragraph or section reference

c) Equipment to be tested

d) Test set-up

e) Chronological step-by-step test sequence

f) Pass/fail acceptance criteria

g) Test data form for recording and documenting test information

h) Pass/fail test conclusions

i) Signature of personnel

j) Date of testing

k) Test Duration and Schedule


2. No testing shall commence until SEPTA’s Project Manager or designated representative, reviews and approves the test procedures.

3. No testing shall commerce until all control equipment, keypads, alarms, detectors, and switches have been checked as an integrated system in accordance with the manufacturer’s recommendations.

D. Prepare test reports. Two copies shall be submitted to SEPTA’s Project Manager for review and comments. After acceptance, six final copies of the certified test report shall be submitted to SEPTA’s Project Manager.


A. IEEE - Institute of Electrical and Electronic Engineers

B. ANSI - American National Standards Institute

C. AEIC - Association of Edison Illuminating Companies

D. NFPA - National Fire Protection Association

E. NEMA - National Electrical Manufacturer’s Association

F. Perform the testing described herein, according to the referenced standards and this Specification.

G. Factory Testing Witness Program

In case of a design or manufacturing failure during factory testing, design tests need to be performed on all similarly-designed equipment that are included in this Project. Perform such tests on replacement equipment until, and unless, a satisfactory resolution of the problem is accepted by SEPTA. In the event of such a failure, assume all costs of replacement, retesting, including the cost for SEPTA’s representatives to witness the testing.

In the event that equipment provided for this Project fails during Field Commissioning, assume complete costs for shipping the equipment to the manufacturer, replacement equipment, complete factory testing, SEPTA witness of factory testing, return shipment to the Project site, installation, and commissioning.

In the event that equipment provided for this Project fails during Warranty, after Project Acceptance (All Warranties begin with Final Acceptance), SEPTA will follow standard warranty procedures.

H. Field Testing

1. Provide the services of a certified National Electrical Testing Agency independent testing company to perform the field testing Work covered in this Section.

1.05 DELIVERABLES

A. Six hard copies and one CD-ROM of the certified test reports for all field tests in Adobe Acrobat (PDF) format

PART 2 - PRODUCTS

NOT USED

PART 3 - EXECUTION


3.01 FACTORY TESTING

A. General Requirements

1. The purpose of the factory test is to demonstrate that each of the systems meet or exceed the functionality and performance requirements specified in the specifications.

a) Perform all factory tests according to the applicable standard whether such tests are specified herein or not.

b) Provide the services of an independent testing laboratory to perform design tests of equipment manufactured for specification compliance. Submit copies of certified results from prior design testing for all items of equipment that are being furnished without any modification from the item of equipment originally tested. Design tests are required if certified test results from prior article testing are not available.

c) In addition to the specific design tests, the testing shall include items such as:

1) Verification of all mechanical specifications

2) Verification of all operating, control and indicating functions

3) Electromagnetic compatibility, temperature, humidity, shock and vibration testing

d) The test data for each unit shall be certified by the testing laboratory. The equipment shall be fully operational during electromagnetic compatibility, temperature, humidity, shock and vibration testing.

e) Submit the certified test data reports to SEPTA’s Project Manager for approval. Do not withhold any certified test data from SEPTA’s Project Manager even though the certified test data may indicate that a unit of equipment has failed the test. If any single unit equipment fails to meet the specifications, or fails to provide the correct control or indication functions, then the unit of equipment will be inspected by SEPTA’s Project Manager, who shall determine whether the equipment shall be repaired, redesigned or shall be replaced and completely retested. In order to pass the test, the test report must indicate that each unit of equipment meets or exceeds the functionality and performance requirements of the tested equipment.

2. Require that, at designated stages of the production process, the materials, components, assembly, subsystems and systems under test comply with the Contract Drawings and Specifications. The Proof of Verification shall be submitted to SEPTA’s Project Manager.

3. SEPTA’s Project Manager reserves the right to witness all Factory Testing. Within 45 days prior to the start of all factory testing, notify SEPTA’s Project Manager in writing. A detailed bar-chart schedule of the tests and inspections and sample test reports shall be included. Equipment or material that fails factory testing or malfunctions during the testing shall be replaced with new equipment and retested until the requirements are met. The equipment or material will not be accepted until the test reports are submitted to SEPTA’s Project Manager for approval.


3.02 FACTORY AND FIELD TESTS OF EQUIPMENT AND MATERIALS

A. SCADA RTU

1. Factory Tests

a) Perform SCADA RTU – mainframe operational and functional tests that exercise all I/O and their associated control, supervisory, and indications.

2. Field Tests

a) After the installation of the system has been completed, conduct a test of the system similar to the witnessed factory acceptance test to verify that the system has been properly installed and is properly operating.

b) Assume responsibility for the SCADA system and the Communications system performing as an integrated system. Assume responsibility for any and all equipment and cabling failures that prevent full SCADA operation.

c) Submit copies of test reports to SEPTA within five (5) days after completion of testing in accordance with Section 01300 – Submittals.

3. Test Equipment:

a) Provide all necessary test equipment and instruments to perform the required tests.

4. Site Tests:

a) SEPTA and manufacturer’s Field Engineer will test the supervisory system from the Power Dispatcher’s location of the SEPTA Control Center, 1234 Market Street, 19th floor, Philadelphia, Pennsylvania, for correct operation. Supervisory Master Unit and telephone line failures will be SEPTA’s responsibility. Assume responsibility to require all other failures and deficiencies be corrected under this Contract, by the SCADA RTU manufacturer’s Field Engineer.

B. Cables and Conductors

1. Medium Voltage Cables

a) Factory Tests in accordance with NEMA Standard WC74

1) Unaged and Accelerated aging tests

2) Conductor DC Resistance

3) Conductor Diameter Measurement

4) Tensile, Elongation & Set

5) Cold Bend

6) Electrical Accelerated Water Absorption

7) Ac Voltage Withstand

8) Partial-Discharge Test

Each reel of shielded power cable shall comply with the partial discharge test requirements of AEIC.

9) Insulation Resistance


10) Dielectric Constant & Dissipation Factor

11) Sunlight Resistance Test

12) Cable Tray Flame Test

13) Spark Test

14) Insulation Corona Discharge

15) Resistance for Class IV EPR

b) Field Tests

1) Megger Test

2) Hi-Pot Test using dc voltage level as recommended by the manufacturer

C. Composite Copper/Fiber Optic Cable

1. Field Tests

a) Procure and provide all necessary test equipment, test cables, adapters, load boxes, light sources, and any other hardware required to perform cable testing.

b) Before beginning testing, submit a list of all test equipment to be used to SEPTA for their approval.

c) Schedule all testing with SEPTA’s Project Manager in advance of testing: Additionally, SEPTA reserves the right to witness testing of all installed cabling

d) Submit each test report to SEPTA for approval. Approval is based upon the expected results for the cable being tested, and upon the corrective actions taken by the contractor when specific tests fail

e) Each optical fiber shall be tested from end-to-end at each patch panel to determine end-to-end attenuation, including connector and splice loss

f) Each element of all new single-mode fiber optic cabling shall be tested for continuity and attenuation in both directions at both 1310 nm and 1500 nm, with a fiber optic light source and power meter. Before beginning testing, the contractor shall submit a design fiber optic loss budget for the segment to be tested, based upon the length of fiber optic cable installed. When tested at both windows in both directions, the measured attenuation of each fiber optic cable segment shall be less than or equal to the design attenuation of the segment being tested. Until this condition has been met, the installation shall not be considered complete, and will not be accepted.

g) Each and every multi-pair copper conductors shall be tested for shorts, opens, continuity, and grounds. These test results for the cable shall be furnished to SEPTA’s Project Manager.

Corrective Action:

If a cable test fails for any reason, the contractor shall determine the cause of the failure. If a defective cable, outlet insert, wiring block, and/or patch panel is found to be the cause of failure, replace the material in the question and assume responsibility for all costs associated with its replacement.


h) Perform the tests at both 1310 nm and 1550 nm wavelength. If any fiber testing reveals an abnormal test result, outside of the manufacturer’s normal parameters, then conduct a test of all fiber strands in the affected sheath with an Optical Time Domain Reflectometer (OTDR) to identify the source and location of the problem.

D. Batteries

1. Field Tests

a) Develop test procedures for function tests of the battery systems and submit to SEPTA’s Project Manager for approval prior to testing.

b) Perform the following field test in the substation during the commissioning of the battery system:

1) Constant current capacity discharge test in accordance with ANSI Standard 450. The test shall verify the capacity discharge rate of the battery system for eight hours. Provide computer plots and tabular data of the cell voltage taken before and after installation of the “Cell Voltage Equalizers”, to SEPTA’s Project Manager.

2) Upon completion of the testing, the float voltage, equalizing voltage, specific gravity, and temperature basis shall be set and maintained in accordance with the manufacturer’s recommendations.

E. Battery Chargers

1. Factory Tests

a) The following factory tests shall be performed on one battery charger per NEMA PE-5 as follows:

1) Dielectric

2) Voltage adjustment

3) Temperature rise

4) Current limit

5) Short circuit

6) Static voltage deviation

7) Efficiency measurement

8) Power factor measurement


10) Audible Noise

11) Stability and response

12) Transient voltage withstand

13) No load

b) Additional factory tests shall be performed on all battery chargers per NEMA PE-5 as follows:


1) Dielectric

2) Full load tests with a 270 ampere-hour, 60 cell, lead-acid battery, running in parallel with, and without a battery, with momentary overload. The full load test shall show output ripple voltage lies within .06% of normal output voltage.

3) Voltage

4) Current limit


6) Charging capability within 12 hours, of a battery already discharged to 105 Vdc from its nominal 130 Vdc value

7) Float voltage tests

8) Detection of positive and negative grounds circuit and system, overload protection, and “low battery voltage” status indications

9) Temperature compensation

10) Automatic “Equalizing Charge” capability

F. Vacuum Circuit Breakers

1. Factory Tests

The circuit breakers shall be tested in accordance with the Production Test outlined in IEEE C37.09 and shall include, but not be limited to, the following:

a) Leak Test

b) Resistance Test (switch contacts)

c) Megger control and power wiring

d) Dielectric Tests (Hi-pot test of vacuum interrupter)

e) Mechanical Operation Tests

f) Switch interlock scheme operation and restraint

g) Grounding of Instrument Transformer Cases Tests

h) Electrical Operation and Control Wiring Tests

i) Current transformer test

j) Nameplate check

k) Resistors, heaters, and coils check tests

l) Control and secondary wiring check tests

m) Clearance and mechanical adjustment check tests

2. Other Factory Tests

The following factory tests need not be performed if the manufacturer has tested identical product within the past two years. If such conditions apply, provide certified test reports for the following type tests:

a) Basic Impulse Level


b) Mechanical operational tests

c) Timing test

d) Stored energy system test

e) Low frequency withstand voltage tests on major insulation components

f) Low frequency withstand voltage tests on control and secondary wiring

3. Field Tests

a) Inspect the unit for any damage during shipment to the site and confirm that all safety signs are affixed to the cubicle exterior

b) Verify phase rotation of all cables

c) Megger test

d) Perform mechanical operation of all switches and interrupter.

e) Test the cubicle heater/thermostat system

f) Test the controller

g) TTR tests

h) Hi-pot tests

i) Phase sequence tests

G. Disconnect and Grounding Switches

1. Factory Tests

All disconnect/ground switches and related equipment shall receive the following tests as described in IEEE 1247.

a) 60 Hz wet and dry withstand tests

b) Impulse wet and dry withstand voltage test

c) Open gap withstand test

d) Radio-influence tests

1) When tested at the test voltages that are applicable to the circuits on which the switches are to be used, all switches, including all terminal parts, shall be corona-free and the limits of radio influence voltage established by applicable NEMA standards shall not be exceeded.

e) Temperature rise tests

f) Interrupting tests

g) Short-time current tests

h) Capacitive current tests

i) Routine manufacturers tests

j) Voltage tests on control and auxiliary contacts

k) Mechanical Operations tests


2. The manufacturer must have available for SEPTA’s Representative, a disconnect/ground switch at the plant location. This switch shall be inspected and tested for dimensional accuracy and compatibility with mating components.

3. Certified copies of test reports shall be submitted as referenced herein to SEPTA’s Project Manager.

4. The SEPTA Project Manager and/or Representative, reserves the right to attend the test.

H. Automatic Transfer Switches

1. Factory Tests

a) The complete ATS shall be factory tested to ensure proper operation of the individual components and correct overall sequence of operation and to ensure that the operating transfer time, voltage, frequency and time delay settings comply with the specification requirements.

b) Upon request, the manufacturer shall provide a notarized letter certifying compliance with all of the requirements of this specification including compliance with the above codes and standards, and withstand and closing ratings. The certification shall identify, by serial number(s), the equipment involved. No exceptions to the specifications, other than those stipulated at the time of the submittal, shall be included in the certification.

c) The ATS manufacturer shall be certified to ISO 9001 International Quality Standard and the manufacturer shall have third party certification verifying quality assurance in design/development, production, installation and servicing in accordance with ISO 9001.

I. Enclosed Switches

1. Field Tests

a) Continuity

b) Megger Test

J. Panelboards

1. Field Tests

a) Cable Lug Mechanical Torque (All lugs)

b) Continuity Test

c) Megger Test

K. Fuse Cutout

1. Field Tests

a) Visual inspection of fuse type and rating

b) Function test (Close – Open)

c) Megger Test

L. Receptacles

1. Field Tests


a) Continuity Test

b) Polarity / Ground Configuration

c) Visual Inspection of receptacle

M. Motor Starters

1. Field Test

a) Visual Inspection of starter and enclosure

b) Continuity Test

c) Function Tests and Control Circuit

d) Megger Test

e) Confirm proper overload units are installed

N. Enclosed Switches

1. Field Tests

a) Visual inspection of enclosure and switch mechanism

b) Functional Tests (Close – Open) or (Close ‘A’-Open-Close ‘B’)

c) Continuity

d) Megger

e) Confirm proper fuse type and ratings of fusible switches

O. Lighting System

1. Field Tests

a) Submit an illumination level report performed by a qualified independent testing agency after final installation/construction of the lighting system.

b) The report shall include normal lighting and emergency lighting.

c) Submit an illumination level report for the Emergency Lighting system as follows:

1) Measure lighting levels on all egress paths, at each stair landing, at middle of stairs, at changes in direction, at doorways and every 25’ along path

2) In areas where daylight contributes to the total illumination, measure lighting levels at night.

P. Fire Alarm System

1. Field Tests

a) Provide the service of a competent, factory-trained engineer or technician authorized by the manufacturer of the fire alarm equipment to technically supervise and participate during all of the adjustments and tests for the system.

b) Before energizing the cables and wires, check for correct connections and test for short circuits, ground faults, continuity, and insulation.


c) Open initiating device circuits and verify that the trouble signal actuates.

d) Open and short notification appliance circuits and verify that the trouble signal actuates.

e) Ground initiating device circuits and verify response of trouble signals.

f) Check all alarm notification devices.

g) Check installation, supervision, and operation of smoke detectors.

h) Verify that each initiating device alarm signal is properly received and processed by the fire alarm control panel (Walk Test).

i) Conduct tests to verify trouble indications for common mode failures, such as alternating current power failure. Consult the manufacturer’s manual for other common mode failures and conduct the described testing procedures.

j) At the final inspection a factory-trained representative of the manufacturer of the major equipment shall demonstrate that the systems function properly in every respect.

Q. Intrusion Detection and Alarm System

1. Field Tests

a) Provide the service of a competent, factory-trained engineer or technician authorized by the manufacturer of the intrusion alarm equipment to technically supervise and participate during all of the adjustments and tests for the system.

b) Before energizing the cables and wires, check for correct connections and test for short circuits, ground faults, continuity, and insulation.

c) Open initiating device circuits and verify that the trouble signal actuates.

d) Open and short notification appliance circuits and verify that the trouble signal actuates.

e) Ground initiating device circuits and verify response of trouble signals.

f) Check all alarm notification devices.

g) Verify that each initiating device alarm signal is properly received and processed by the intrusion alarm control panel (Walk Test).

h) Conduct tests to verify trouble indications for common mode failures, such as alternating current power failure. Consult the manufacturer’s manual for other common mode failures and conduct the described testing procedures.

i) At the final inspection a factory-trained representative of the manufacturer of the major equipment shall demonstrate that the systems function properly in every respect.

R. Auxiliary Power Transformers

1. Field Tests


a) The purpose of the field testing of the auxiliary power transformers is to confirm that there are no degraded components in the existing transformers.

b) Perform loss angle and dissipation factor tests at the beginning of the construction phase. Provide written results to SEPTA for evaluation.

S. Thermographic Testing of Auxiliary Power Equipment

1. Perform thermographic testing and record circuit parameters for the following auxiliary power equipment:

a) All electrical equipment cable terminations whose conductor size is #4 AWG or larger

b) Panelboards

c) Vacuum switches

d) Transformers

e) Transfer switches

f) Motor starters

g) Contactors

END OF SECTION




SECTION 16951

SEQUENCE OF EVENTS RECORDER

PART 1 - GENERAL


A. This specification provides details for a Sequence of Events Recorder (SER) for a four-unit static frequency converter station being supplied by a 230 kV, 60 Hz, 3-phase system and which delivers power to a 13.2 kV, 25Hz, 1-phase system. The Sequence of Events Recording system shall gather hardware and software events from equipment and stores the data into a database for viewing and analysis. The system is useful for troubleshooting problems that may occur at the Wayne Junction Static Frequency Converter Building.




C. Section 16050 – Basic Electrical Materials and Methods

D. Section 16170 – Grounding and Bonding

E. Section 16970 – Electrical Testing – Traction Power Equipment

1.03 REFERENCE STANDARDS

A. Pertinent provisions of the following listed standards shall apply to the work of this Section, except as they may be modified herein, and are hereby made a part of this Specification to the extent required:

B. Institute of Electrical and Electronic Engineers (IEEE)

1. C2 – National Electrical Safety Code (NESC)

2. C37-90 – Relays and Relay Systems Associated with Electric Power Apparatus

3. C39-90.1 – Surge Withstand Capability (SWC) Tests for Protective Relays and Relay Systems

4. 802.3 – Standard for Information Technology – Telecommunications and Information Exchange between Systems – Local and Metropolitan Area Networks – Specific Requirements Part 3 (10 Base T)

5. 802.3u – Ethernet Standards for Local and Metropolitan Area Networks (100 Base T)

6. C62.41 – Recommended Practice for Surge Voltage in Low-Voltage AC Power Circuit

1.04 SUBMITTALS

A. Submittals shall be in accordance with the requirements of Section 01300, SUBMITTALS, except as modified herein.

B. Submit manufacturer's data for all products specified herein including, but not limited to, dimensions, electrical rating and identification.


C. Outline drawings for type of equipment and each shipping section with overall dimensions, sizes and weights.

D. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

1. The following information shall be submitted for record purposes:

a) Final as-built drawings and information for items listed in this section.

b) Connection diagrams.

c) Installation information.

d) Equipment anchorage details.

e) Hardware, software, and operation manuals for all hardware and software products to be utilized in the system.


A. Quality Assurance/Quality Control shall be in accordance with the requirements of Section 01400, QUALITY REQUIREMENTS.

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

C. Select a manufacturer who is regularly engaged in the repetitive production of SER of the types and ratings described in this Section using the latest technology and who has proven record of successful manufacturing and testing of same or similar type equipment. The equipment manufacturer shall have and maintain ISO 9001 certification.

1.06 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Ship each unit securely packaged and labeled for safe handling in shipment and to avoid damage or distortion.

B. Protection against concealed damage.

PART 2 - PRODUCTS

2.01 SER HARDWARE AND SOFTWARE COMPONENTS

A. The SER System shall be ibaPDAv6 System or approved equal.

B. The SER software shall be provided per manufacturers recommendations and shall include:

1. Multiple client connection licenses.

2. Data Store licenses.

PART 3 - EXECUTION

3.01 GENERAL

A. The work under shall be performed in accordance with NEC, local codes and regulations, manufacturers’ recommendations and in accordance with these Specifications.


B. The Contractor shall use the SCADA/RTU internal clock for a synchronized time at the facility.

C. The Contractor shall locate and install all equipment as indicated on the Contract Drawings.

3.02 TESTING

A. Perform testing as required by these Specifications and accepted industry practice.

B. The Contractor shall test the SER hardware and software system to ensure that it is fully functional and operational. Successful test shall be where the user can view the event logs of all equipment or components being monitor and can sort, filter, and print the events logs.

C. The tests required by this specification are as follows:

1. Continuity tests on all wiring

2. Insulation resistance tests

3. Functional tests including test to verify time response with maximum number of inputs during a “Waterfall Test”. The Waterfall Test shall consist of having 100% of the input change state four (4) times in ten (10) seconds with no loss of data or resolution. The test shall also include changing state one millisecond apart from each other during the last one second of the test. The “passed” criteria shall be no loss of data with the full millisecond resolution and accuracy.

4. Software validation/verification.

END OF SECTION




SECTION 16970

ELECTRICAL TESTING – TRACTION POWER EQUIPMENT

PART 1 - GENERAL


A. This section includes requirements for testing of traction power equipment for the Wayne Junction SFC Rehabilitation Project.

B. Factory Tests:

1. The factory tests include:

a) Design Tests

b) Production Tests

2. This section describes the factory tests in general. Detailed requirements for equipment factory tests are specified in the individual equipment sections.

C. Field Tests:

1. The field tests include all commissioning and operation tests. The tests include:

a) Tests performed prior to the equipment energization

b) Tests performed following the equipment energization

2. This section describes detailed requirements for the field tests.

D. Describe in the bid any deviations to the specified tests





D. Section 09910 – Paints and Coatings



G. Section 16262 – Static Frequency Converter

H. Section 16330 – Traction Power Two-Pole Circuit Breakers

I. Section 16791 – Combined Relay and Control Switchboard

J. Section 16910 – Electrical System Control (SCADA)

1.03 SUBMITTALS

A. Submit the following documents for each test for SEPTA’s review and approval:

1. Test Plans:


a) Prepare and submit to SEPTA a comprehensive Test Plan for all factory and field tests to be performed. Include a detailed schedule of all tests including starting and completion dates.

b) Include the following information for each test:

1) Title of the test with reference to the appropriate Section of the Contract Documents.

2) Name and qualifications: of the testing company to be used for the test. Include the full background data of the proposed testing company, including references of prior work or projects having requirements and/or complexities similar to this Project.

3) Names and qualifications: of the management personnel responsible for the test and senior engineering personnel performing the test.

4) Test location.

5) Test objectives including pass/fail criteria.

2. Test Procedures:

a) Prepare and submit to SEPTA Test Procedure for each test to be performed. No testing shall occur and no results shall be considered valid until approval of the test procedures by SEPTA.

b) Include in each test procedure the following information:

1) Title of the test with reference to the appropriate Section of the Contract Documents

2) The name of the organization performing the test

3) Test location

4) Scheduled starting and completion date

5) Test objectives

6) Applicable procedures specified in ANSI, IEEE, or NEMA standards

7) Test methodology and step-by-step procedure for performing the test

8) Instrumentation setup, circuit diagrams, and test sequence.

9) Required equipment and instrumentation

10) Forms to be used to record and evaluate data

11) Pass/fail criteria and justification for the criteria

12) SEPTA's personnel requirements

13) Test evaluation procedures

14) Test report format

3. Test Reports:

a) Prepare a Test Report for each test performed.


b) Include the following information in each test report:

1) Title of the test with reference to the appropriate Section of the Contract Documents

2) The name of the organization performing the test

3) Test location

4) Starting and completion date

5) Test objectives

6) Applicable procedures specified in ANSI, IEEE, or NEMA standards

7) Test methodology and step-by-step procedure for performing the test, including instrumentation setup, circuit diagrams and test sequence

8) List of all equipment and instrumentation used including model number, serial number and calibration date

9) Pass/fail criteria and justification for the criteria

10) Test evaluation procedures

11) Conditions of test, including precipitation, temperature and humidity

12) Raw test data

13) Reduced test data in tables, charts, photographs and any additional data required to support the test results

14) Descriptions of all equipment and material failures and the reasons for the failure

15) Descriptions of all modifications to the equipment or wiring performed and the reasons for the modifications, and the names of individuals approving such modifications

16) Conclusions and signatures of responsible test supervisors

c) Submit certified test reports to SEPTA.

4. Arc Flash Study per methods compliant with NFPA 70E.



1. ANSI C 29.1: Test Methods for Electric Power Insulators

2. ASTM D 3487: Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus

3. ASTM D 3612: Standard Test Method for Analysis of Gasses Dissolved in Electrical Insulating Oil by Gas Chromatography

4. IEEE 81: Guide for Measuring Ground Impedance of a Ground System

5. NETA: Standards for Testing


PART 2 - PRODUCTS

2.01 TEST RESPONSIBILITY

A. The Contractor is responsible for all tests specified.

B. Perform tests under this Contract to verify compliance with all Contract Documents and design and performance requirements to the satisfaction of SEPTA.

2.02 TESTS INCLUDED

A. Perform all tests specified in the Contract Documents, and any other tests required in connection with Quality Assurance program. Perform all tests otherwise required to bring the substation to revenue service.

B. Include all tests normally performed and tests called for in the ANSI, IEEE and NEMA Standards.

C. The tests specified under the Contract are not to be considered to be all-inclusive and shall not relieve the Contractor from the responsibility of verifying compliance with all Contract Documents and design and performance requirements to the satisfaction of SEPTA.

2.03 TEST INSTRUMENTS, PERSONNEL, AND MATERIALS

A. Furnish all test instruments and equipment as well as personnel and materials necessary for performing all tests.

B. Define any support required from SEPTA or others for tests

2.04 TEST FAILURE

A. Replace and/or repair damaged items due to test failures at no cost to SEPTA.

B. Repeat any test showing unsatisfactory results. The original unsatisfactory results, description of corrections, and the new satisfactory results shall be part of the test report provided to SEPTA.

2.05 TEST WITNESSING

A. Notify SEPTA prior to performing any test.

B. Coordinate all field tests with SEPTA. Request flagmen, track and power outage at the time of test notification.

C. SEPTA may witness any and all testing.

2.06 TEST ACCEPTANCE

A. Final acceptance of each test will be made by SEPTA upon satisfactory completion of the test.

PART 3 - EXECUTION

3.01 FACTORY TESTS

A. Perform design and production tests in the factory prior to shipment of the equipment. Setup, adjust, and test all equipment to ensure completeness, adequacy and proper functioning of equipment for the application intended.


1. Design Tests:

a) Perform design tests on the first completely finished system component or equipment assembly of each type to establish their characteristics and conformity to the requirements of the Contract Documents or to applicable industry standard if there is not an explicit Contract Document requirement.

b) SEPTA will waive requirements for design tests on components and equipment assemblies in regular production, for which design tests have already successfully been performed on the same or substantially the same equipment as that proposed for this Contract, and provided copies of the certified Design Test Reports are furnished to SEPTA.

c) If the design tests were performed at power frequencies other than 25 Hz, calculations must be made to show that the expected performance will be successful at 25 Hz. Calculations must be performed by a professional Engineer, registered in the state of Pennsylvania. A complete set of calculations, with the results clearly shown must be submitted to SEPTA.

d) Such a waiver does not in any way relieve the Contractor from full responsibility regarding the equipment quality, reliability, performance, and safety.

2. Production Tests: Perform production tests on every system component and equipment assembly for the purpose of checking the correctness, quality and uniformity of manufacturing processes.

B. Refer to the specific sections of the Contract Documents for individual equipment test requirements.

3.02 FIELD TESTS

A. Tests Prior to Equipment Energization:

1. Verify that all equipment is installed according to Contract Documents.

2. Verify that test personnel are wearing PPE in accordance with NFPA 70E Arc Flash Study results report.

3. Ground Grid Resistance Test:

a) Measure the substation ground grid resistance. Compare the test results with design calculations.

b) In the event that the measured value of resistance is higher than the design value, drive additional ground rods into the earth and connect the rods to the grounding grid to bring down the resistance to the design value.

c) Verify grounding connections to all equipment and components. Measure the resistance of a few sample connections by low resistance ohmmeter.

4. Visual Inspection:

a) Perform visual inspection to verify that all substation equipment has been correctly installed, connected, and grounded, and that there are no equipment incompatibilities or omissions.

b) Include visual inspection and checks of all equipment, including:


1) Equipment mountings

2) Conductor installation

3) Bus connections

4) Bus insulation installation

5) Electrical clearances especially between the cable terminations and the switchgear cubicles and on the disconnect switches and surge arresters

6) Control and power cable connections and terminations

7) Wire and cable termination markings with respect to shop drawings

8) Cable attachments

9) Disconnect switch and surge arrester cable connections

10) Disconnect switch installation, operation, and blade to contact alignment

11) Relay and auxiliary contact configuration check

5. Functional and Operational Tests:

a) Perform functional and operational tests to verify that all substation equipment functions correctly and in accordance with the Contract Documents and SEPTA approved control schematics.

b) After successful testing, each function circuit shall be approved and so designated on the applicable control schematic.

c) Test all interlocking functions to verify correct operation and safety of the design.

d) Calibrate and adjust all instruments.

6. Dielectric Tests:

a) Perform dielectric test for duration of one minute at manufacturer-recommended and SEPTA-approved voltages complying with the ANSI/IEEE standards for the equipment voltage class.

b) Test the following equipment

1) Power cables and control wiring interior and exterior to the substation

2) Switchgear wiring

3) Switchgear cubicles and circuit breakers

4) Switchgear busbars

5) Circuit breakers

6) Disconnect switches

7. Continuity and Resistance Tests:


a) Check all power cables for electrical continuity. With the switchgear de-energized, the resistance of the cables shall be measured and the results shall be compared with calculated values and any deviations shall be analyzed and explained.

8. Relay Coordination and Calibration Tests:

a) Set all protective devices in accordance with the results of the Protective Device Coordination Study.

b) Perform high current, low voltage secondary injection tests at 25 Hz on all circuit breaker protective devices.

c) For each protective device verify simultaneously satisfactory operation of the current transformer, the voltage transformer, the secondary winding polarity, the relay operation, the integrity of tripping circuit, and the circuit breaker operation.

d) Perform all necessary tests to demonstrate and confirm satisfactory and correct coordination of all protective devices and circuit breakers.

9. Transformer Testing:

a) Perform the following tests and analyses on Traction Power transformers:

1) Determine insulation resistance and power factor using Doble test.

2) Determine the dielectric strength and total acid number of the transformer oil in accordance with ASTM D 3487.

3) Perform dissolved gas analysis of the transformer oil in accordance with ASTM D3612.

4) Perform test for corrosive sulfur in accordance with ASTM D1275 (latest edition).

10. Supervisory Control and Data Acquisition System Tests

a) Following installation of local area network, the network server, the SCADA interfaces, conduct the following tests:

1) Confirm proper operation of all bay modules, local area network, and the network server.

2) Confirm all lines for proper data communication.

b) Perform a complete operational test of the equipment. Test all SCADA control, monitoring, and measuring functions on all equipment. Test all SCADA functions for satisfactory local operation, remote operation from the Control Center, and remote operation from the network server. Perform point-to-point checks on all equipment as follows:

1) Initiate a status change at each supervised, controlled and measured item of equipment and verify that the status change has been correctly transmitted to the Control Center.

2) Apply a control signal at each control point in the Control Center and the network server and verify that the controlled item of equipment responded correctly.


3) Apply an input signal to all measurement transducers and confirm the receipt of correct measurement at the Control Center.

4) Verify correct operation of annunciator functions that are reflected in the HMI screens.

c) Ensure that all appropriate indications are displayed and logged and that all appropriate control actions are granted.

B. Tests Following Equipment Energization:

1. System Energization:

a) Close all feeder, trolley, and bus tie circuit breakers.

b) Check voltage on all busbars.

c) Close the transformer circuit breakers.

d) Monitor feeder and trolley circuit breaker currents while one train operates between Wayne Junction and Jenkintown on each track, one track at a time.

2. Closing and Opening Switching Surge Test:

a) Close and open one 2-pole circuit breaker randomly 20 times and measure the switching surge.

b) Close and open one 24 kV circuit breaker randomly 20 times and measure the switching surge.

c) Close and open one 12 kV circuit breaker randomly 20 times and measure the switching surge.

3. Short Circuit Tests:

a) Develop a comprehensive, step-by-step program of short-circuit tests in order to achieve all of the test objectives. Wherever possible, use a single fault test to simultaneously accomplish several requirements.

b) Perform short circuit tests to verify correct settings and operation sequence of protective relays.

c) The Traction Power system configuration shall be the same as for revenue operation.

d) Short Circuit Test Locations: Apply bolted short circuits at SEPTA’s Wayne Junction Substation by closing a disconnect switch or circuit breaker on energized line.

e) Perform the following line-to-rail short circuit tests at each location:

1) Trolley-to-rail on one selected trolley circuit

2) Feeder-to-rail on one selected feeder circuit

f) Perform the following line-to-ground short circuit tests at each location:

1) Trolley-to-ground on one selected trolley circuit

2) Feeder-to-ground on one selected feeder circuit


g) Perform the following feeder-to-trolley short circuit test at each location:

1) Feeder-to-trolley on one selected feeder and trolley circuit

h) Fault resistance: No intended resistance is to be inserted.

i) Monitor each test in the substation and in the Control Center via SCADA system.

j) Measure and record the following variables.

1) Currents in the circuit breakers under test

2) Current returning via return cables

3) Operation of the of protective relays and circuit breakers

4) Location of the fault as displayed by the distance protective relay

5) Transient recovery voltage in one 2-pole circuit breaker

6) Transient recovery voltage in one 12 kV circuit breaker

k) If substation circuit breakers do not clear the fault, the test shall be terminated. Analyze the test results, implement any corrective measures and repeat the tests.

4. Post Short Circuit Inspection:

a) Apply all required safety measures by equipment grounding and by other approved means.

b) Switchgear:

1) De-energize the switchgear and open all cubicles.

2) Perform a visual check and inspect for any signs of damage.

3) Revise the relay settings and reset relays, if required.

c) Transformers:

1) Determine insulation resistance and power factor using Doble test.

2) Perform dissolved gas analysis of the transformer oil in accordance with ASTM D3612.

5. System Operation Tests

a) Reenergize the system and observe system revenue operation.

b) Monitor and record all measured values for two hours.

c) Thermo-graphic Measurement

1) Apply all required safety measures and recommendations provided in the Arc-flash Study. Wear the appropriate Personal Protective Equipment.

2) Test all traction power busbar connections and overhead system connections with Thermo-graphic Test Instrument.


END OF SECTION

SOUTHEASTERN PENNSYLVANIA TRANSPORTATION AUTHORITY

SEPTA WAYNE JUNCTION SFC REHABILITATION

SEPTA PO NO. S-863197

STV PROJECT NO. 4017500

DESIGN CRITERIA DOC. NO. EVAL-4017500-E-002

REV. C NOVEMBER 29, 2016

Document Name Design Criteria Seal, Signature, and Date Document Number EVAL-4017500-E-002 Revision C Date November 28, 2016 Total Pages 101 Client SEPTA Project Wayne Junction SFC Rehabilitation Location Philadelphia, PA Engineering Firm STV Incorporated

1818 Market St., Suite 1410 Philadelphia, PA 19103

Certificate of Authorization N/A Professional Engineer Brandon S. Swartley, P.E. License Number PE055403E

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 2 of 87

Revision Description

Revision Date Description A 3/27/16 30% submittal B 9/23/16 60% submittal C 11/29/16 60% submittal revised

Action Name

Prepared Brandon S. Swartley, P.E.

Reviewed John Fish, P.E.

Approved Brandon S. Swartley, P.E.

Contributing Authors

Brandon Swartley SFC and Power Systems Jerry Jakubowski Traction Power John Hopkins Electrical Power Gustav Hertz Communications and SCADA Gavin McManaman Structural John Pizzi Geotechnical Daryl Summerson Mechanical Kevin Brady Plumbing and Fire Protection Doug Glorie Environmental Ahmed Osman Civil Kelly Freeman Architectural Ron Pierri Site Survey Brian Hobbs Zoning and Permits


Table of Contents

1.0 General ............................................................................................................................................................ 9

1.1 Introduction ............................................................................................................................................... 9 1.2 Project Requirements ............................................................................................................................... 9 1.3 Site Description....................................................................................................................................... 10 1.4 Definitions ............................................................................................................................................... 12 1.5 Codes, Standards, and References ........................................................................................................ 14 1.6 Design Life .............................................................................................................................................. 19 1.7 Project Integration ................................................................................................................................... 19

2.0 Electrical ........................................................................................................................................................ 21 2.1 Design Conditions ................................................................................................................................... 21 2.2 Station Single-Line Diagram ................................................................................................................... 21 2.3 SFC Power Block .................................................................................................................................... 22 2.4 SFC Control Room ................................................................................................................................. 24 2.5 SFC 60 Hz Input Transformers ............................................................................................................... 25 2.6 SFC 60 Hz Filter Yard ............................................................................................................................. 27 2.7 SFC 25 Hz Output Transformers ............................................................................................................ 28 2.8 SFC 25 Hz Filter and Breaker Yard ........................................................................................................ 30 2.9 25 Hz Traction Power Substation ........................................................................................................... 31 2.10 System Load Demand ............................................................................................................................ 31 2.11 PECO Customer Requirements .............................................................................................................. 38 2.12 60 Hz Operating Requirements .............................................................................................................. 38 2.13 60 Hz Short-Circuit Availability ............................................................................................................... 39 2.14 60 Hz Harmonics .................................................................................................................................... 39 2.15 230 kV Substation ................................................................................................................................... 39 2.16 13.2 kV, 60 Hz Switchgear ..................................................................................................................... 42 2.17 13.2 kV, 60 Hz Auxiliary Power Transformers ........................................................................................ 44 2.18 13.2 kV, 60 Hz System Operating Characteristics .................................................................................. 44 2.19 13.2 kV, 60 Hz SFC Supply Circuits ....................................................................................................... 45 2.20 13.2 kV, 60 Hz Circuit Breakers .............................................................................................................. 46 2.21 13.2 kV, 60 Hz Busbars .......................................................................................................................... 46 2.22 13.2 kV, 60 Hz Air Disconnect and Grounding Switches ........................................................................ 47 2.23 13.2 kV, 60 Hz Surge Arresters .............................................................................................................. 47 2.24 13.2 kV, 60 Hz Instrument Transformers ................................................................................................ 48 2.25 13.2 kV, 60 Hz Insulators ........................................................................................................................ 48 2.26 6.9 kV, 60 Hz Switchgear ....................................................................................................................... 48 2.27 480 V, 60 Hz Switchgear ........................................................................................................................ 48 2.28 Low-Voltage Distribution System ............................................................................................................ 49


2.29 125 V dc Power System ......................................................................................................................... 49 2.30 Lighting ................................................................................................................................................... 49 2.31 Grounding ............................................................................................................................................... 50 2.32 Lightning Protection ................................................................................................................................ 51 2.33 Power and Control Cable ........................................................................................................................ 51 2.34 Cable Installation Criteria ........................................................................................................................ 52 2.35 Underground Installation Criteria ............................................................................................................ 52 2.36 Medium-Voltage Cable Terminations ...................................................................................................... 52 2.37 Control Circuit Voltage Ranges .............................................................................................................. 52 2.38 Conduit Bends and Fill ............................................................................................................................ 53 2.39 25 Hz, 24/12 kV System Characteristics ................................................................................................. 53 2.40 25 Hz, 24/12 kV Circuit Breakers ............................................................................................................ 54 2.41 25 Hz Busbars ........................................................................................................................................ 54 2.42 25 Hz Air Switches .................................................................................................................................. 55 2.43 25 Hz Surge Arresters ............................................................................................................................ 55 2.44 25 Hz Instrument Transformers .............................................................................................................. 56 2.45 25 Hz Insulators ...................................................................................................................................... 56 2.46 25 Hz Power Cables ............................................................................................................................... 57 2.47 Interlocking ............................................................................................................................................. 58 2.48 SFC Protective Relaying ......................................................................................................................... 58

3.0 Fire Detection and Annunciation .................................................................................................................... 59 3.1 Introduction ............................................................................................................................................. 59 3.2 Design Criteria ........................................................................................................................................ 59

4.0 Communications and Control ......................................................................................................................... 60 4.1 Introduction ............................................................................................................................................. 60 4.2 Design Criteria ........................................................................................................................................ 60

5.0 Security .......................................................................................................................................................... 61 5.1 Introduction ............................................................................................................................................. 61 5.2 Design Criteria ........................................................................................................................................ 61

6.0 Heating, Ventilation, and Air-Conditioning ..................................................................................................... 62 6.1 General Design Criteria .......................................................................................................................... 62 6.2 Roof Top Units ........................................................................................................................................ 62 6.3 Make-Up Air Units ................................................................................................................................... 62 6.4 Ductwork ................................................................................................................................................. 62 6.5 Exhaust Fans .......................................................................................................................................... 62 6.6 Outdoor Air Intakes ................................................................................................................................. 62 6.7 New Control System ............................................................................................................................... 63 6.8 New HVAC Systems for SFC Rooms ..................................................................................................... 63 6.9 New HVAC Systems for SFC Corridors .................................................................................................. 63

7.0 Plumbing ........................................................................................................................................................ 64 7.1 Introduction ............................................................................................................................................. 64


7.2 Design Criteria ........................................................................................................................................ 64 8.0 Fire Protection ............................................................................................................................................... 65

8.1 Introduction ............................................................................................................................................. 65 8.2 Design Criteria ........................................................................................................................................ 65

9.0 Architectural ................................................................................................................................................... 67 9.1 Introduction ............................................................................................................................................. 67 9.2 Building Classification ............................................................................................................................. 67 9.3 Repairs and Upgrades ............................................................................................................................ 69 9.4 SFC #4 Building Design .......................................................................................................................... 72

10.0 Structural ....................................................................................................................................................... 73 10.1 Introduction ............................................................................................................................................. 73 10.2 Building Design Criteria .......................................................................................................................... 74

11.0 Geotechnical .................................................................................................................................................. 77 11.1 Introduction ............................................................................................................................................. 77 11.2 Design Criteria ........................................................................................................................................ 77

12.0 Civil ................................................................................................................................................................ 79 12.1 Introduction ............................................................................................................................................. 79 12.2 Design Criteria ........................................................................................................................................ 79

13.0 Survey ............................................................................................................................................................ 80 13.1 Introduction ............................................................................................................................................. 80 13.2 Site Survey ............................................................................................................................................. 81

14.0 Environmental ................................................................................................................................................ 81 14.1 Introduction ............................................................................................................................................. 81 14.2 Design Criteria ........................................................................................................................................ 81

15.0 Regulatory Compliance and Permits ............................................................................................................. 83 15.1 Wetlands ................................................................................................................................................. 83 15.2 100-year Floodplains .............................................................................................................................. 83 15.3 Threatened and Endangered Species Habitat ........................................................................................ 83 15.4 Permitting Requirements ........................................................................................................................ 83 15.5 Buy America ........................................................................................................................................... 83

16.0 Site Construction Phasing .............................................................................................................................. 84 16.1 General Construction Sequence ............................................................................................................. 84 16.2 Construction of New SFC building .......................................................................................................... 85 16.3 Construction of Duct Banks .................................................................................................................... 85 16.4 Construction of Oil Containment Pits ...................................................................................................... 86 16.5 Repair of Existing Foundations and Building .......................................................................................... 86 16.6 Installation of New SFCs ........................................................................................................................ 86 16.7 Testing and Commissioning of New SFCs ............................................................................................. 86 16.8 Operation in Parallel with Existing Converters ........................................................................................ 86 16.9 Rigging and Transportation Constraints ................................................................................................. 86 16.10 Protection of Equipment During Excavation, Demolition, and Construction ............................................ 87


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Tables Table 1 - Design Conditions ......................................................................................................................................... 21 Table 2 - Existing Converter Unit Ratings and Design ................................................................................................. 22 Table 3 - New SFC Requirements ............................................................................................................................... 24 Table 4 - Existing 60 Hz Input Converter Transformer (Typical) .................................................................................. 25 Table 5 - Existing 60 Hz Filter Yard .............................................................................................................................. 28 Table 6 - 25 Hz Output Transformer Specifications ..................................................................................................... 29 Table 7 - PECO Billing Data ......................................................................................................................................... 32 Table 8 - SFC #3, July 24, 2014, Measurements vs Ratings ....................................................................................... 34 Table 9 - SFC #3, January 7, 2015, Measurements vs Ratings ................................................................................... 36 Table 10 - 60 Hz System Characteristics ..................................................................................................................... 38 Table 11 - 60 Hz Short-Circuit Characteristics ............................................................................................................. 39 Table 12 - Existing 230-13.2 kV Substation Transformer 1 .......................................................................................... 40 Table 13 - Existing 230-13.2 kV Substation Transformer 2 .......................................................................................... 41 Table 14 - SFC Input Circuit Breaker Ratings .............................................................................................................. 43 Table 15 - Existing 13.2 kV Auxiliary Power Transformers .......................................................................................... 44 Table 16 - 13.2 kV System Characteristics .................................................................................................................. 44 Table 17 - 13.2 kV, 60 Hz SFC Supply Cables ............................................................................................................ 45 Table 18 - 13.2 kV, 60 Hz Manholes ............................................................................................................................ 46 Table 19 - New 13.2 kV Circuit Breakers ..................................................................................................................... 46 Table 20 - 13.2 kV Open-Air Substation Busbars ......................................................................................................... 46 Table 21 - 13.2 kV Disconnect and Grounding Switches ............................................................................................. 47 Table 22 - 60 Hz Surge Arresters Connected Line-to-Ground ..................................................................................... 47 Table 23 - 60 Hz Surge Arresters Connected Line-to-Line .......................................................................................... 47 Table 24 - 13.2 kV, 60 Hz Current Transformers ......................................................................................................... 48 Table 25 - 13.2 kV, 60 Hz Potential Transformers ....................................................................................................... 48 Table 26 - 60 Hz Insulators .......................................................................................................................................... 48 Table 27 - 480 V Distribution Feeder Data ................................................................................................................... 49 Table 28 - Cable Installation Parameters ..................................................................................................................... 52 Table 29 - Control Circuit Voltages .............................................................................................................................. 52 Table 30 - Conduit Fill Capacity ................................................................................................................................... 53 Table 31 - Conduit Minimum Bend Radius ................................................................................................................... 53 Table 32 - 13.2 kV, 25 Hz System Characteristics ....................................................................................................... 53 Table 33 - 25 Hz, 46 kV, Two-Pole Circuit Breaker ...................................................................................................... 54 Table 34 - 25 Hz Open-Air Substation Busbars ........................................................................................................... 54 Table 35 - 25 Hz Disconnect and Grounding Switches ................................................................................................ 55 Table 36 - 25 Hz Surge Arresters ................................................................................................................................. 55 Table 37 - 25 Hz Current Transformers ....................................................................................................................... 56 Table 38 - 25 Hz Potential Transformers ..................................................................................................................... 56 Table 39 - 25 Hz Insulators .......................................................................................................................................... 56 Table 40 - 25 Hz Power Cables ................................................................................................................................... 57 Table 41 - 13.2 kV, 60 Hz Protective Relaying ............................................................................................................. 58 Table 42 - 24/12 kV, 25 Hz Protective Relaying ........................................................................................................... 58 Table 43 - Outdoor Design Temperatures .................................................................................................................... 62 Table 44 - Indoor Design Temperatures ...................................................................................................................... 62 Table 45 - Internal Loads ............................................................................................................................................. 62 Table 46 - Water Flow Test Data from 6/13/15 ............................................................................................................ 66 Table 47 - Preliminary Code Review - 2009 IBC .......................................................................................................... 67 Table 48 - SFC #1 Repairs and Upgrades ................................................................................................................... 69 Table 49 - SFC #2 Repairs and Upgrades ................................................................................................................... 70 Table 50 - SFC #3 Recommended Repairs and Upgrades .......................................................................................... 70 Table 51 - Control Building Repairs and Upgrades ...................................................................................................... 71 Table 52 - Structural Steel ........................................................................................................................................... 74 Table 53 - Concrete 28-Day Compressive Strength ..................................................................................................... 74 Table 54 - Reinforcing Steel ......................................................................................................................................... 74 Table 55 - Masonry ...................................................................................................................................................... 74 Table 56 - Dead Loads ................................................................................................................................................. 75 Table 57 - Floor and Roof Live Loads .......................................................................................................................... 75 Table 58 - Wind Loads ................................................................................................................................................. 75

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 8 of 87 Table 59 - Snow Loads ................................................................................................................................................ 75 Table 60 - Seismic Loading .......................................................................................................................................... 76 Table 61 - Allowable Deflections .................................................................................................................................. 76 Table 62 - Allowable Building Story Drifts .................................................................................................................... 76 Table 63 - P-Multipliers ................................................................................................................................................ 78 Table 64 - Seismic Design Parameters ........................................................................................................................ 78

Figures

Figure 1 - Wayne Junction SFC Site ............................................................................................................................ 11 Figure 2 - Proposed Single-Line Diagram .................................................................................................................... 21 Figure 3 - Block Diagram of Existing Cycloconverter Unit ............................................................................................ 23 Figure 4 - Existing SFC #2 Converter Room ................................................................................................................ 23 Figure 5 - SFC Control Room ...................................................................................................................................... 25 Figure 6 - 60 Hz Converter Transformer (SFC #1 left, SFC #2 right) ........................................................................... 26 Figure 7 - 60 Hz Converter Transformer (cable connections) ...................................................................................... 27 Figure 8 - 60 Hz Filter Yard #2 ..................................................................................................................................... 28 Figure 9 - 25 Hz Output Transformer ........................................................................................................................... 29 Figure 10 - 25 Hz SFC Filter and Circuit Breaker Yard ................................................................................................ 30 Figure 11 - Existing 25 Hz Traction Power Substation ................................................................................................. 31 Figure 12 - SFC #3, July 24, 2014 ............................................................................................................................... 33 Figure 13 - SFC #3, July 24, 2014, Measurements vs Ratings .................................................................................... 33 Figure 14 - WJSFC Station Output, July 24, 2014, 30-Minute Average ....................................................................... 34 Figure 15 - SFC #3, January 7, 2015 ........................................................................................................................... 35 Figure 16 - SFC #3, January 7, 2015, Measurements vs Ratings ................................................................................ 35 Figure 17 - WJSFC, Station Output, 30-Minute Average ............................................................................................. 36 Figure 18 - WJSFC, Station Output, 1-Second Measurement Rate ............................................................................. 37 Figure 19 - PECO 230 kV System Supplying Wayne Junction .................................................................................... 39 Figure 20 - 230-13.2 kV Substation Transformer ......................................................................................................... 41 Figure 21 - Spare SFC 15 kV Circuit Breaker .............................................................................................................. 43 Figure 22 - SFC #4 13.2 kV circuit breaker and relay cabinet (outside and inside) ...................................................... 43 Figure 23 - Auxiliary Power Transformers .................................................................................................................... 44 Figure 24 - Control Room lighting fixtures .................................................................................................................... 50 Figure 25 - Suspended fixtures in the SFC building corridor ........................................................................................ 50 Figure 26 - Existing Fire Alarm and Halon System Control Panel in SFC building ....................................................... 59 Figure 27 - Existing QEI Cabinet located in the SFC building Control Room ............................................................... 60 Figure 28 – Existing occupancy sensor located in SFC building corridor ..................................................................... 61

Attachments

Attachment 1 - Summary of Assessment and Options (13 pages)

Appendices

None

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 9 of 87 1.0 General The scope of this document is to define the engineering design criteria for the Wayne Junction Static Frequency Converter Station (WJSFC) Rehabilitation Project. This design criteria shall be used as the basis for all equipment specifications and design documents, providing the minimum design requirements. Where conflicts exist between design documents, the more stringent requirement shall take precedence, unless otherwise approved by SEPTA.

1.1 Introduction The Southeastern Pennsylvania Transportation Authority (SEPTA) operates a system of commuter rail lines in the Philadelphia metropolitan area. The system, known as the Regional Rail Division (RRD), consists of various routes formerly owned by the Reading and Pennsylvania Railroads. The former Reading system is supplied with traction power from SEPTA's converter substation at Wayne Junction and the former Pennsylvania system is supplied by the Amtrak traction power system. Although the railway tracks of both systems are joined through the Center City Commuter Connection, the traction power networks for each are of different types and operate independently. The electrical systems are separated by phase breaks in the overhead power distribution system.

The majority of the RRD was electrified in the early 1900's and has operated safely and reliably ever since. Today, some of the original equipment is still in service, but due to equipment age, many electrical subsystems and components are at or near the end of their useful life and need to be replaced. One of these subsystems is the static frequency converter facility at the Wayne Junction power substation, located at 18th Street and Wagner Avenue in Philadelphia, PA 19141, USA.

The three existing SFCs at the Wayne Junction facility were built in the 1980s by ASEA (now ABB), and are now in need of replacement due to age. These SFCs consist of three 15 MVA, solid-state, cycloconverter-based modules converting 13.2 kV, 60 Hz, three-phase power into 36/24/12 kV, 25 Hz, single-phase power for use on SEPTA's Regional Rail system. In addition, to achieve greater capacity and reliability, a fourth converter is to be added to, and integrated with, the existing three converters.

1.2 Project Requirements

As part of this contract, SEPTA requires to supplement these existing SFCs with a fourth SFC unit and also upgrade the existing three SFC units. The project requirements related to the new SFC power block include:

• The design, construction, testing, and commissioning into full service of one new SFC, with an input of 13.2 kV, 60 Hz, 3-phase and an output of 36/24/12 kV, 25 Hz, single phase. The full-load power capacity of the new SFC shall be not less than 15 MW. The Wayne Junction converter output transformer has three bushings on its secondary side: 12 kV trolley, 24 kV feeder, and a solidly-grounded rail connection tapped at 1/3 of the secondary winding. Voltage measured from trolley-to-feeder is 36 kV, trolley-to-rail is 12 kV, and feeder-to-rail is 24 kV.

• The construction of a new building for the fourth SFC attached to the existing SFC #3 facility with control and protection equipment for the new SFC in the existing Control Room.

• A new isolation switch and relay protection supplied in the 25 Hz substation. The new SFC shall be fully interoperable and compatible with the existing SFCs so that it can perform its function either alone or with any combination of the existing SFCs on line.

• Complete functional overhaul of the three existing SFCs. All components of the SFC systems are to be refurbished or replaced as necessary to restore the system to like-new performance, with an expected lifetime of no less than forty years. This activity includes, but is not limited to, the SFC power block equipment, input and output circuit breakers and transformers, conduits, medium voltage cables and control cables and terminations, and miscellaneous electrical accessories. In particular, it is required that:

1. The control computer be brought up to date and include controls for all four converters.


2. The protection relays be brought up to date with the latest technology.

3. The individual converter control equipment be brought up to date with the latest technology.

4. All cooling fans be renewed.

5. All electronic equipment in the converter cubicles and control cubicles be replaced with new technology.

6. The traction power bus protection be recalibrated, incorporating the fourth converter.

In addition to the SFC power block equipment, the project also requires:

1. The replacement of the existing Pyrotronic suppression/fire alarm control panels with a new updated addressable fire alarm system and a Halon suppression activation panel in the Wayne Junction 230 kV substation and SFC building.

2. An analysis of the structural stability of the existing SFC building with recommendations for remediation of any defects found.

1.3 Site Description

Site Name: Wayne Junction SFC Station

Site Billing Address: SEPTA Wayne Junction 4500 Germantown Ave Philadelphia, PA 19144

Site Property Address: SEPTA Wayne Junction 1754 Wagner Ave Philadelphia, PA 19144

Project Owner: Southeastern Pennsylvania Transportation Authority (SEPTA)

Owner’s Address: SEPTA 1234 Market St. Philadelphia, PA 19103

Quadrangle Name: Germantown

Decimal Degrees: 40.0261 N, -75.1552 W (Google Maps)

Proposed Construction: PECO provides electrical power for SEPTA's train service. At present, frequency conversion is accomplished by three 1980 vintage, 15 MVA static converters at WJSFC station. Four new 15 MVA frequency converters are proposed for WJSFC station. The existing three SFCs will be removed one at a time and replaced with three new SFCs. A new building will be constructed to house one new SFC.

Major SFC Equipment: Four identical SFCs, each rated at 15 MVA, located within a concrete masonry unit (CMU) constructed building. The SFC equipment includes four new step-down transformers, power converters, filters, cooling equipment, local controls, and step-up transformers, as required.

Auxiliary Equipment: An existing SFC Building contains SFC controls, SCADA, SER, power distribution switchgear, batteries, lighting, HVAC, and plumbing for the existing three SFC units. An addition will extend the building to house one new SFC unit.


There are two existing 1500/2250 kVA, 13.2 kV-480Y/277 V, 3-phase, 60 Hz transformers that supply auxiliary power to the SFC Building. They are located on the west side of the 230 kV Control Building.

Converter Input Voltage: 13.2 kV, 60 Hz, 3-ph from the 230 kV Substation Control Building.

480Y/277 V, 60 Hz, 3-ph, 4-wire for auxiliary equipment.

Converter Output Voltage: 24/12 kV, 1-ph, 25 Hz, to the SEPTA Wayne Junction Traction Power Substation (WJTPSS). The converter output transformer supplies a traction power system directly. The system voltages are 12 kV from trolley-to-rail, 24 kV from feeder-to-rail, and 36 kV from trolley-to-feeder. The output transformer secondary is rated 36 kV bushing-to-bushing with the winding tapped at 1/3 from the trolley bushing. The connection to rail is solidly-grounded.

Figure 1 - Wayne Junction SFC Site

230 kV control building

(13.2 kV switchgear)

60 Hz Filter Yard

SFC #1 SFC #2

SFC #3

Future SFC #4

25 Hz Filter Y d

25 Hz Traction Power

S b t ti

Control Bld

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 12 of 87 The site layout is shown in Figure 1 above. From left to right:

1. 230 kV control building - contains 13.2 kV and 480 V switchgear that supplies converter power block and auxiliary systems.

2. Auxiliary power transformers - located to the right of the control building.

3. 60 Hz filter yard

4. 60 Hz converter input transformers

5. SFC control building and SFC rooms

6. 25 Hz converter output transformers

7. 25 Hz filter yard

8. 25 Hz traction power substation

1.4 Definitions

ac alternating current

AMCA Air Movement and Control Association

ARI Air Conditioning and Refrigeration Institute

BJT bipolar junction transistors

BUR built-up roof

CMU concrete masonry unit

dc direct current

FEMA Federal Emergency Management Agency

FIRM flood insurance rate map

GIS geographic information system

GPR ground penetrating radar

GTO gate turn-off thyristor

HVdc high-voltage direct current

IGBT insulated-gate bipolar transistor

IGCT integrated gate-commutated thyristor

MMC modular multilevel converter

MMDC modular multilevel direct converter

MOSFET metal-oxide-semiconducting field effect transistor

NPDES National Pollutant Discharge Elimination System

NWI National Wetlands Inventory

PA Pennsylvania

PADEP Pennsylvania Department of Environmental Protection

PECO Philadelphia Electric Company

PNDI Pennsylvania Natural Diversity Index


PPI press-pack IGBT

RCP reinforced concrete pipe

RTU (Communications) remote terminal unit

RTU (Mechanical) roof top unit

SCADA supervisory control and data acquisition

SCR silicon-controlled rectifier

SEPTA Southeastern Pennsylvania Transportation Authority

SER sequence of events recorder

SFC static frequency converter

SONET synchronous optical network

SOW scope of work

TPSS traction power substation

USFWS United States Fish and Wildlife Service

VSC voltage-source converter

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 14 of 87 1.5 Codes, Standards, and References All design shall conform to or exceed the requirements of the latest version of the codes or standards that are identified throughout every section of these criteria. If a new edition or amendment to a code or standard is issued before the design is completed, SEPTA shall determine if the new edition or amendment is to be used.

All codes, standards, and references have been numbered in continuous sequential order in order to be uniquely cross-referenced in this document.

1.5.1 Electrical Codes and Standards

1. Exelon, ComEd and PECO Transmission Facility Connection Requirements, 5/2014.

2. ICEA S-108-720-2012, Extruded Insulation Power Cables Rated 46 kV Through 345 kV.

3. IEEE 1119-1998, IEEE Guide for Fence Safety Clearances in Electric Supply Stations.

4. IEEE 141-1993, IEEE Recommended Practice for Electric Power Distribution for Industrial Plants.

5. IEEE 32-1972, IEEE Standard Requirements, Terminology, and Test Procedure for Neutral Grounding Resistor.

6. IEEE 519-1992, IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems.

7. IEEE 80-2002, IEEE Guide for Safety in AC Substation Grounding.

8. IEEE 835-1994, IEEE Standard Power Ampacity Tables.

9. IEEE 837-2002, IEEE Standard for Qualifying Permanent Connections Used in Substation Grounding.

10. IEEE 998-2012, IEEE Guide for Direct Lightning Stroke Shielding of Substations.

11. IEEE C2-2012, National Electrical Safety Code.

12. IEEE C37.06-2009, IEEE Standard for ac High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities for Voltages Above 1000 V.

13. IEEE C37.20.2-1999, IEEE Standard for Metal-Clad Switchgear.

14. IEEE C37.30-1997, IEEE Standard Requirements for High-Voltage Switches.

15. IEEE C37.32-2002, American National Standard for High Voltage Switches, Bus Supports, and Accessories Schedules of Preferred Ratings, Construction Guidelines, and Specifications.

16. IEEE C37.90-2005, IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus

17. IEEE C50.13-2005, IEEE Standard for Cylindrical-Rotor 50 Hz and 60 Hz Synchronous Generators Rated 10 MVA and Above.

18. IEEE C57.13-2008, IEEE Standard Requirements for Instrument Transformers.

19. IEEE C62.22-2009, IEEE Guide for the Application of Metal-Oxide Surge Arresters for Alternating-Current Systems.

20. NEMA C29.9-1983, Wet Process Porcelain Insulators - Apparatus, Post Type.

21. NEMA WC 53-2008/ICEA T-27-581, Standard Test Methods for Extruded Dielectric Power, Control, Instrumentation, and Portable Cables for Test.


22. NEMA WC 57-2004/ICEA S-73-532, Standard for Control, Thermocouple Extension, and Instrumentation Cables.

23. NEMA WC 63.2-1996, Performance Standard for Coaxial Premise Data Communications Cables.

24. NEMA WC 70-2009/ICEA S-95-658, Power Cables Rated 2000 V or Less for the Distribution of Electrical Energy.

25. NEMA WC 74-2006/ICEA S-93-639, 5-46 kV Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy.

26. NFPA 70-2008, The National Electrical Code (adopted by City of Philadelphia).

27. NFPA 72-2013, National Fire Alarm Signaling Code.

28. PECO Electric Service Requirements (ESR) Manual, Section 7, Services Over 600 V, 10/2011.

29. PECO Energy Company, Electric Service Tariff, issued 7/17/2015, effective 9/1/2015.

30. Philadelphia Building Construction and Occupancy Code, Subcode “E” Philadelphia Electrical Code.

31. Philadelphia Building Construction and Occupancy Code. Subcode “F” Philadelphia Fire Code.

32. PJM Design Criteria for Electrical Facilities Connected to the PJM 500 kV, 345 kV and 230 kV Transmission System, TSDS Technical Requirements, 5/20/2002.

33. PJM Manual 03, Transmission Operations, Rev. 47A, 7/1/2015.

34. RUS Bulletin 1724E-300, Design Guide for Rural Substations, USDA RUS, Issued 6/2001.

1.5.2 Mechanical Codes and Standards

35. Air Conditioning and Refrigeration Institute (ARI) Standards.

36. Air Movement and Control Association (AMCA) Standards.

37. American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) Handbooks.

38. City of Philadelphia Code Title 14, Chapter 14-704.

39. City of Philadelphia Code, Title 14 Zoning and Planning Code.

40. Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA) Standards.

1.5.3 Architectural Codes and Standards

41. International Building Code (IBC) 2009, PA Edition.

42. International Energy Conservation Code (IECC) 2009.

43. International Mechanical Code (IMC) 2009.

44. National Environmental Balancing Bureau (NEBB) Standards.

45. National Fire Protection Association (NFPA) Standards.

1.5.4 Structural Codes and Standards 46. ACI 301-05, Specifications for Structural Concrete.


47. ACI 318-08/ACI 318R-08, Building Code Requirements for Structural Concrete and Commentary.

48. ACI 530.1-08, Specification for Masonry Structures & Commentary.

49. ACI 530-08, Building Code Requirements for Masonry Structures & Commentary.

50. ACI Precast and Prestressed Concrete (PCI) Design Handbook.

51. AISC Code of Standard Practice for Steel Buildings and Bridges, 2005

52. AISC Design Guide No. 3, Serviceability Design Guide Considerations for Low-Rise Buildings, 2nd ed.

53. AISC Design Guide No. 7, Industrial Buildings, Roofs to Anchor Rods, 2nd ed.

54. AISC Steel Construction Manual, 13th Edition.

55. ASCE 7-05, Minimum Design Loads for Buildings and Other Structures.

56. AWS D1.1-04, Structural Welding Code – Steel.

57. AWS D1.3-98, Structural Welding Code – Sheet Steel.

58. AWS D1.4-98, Structural Welding Code – Reinforcing Steel.

59. Concrete Reinforcing Steel Institute (CRSI).

60. International Building Code (IBC) 2009, PA Edition.

61. Manual of Standard Practice for Reinforced Concrete Construction.

62. SDI No. 31, Design Manual for Composite Decks, Form Decks and Roof Decks.

63. SDI No. DDMO3, Diaphragm Design Manual, 3rd ed.

64. SDI No. MOC2, Manual of Construction with Steel Deck.

1.5.5 Geotechnical Codes and Standards 65. International Building Code, 2009 Edition (IBC 2009).

66. ASCE/SEI 7-05 Minimum Design Loads for Buildings and Other Structures.

67. Subsurface Investigations – Geotechnical Site Characterization, FHWA NHI-01-031, May 2002.

68. Geotechnical Engineering Circular No. 6 – Shallow Foundations, FHWA-SA-02-054, September 2002.

69. Design and Construction of Driven Pile Foundations – FHWA NHI-05-042 Volume 1 and 2 April 2006.

1.5.6 Civil Codes and Standards 70. Pennsylvania Stormwater Best Management Practices Manual, PA Department of

Environmental Protection, 2006 Edition.

71. Erosion and Sediment Pollution Control Program Manual, PA Department of Environmental Protection, 2012 Edition.

72. Urban Drainage Design Manual, Federal Highway Administration, Third Edition.

1.5.7 Environmental Codes and Standards 73. National Emission Standards for Hazard Air Pollution (NESHAP) (cited as 40 CFR Part

61 Subpart M).


74. OSHA 29 CFR 1926.62, Lead.

75. OSHA 29 CFR 1910.120, Hazardous Waste Operations and Emergency Response.

76. OSHA 40 CFR Part 265 Subpart D, Resource Conservation and Recovery Act (RCRA), Contingency Plan.

77. Title 25, Part 1, Subpart C Article III, Chapters 123, 133, 137, Pennsylvania Department of Environmental Protection (PADEP).

78. Pennsylvania Code, Title 25, Chapter 101 (Hazardous Substances).

79. Pennsylvania Code, Title 25, Chapter 91.34 (PA Water Quality Program).

80. PADEP Act 2 of 1995, The Land Recycling and Environmental Remediation Standards Act.

81. Pennsylvania Asbestos Occupations Accreditation and Certification Act of 1990 (Act 194 and Act 161).

82. City of Philadelphia, Title 6, Asbestos Control Regulation of Board of Health.

1.5.8 References

83. Dwg. 3101D-G100, Rev. 2, Wayne Junction Substation Static Frequency Converter Drawing List (Phase I), International Engineering Company (IECo), 12/16/1985.

84. Dwg. 3101D-E340, Sht. 1, Rev. 2, 60 Hz Filter Yard Raceway Layout.

85. Dwg. 3101D-E440, Sht. 1, Rev. 3, Converter and Control Building Raceway Layout - Plan.

86. Dwg. 3101D-E540, Rev. 2, 25 Hz Filter Yard Raceway Layout.

87. Dwg. 5I-26390, G-101, Cover Sheet, Wayne Junction Substation Modernization Program Phase II, Stone and Webster Engineering Corporation (SWEC), 1/16/1987.

88. Dwg. 5I-26391, G-102, Rev. 1, Drawing Number Index, Wayne Junction Substation Modernization Program Phase II, Stone and Webster Engineering Corporation (SWEC), 8/12/1987.

89. Dwg. 5I-26392, G-103, Rev. 1, Drawing Number Index, Wayne Junction Substation Modernization Program Phase II, Stone and Webster Engineering Corporation (SWEC), 8/12/1987.

90. Dwg. 5C-26399, C1, Road and Plot Plan.

91. Dwg. 5C-26400, C2, Road and Plot Plan.

92. Dwg. 5C-26401, C3, Grading and Drainage Plan, Sht. 1.

93. Dwg. 5E-26470, DE-1J, Rev. 1, Main One-Line Diagram, SFC and Traction Power Distribution Interim Arrangement.

94. Dwg. 5E-26471, DE-1S, Rev. 0, Main One-Line Diagram Plant Distribution System.

95. Dwg. 5E-26469, DE-1B, Main One-Line Diagram, 230 kV Static Frequency Converter, Traction Power Substation.

96. Dwg. 5C-26042, C3, Grading and Drainage Plan, Sht. 2.

97. Dwg. 5E-26493, DE-52A, 60 Hz Filter Yard No. 1, Raceway Layout Plan.

98. Dwg. 5E-26494, DE-52B, 60 Hz Filter Yard No. 3, Raceway Layout Plan.

99. Dwg. 5E-26495, DE-52C, 60 Hz Filter Yard No. 4, Raceway Layout Plan.


100. Dwg. 5E-26507, DE-54A, 25HZ Filter Yard-Unit No. 1, Raceway Layout Plan.

101. Dwg. 5E-26507, DE-54A, 25HZ Filter Yard-Unit No. 1, Raceway Layout Plan.

102. Dwg. 5E-26516, DE-58A, Raceways from New 230 kV Substation Control Building to Filter Yards, SFC Building and Traction Power Building, Plan Sht. 1.

103. Dwg. 5E-26517, DE-58B, Raceways From New 230 kV Substation Control Building, Plan Sht. 2.

104. Dwg. 5E-26522, DE-58G, Interim Raceways Between SFC Areas & 25 HZ Switch Yard & Control Building, Plan Sht. 1.

105. ABB Ref. L 5834.1004, XT 180 065-K, SEPTA Wayne Junction SFC Units 1 and 3 Operating Manuals, BK 1990-12-12 - cycloconverter description, ratings, block diagram.

106. ABB SF6 Circuit Breaker, Type HPL 72.5 - 170/25A1-40 A1 with BLG-1002, BK 87-02-03.

107. ASEA Ref. 3834.1002, XN 320 028-A, SEPTA Wayne Junction SFC Unit 2 Operating Manuals - cycloconverter description, ratings, block diagram.

108. L3834.1002 12-22-1983, Ake Petersson, SFC Design Criteria.

109. ASEA XN 350 097-D, Busbar System Data, Three-Phase System.

110. ASEA XN 350 097-C, Busbar System Data, Single-Phase System.

111. Calc. 15948-SK-A, 13.2 kV, 6.9 kV, 480 V Relay Settings, Stone and Webster Engineering Corporation, 6/6/89

112. SEPTA Preliminary Engineering of the Regional Rail Traction Division Power System, LTK Engineering Services, July 1993.

113. Email from W. Szela to B. Swartley, RE: 4017500 Wayne Junction SFC upgrade - utility system information, 8/19/2015.

114. Email from P. Kirlin to B. Swartley, Wayne Junction SFC, 9/2/2015 - service and meter application.

115. Email from P. Kirlin to B. Swartley, Wayne Junction SFC, 9/3/2015 - demand and power factor measurements.

116. "Static Converters, Dynamic Performance," ABB Review, Feb. 2010.

117. "The Railway Connection: Frequency converters for railway power supply," ABB Review, March 2008.

118. Adapa, R., "High-Wire Act," IEEE Power & Energy Magazine, Nov/Dec 2012.

119. Gyugyi, L., and Pelly, B. R., Static Power Frequency Changers: Theory, Performance, and Application, John Wiley & Sons, Inc., New York, 1976.

120. Jones, A., "Amtrak’s Richmond Static Frequency Converter (SFC) Project," 2002.

121. Mohan N., Power Electronics: Converters, Applications, and Design, 2nd Ed., John Wiley & Sons, Inc., New York, 1995.

122. Southwire Power Cable Manual, 2nd Edition, 1997.

123. Okonite Okoguard-Okoseal Type MV-105, 15 kV Shielded Power Cable, Product Data, Section 2, Sheet 8, M/15120208.

124. Okonite Okoguard-Okoseal Type MV-105, 25 kV Shielded Power Cable, Product Data, Section 2, Sheet 14, L/15120214.


125. Okonite Okoguard-Okoseal Type MV-105, 69 kV Shielded Power Cable, Product Data, Section 2, Sheet 18, E/13060218.

126. Okonite Okoguard-Okoclear Type MV-105, 1/c, 1000 kcmil, 46 kV Shielded Power Cable, Dwg. CS-21783, dated 10/2/15.

127. Okonite Installation Practices for Cable Raceway Systems, 2011.

1.6 Design Life

All components of the SFC system are to be refurbished or replaced as necessary to restore the system to like-new performance, with an expected station lifetime of no less than forty (40) years.

1.7 Project Integration

The project integration requirements are summarized as follows:

1. The final project configuration will have four 15 MVA SFCs with ratings given in Table 3.

2. The new frequency converters shall be required to operate both independently and in parallel with each other under either manual or automatic load sharing control.

3. Always keep two SFC units in operation (live) with a third in stand-by (de-energized, but ready to start when needed).

4. Minimize disruption to existing SFC station operations during design, construction, testing, and commissioning.

5. Accommodate concurrent infrastructure improvement projects.

6. Minimize adverse operational, aesthetic, and environmental impacts.

7. The spare 13.2 kV, 60 Hz, 3-phase circuit breaker in the 230 kV control building (contains 13.2 kV switchgear) will be used for powering the new SFC #4.

8. The spare 480 V, 60 Hz, 3-phase circuit breakers in the 230 kV control building will be used for supplying auxiliary power to the new SFC #4.

9. Existing filter equipment in the 60 Hz filter yard will be removed. The foundations for these filters will remain in place. Any new reactors, charging transformers/circuit breakers, or heat exchangers can be located in these areas.

10. A new duct bank will be constructed from the 230 kV control building to the new SFC #4 open-air bus to be constructed in the 60 Hz filter yard. Another duct bank will be constructed from the open-air bus to the SFC #4 input transformer, with a portion extended to the basement of the SFC #4 building. The duct banks will contain power and control cables. The existing 60 Hz filter yard duct banks will be re-used for SFCs #1, #2, and #3.

11. The new SFC #4, 60 Hz open-air bus will utilize a manually-operated grounding switch similar to SFCs #1, #2, and #3. The open-air bus will also have a set of PTs and CTs for use with the new SFC #4 protective relaying, metering, and/or control scheme.

12. The existing 60 Hz, 13.2 kV, 1000 kcmil cables will remain connected between the 13.2 kV switchgear and open-air bus. The existing 60 Hz, 13.2 kV, 500 kcmil cables to SFC #1, #2, and #3 input transformers will be replaced as required by the new SFC design.

13. All duct banks associated with SFCs #1, #2, and #3 will remain in place in the 60 Hz filter yards in order to minimize risks and operational impact during construction.

14. The existing grounding switches, PTs, and CTs will remain connected to the existing 60 Hz open-air bus for SFCs #1, #2, and #3. Based on the accuracy class, the PTs and/or CTs may be replaced if required by the SFC vendor.


15. New input transformers must fit into the existing 60 Hz transformer areas.

16. New SFC equipment must fit into the existing converter rooms with sufficient working space to meet all building and electrical codes and standards.

17. New SFC equipment will be transported into the existing SFC rooms through doorways that are approximately 6 ft wide and 13 ft-4 in high (182.9 cm x 406.4 cm).

18. The new SFC #4 building addition will have the same overall dimensions as the SFC #3 room.

19. The existing and new converter rooms are approximately 45 ft-8 in long, 28 ft wide, and 19 ft-1 in high to lowest overhead beam (13.9 m x 8.5 m x 19.1 m).

20. New SFC heat exchangers shall be located on the roof of the converter buildings. These heat exchanges will share room with roof top units used for building heating and cooling.

21. New output transformers must fit into the existing 25 Hz transformer areas.

22. The existing filter equipment in the 25 Hz filter yard will be removed. The foundations for these filters will remain in place.

23. A new duct bank will be constructed from the output of the SFC #4 building basement, joining a new duct bank from the 25 Hz output transformer to the 25 Hz yard cable riser. The duct bank will contain power and control cables. A new open-air bus will be constructed to terminate the SFC #4, 24/12 kV cables from the 25 Hz output transformer. The new open-air bus will contain surge arresters, PTs, CTs, disconnect switches, grounding switches, and a circuit breaker. An exposed rail return bus will be constructed near the SFC #4 output breaker, similar to the SFC #1, #2, and #3 rail return buses, in order to bond the transformer rail return cable to station ground.

24. A new duct bank will constructed from the SFC #4 output circuit breaker to the 25 Hz traction power substation. The duct bank will contain power and control cables.

25. All duct banks associated with SFC #1, #2, and #3 will remain in place in the 25 Hz filter yards in order to minimize impact during construction.

26. The existing 25 Hz, 12 kV, 24 kV, and rail return cables will remain in place bewteen the 25 Hz traction power substation and the SFC disconnect switches located next to the SFC output circuit breakers.

27. The existing SFC output circuit breakers will be replaced for each SFC. The new circuit breakers are ABB model FSKII. Each is supplied with a CT on both line and load side of each pole. These CTs will replace the existing CTs.

28. The existing 25 Hz disconnect and grounding switches next to the cable riser on the load side of the circuit breaker will be replaced.

29. The 25 Hz disconnect and grounding switches, PTs, and surge arresters on the SFC side of the circuit breaker will be relocated and replaced, as requried, based on the size of the new ABB FSKII circuit breakers.

30. In the exisitng 25 Hz traction power substation, the new SFC #4 12 kV and 24 kV feeders will be routed to a new two-pole disconnect switch along newly installed cable tray. The new rail return cable will be terminated to the existing rail return bus. The new SFC #4 feeders will be integrated into existing bus work. A new multifunction protective relay and associated equipment will be installed in existing relay panels.

These functional system integration requirements shall be periodically assessed during final design and construction.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 21 of 87 2.0 Electrical

2.1 Design Conditions

Electrical systems and equipment shall be designed to operate under design condition limits given in Table 1

Table 1 - Design Conditions

Parameter Value Reference Ambient temperature 11.6 deg F to +92.7 deg F Ref. 37 Altitude Less than 3300 ft Ref. 14 Wind loading substation (no ice)

Per ASCE 7-98, Figure 6-1 depending on location (typically 90 to 110 mph)

Ref. 32

Flood plain Structures shall be outside the 100-year flood plain. Ref. 32

2.2 Station Single-Line Diagram

The final SFC station will consist of four identical SFC units as shown in Figure 2. Refer to project drawing ET602 for the latest verison.

Figure 2 - Proposed Single-Line Diagram

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 22 of 87 2.3 SFC Power Block

Table 2 - Existing Converter Unit Ratings and Design

Parameter Value Primary Side 13.2 kV, +/-10%

3 phase 60 Hz, +/-2%

Secondary Side 12+24 kV, +/-2% 1 phase 25 Hz (fixed 5/12 of the 60 Hz grid)

Rating - continuous 15 MVA continuous power Rating - overload 18 MVA for 1 hour


Losses 155 kW no-load 510 kW at rated load

Primary power factor ≥0.95 lagging ≤0.866 leading (30 minutes integration time)

Number of thyristor cubicles 8 Number of thyristors 192 Number of thyristors in parallel 8 Number of thyristor bridges out of order "trip out" 2 Type of thyristors YST 45-21 Current rating ITAV 2500 A Voltage rating 4200 V Cooling type Double Cooling air demand 68,000 m3/hr (100 ft3/s)

Electrical measurements have determined that the existing converters have an output power factor typically ≥0.70 lagging during heavy loading conditions.

Each SFC is presently located in its own room. All SFC rooms utilize air-conditioning to cool the rooms during maintenance. SFC #2 uses a natural ventilation system during unit operation. SFCs #1 and #3 use a forced ventilation system. All new SFCs will be supplied with liquid cooling systems to remove the majority of power electronic waste heat. New air-conditioning and ventilation systems, not provided by the SFC vendor, will serve to remove residual heat.

Each existing cycloconverter unit consists of two dual-converters connected in series. A dual-converter consists of two six-pulse thyristor bridges connected in antiparallel configuration.


Figure 3 - Block Diagram of Existing Cycloconverter Unit

Figure 4 - Existing SFC #2 Converter Room

Each new SFC unit will follow the same general design criteria as the existing SFC units:

1. The SFC can operate alone.

2. The SFC can operate in parallel with other static converters.

3. Any overload condition or short-circuit in the single-phase railway network will not trip the SFC.

4. The SFC does not generate any voltage harmonic in the three-phase network or in the single-phase network larger than 3%.

5. Start-up time is less than 2 seconds. The SFC has an automatic start-up equipment, which automatically starts converter when the load increases above the preset value.

6. Local or remote control of the SFC is possible.


7. The SFC is equipped with current limitation that protects the converter from overload.

Each new SFC unit shall be designed to have the same ratings as the existing SFC units. Table 3 - New SFC Requirements



Power factor (design) 0.7 pf lagging @ rated output, 24/12 kV, 25 Hz 0.95 pf lagging @ rated output, 13.2 kV, 60 Hz

Power factor (operating limit) 0.95 pf lagging @ rated output, 230 kV, 60 Hz Rated current at 60 Hz, 3-ph (Assuming a 3% loss)

15 MVA / 0.97 loss / 13.2 kV / 1.732 = 676 A rms cont. 18 MVA / 0.97 loss / 13.2 kV / 1.732 = 812 A rms for 1 hr. 24 MVA / 0.97 loss / 13.2 kV / 1.732 = 1082 A rms for 6 min 30 MVA / 0.97 loss / 13.2 kV / 1.732 = 1353 A rms for 30 s 48 MVA / 0.97 loss / 13.2 kV / 1.732 = 2164 A rms for 2 s

Calculated load currents (four converters)

15 MVA x 4 / 0.97 loss = 61.9 MVA 61.9 MVA / 13.2 kV / 1.732 = 2707 A rms during normal operating conditions 2707 A / 0.98 pu = 2762 A rms during normal low voltage conditions 2707 A / 0.95 pu = 2849 A during emergency low voltage conditions

Rated current at 25 Hz, 1-ph (each converter)

15 MVA / 36 kV = 417 A rms balanced (no rail return) 15 MVA / 24 kV = 625 A rms feeder (feeder-to-rail) 15 MVA / 12 kV = 1250 A rms trolley (trolley-to-rail)

Operating output voltage range 24/12 kV -/+5% (25 Hz system may reach +10% due to train regeneration.)

Calculated load currents (one converter)

15 MVA / 36 kV / 0.95 pu = 439 A rms balanced (no rail return) 15 MVA / 24 kV / 0.95 pu = 658 A rms for feeder-to-rail 15 MVA / 12 kV / 0.95 pu = 1316 A rms for trolley-to-rail

Outgoing 24/12 kV feeder minimum ampacity 658 A rms feeder cable 1316 A rms trolley cable

Operating modes Synchronous machine mode (converter acts like a synchronous-synchronous motor-generator set) Constant power mode (converter delivers settable power to the 25 Hz network) Phase shift mode (converter delivers reactive power to the 25 Hz network during loss of the 60 Hz network)

Power flow direction From 60 Hz to 25 Hz only. Reverse power flow not required.

Loss of 13.2 kV, 60 Hz power Converter shall continue to supply reactive power to the 25 Hz network

Loss of 480 V, 60 Hz auxiliary power supply Converter shall continue to fully function and supply both real and reactive power to the 25 Hz system during a loss of auxiliary power up to 3 seconds.

Harmonic distortion on 60 Hz system SFC design must limit harmonic voltage distortion to limits given in IEEE 519 and PECO design standards at the 230 kV cable terminations in the PECO 230 kV switchyard

Harmonic distortion on the 25 Hz system SFC design must limit harmonic voltage distortion to limits given in IEEE 519 at the 24/12 kV, 25 Hz cable terminations at the SFC 24/12 kV output transformers

2.4 SFC Control Room

The SFC Control Room has a raised floor and all wiring from the control room to the SFCs is routed below this raised floor and through the SFC room and basements. The control equipment for SFCs #1, #2, and

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 25 of 87 #3 are located around the walls of the room. The original design included placement of SFC #4 control equipment in the center of this room. The control equipment uses analog indicators and solid-state relays.

All SFC control equipment within this room will be replaced with the new SFC control system equipment. The new SFC control equipment will not be integrated with the existing equipment. It is expected that the SFC Contractor will place a central controller (HMI) in the middle of the control room, and place unit-specific SFC control equipment in the individual SFC rooms. The central controller will communicate with the individual SFCs and coordinate their operation through fiber optic cables. This minimizes the amount of cable work in the control room while allowing operation of the station from a central location.

The SFC Contractor may chose to replace each SFC control panel as the SFC unit is replaced. This methodology is discouraged as it may disrupt the underfloor wiring and could affect the operation of other units. If this methodology is proposed by a SFC Contractor, a detailed design concept will need to be evaluated during the SFC Contractor bid stage.

Any transducers, located within this control room, used for sending signals external to the SFC building, will need to be replaced by new transducers. Final design of these modified transducer circuits can only be made after the SFC Contractor completes his design.

Figure 5 - SFC Control Room

2.5 SFC 60 Hz Input Transformers

The existing converter transformers are located on the east side of the building and surrounded by wing walls. SFCs #1 and #3 both have concrete oil containment pits, while SFC #2 has no oil containment.

All existing converter transformers will be replaced based on the requirements of the new SFCs. If transformers are required, new oil containment pits will be designed for SFC #2 and #4. The new oil containments will be designed similar to existing containment pits. Sump pits will be provided for each containment.

It is assumed that the existing transformer foundations can be re-used for the new transformers. Table 4 - Existing 60 Hz Input Converter Transformer (Typical)

Parameter Value Identification T1 Power rating 60⁰C Rise:

H: 31.9 MVA OA X: 16.6 MVA OA Y: 16.4 MVA OA

Voltage rating 13.2 kV Y-1.11 kV Δ-1.10 kV Y, 3-phase, 60 Hz


Parameter Value Impedance H-X: 9.13% at 31.9 MVA

H-Y: 9.47% at 31.9 MVA X-Y: 2.82% at 31.9 MVA

Insulation rating H: 95 kV BIL Neutral: 26 kV applied X: 5 kV applied Y: 5 kV applied

Weight 158,300 lbs Tap changer No-load tap changer on H winding only, +/-2 x 2.5 % Oil type Mineral oil Oil quantity Oil in tank: 5765 gal

Oil in coolers: 1112 gal Manufacturer ASEA Transformer type TMY 31 Serial No. 7288529 Year of manufacture 1984 Standard ANSI C57.12.00-1980 Grounding Not grounded

Figure 6 - 60 Hz Converter Transformer (SFC #1 left, SFC #2 right)


Figure 7 - 60 Hz Converter Transformer (cable connections)

2.6 SFC 60 Hz Filter Yard The existing SFC power feeders exit the 230 kV control building through the CMU wall and are routed down to duct bank conduit stub-ups via enclosed metal tray. Each SFC uses 2-3/c, 1000 kcmil cables between the 230 kV control building and the filter yard. The existing feeders terminate on overhead bus structures and filters are tapped off of this structure. Each SFC has three filters. Each open-air bus has one current transformer, one potential transformer, and two lightning arresters. The SFC power feeders leave the open-air bus as 4-3/c 500 kcmil cables and feed the SFC input transformers.

All filters in the 60 Hz filter yard will be removed, but foundations will remain in place. The yard can be used for reactors and/or heat exchangers, if required by the SFC vendor.

A new duct bank will be constructed from the 230 kV control building to the new SFC #4 open-air bus to be constructed in the 60 Hz filter yard. Another duct bank will be constructed from the open-air bus to the SFC #4 input transformer, with a portion extended to the basement of the SFC #4 building. The duct banks will contain power and control cables. The existing 60 Hz filter yard duct banks will be re-used for SFCs #1, #2, and #3.

The new SFC #4, 60 Hz open-air bus will utilize a manually-operated grounding switch similar to SFCs #1, #2, and #3. The open-air bus will also have a set of PTs and CTs for use with the new SFC #4 protective relaying, metering, and/or control scheme.

The existing 60 Hz, 13.2 kV, 1000 kcmil cables will remain connected between the 13.2 kV switchgear and open-air bus. The existing 60 Hz, 13.2 kV, 500 kcmil cables to SFC #1, #2, and #3 input transformers will be replaced as required by the new SFC design.

All duct banks associated with SFCs #1, #2, and #3 will remain in place in the 60 Hz filter yards in order to minimize risks and operational impact during construction.

The existing grounding switches, PTs, and CTs will remain connected to the existing 60 Hz open-air bus for SFCs #1, #2, and #3. Based on the accuracy class, the PTs and/or CTs may be replaced if required by the SFC vendor.


Table 5 - Existing 60 Hz Filter Yard

Parameter Value Fixed filter - capacitors, air-cooled reactors, resistors 14 Mvar Switched power reactors 7 Mvar Switched harmonic filter - capacitors and reactors in series 10 Mvar, tuned to 110 Hz

Figure 8 - 60 Hz Filter Yard #2

2.7 SFC 25 Hz Output Transformers

The output transformers are located on the west side of the SFC building. Each transformer is surrounded on its sides by CMU wing walls. Electrical bus duct supplies the transformers from the converter. Insulated cable connects the transformer output to the 25 Hz filter yard via duct banks that run underneath the road between the transformers and filter yard.

The transformers are grounded through the rail bus that is common to all output transformers located in the 25 Hz filter yard.

SFCs #1 and #3 both have concrete oil containment pits, while SFC #2 has no oil containment.

All existing converter transformers will be replaced based on the requirements of the new SFCs. New oil containment pits will be designed for SFC #2 and #4. The new oil containments will be designed similar to existing containment pits. Sump pits will be provided for each containment.


Table 6 - 25 Hz Output Transformer Specifications

Parameter Value Identification T2 Power rating Temperature rise 60⁰C

X1 X2: 15.366 MVA OA H1 H2: 12.5 MVA OA H2 H3: 7.5 MVA OA

Voltage rating X1 X2: 1.62 kV H1 H2: 13 kV H2 H3: 25.8 kV Single-phase, 25 Hz

Impedance X1 X2/H1 H2: 4.19% @ 15.366 MVA, 1.62/13 kV X1 X2/H2 H3: 8.94% @15.366 MVA, 1.62/26 kV H1 H2/H2 H3: 3.72% @15.366 MVA, 13/26 kV X1 X2/ H1 H3: 5.44% @15.366 MVA, 1.62/39 kV

Insulation rating X1 X2: 60 kV BIL H1 H2: 250 kV BIL H2 H3: 250 kV BIL

Weight 106,648 lbs Tap changer None Oil type Mineral oil Oil quantity Oil in tank: 2985 gal

Oil in coolers: 420 gal Manufacturer ASEA Transformer type TMZ 31 Serial No. 7288530 Year of manufacture 1984 Standard ANSI C57.12-1980 Grounding Solid, H2 bushing

Figure 9 - 25 Hz Output Transformer

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 30 of 87 2.8 SFC 25 Hz Filter and Breaker Yard The 25 Hz filter and breaker yard consists of CTs, PTs, disconnect switches, lighting arresters, a RLC filter between the 12 kV trolley power and ground, and a two-pole, 24/12 kV live-tank circuit breaker. The RLC filter will not be required with the new SFC technology.

The existing filter equipment in the 25 Hz filter yard will be removed. The foundations for these filters will remain in place.

A new duct bank will be constructed from the output of the SFC #4 building basement, joining a new duct bank from the 25 Hz output transformer to the 25 Hz yard cable riser. The duct bank will contain power and control cables. A new open-air bus will be constructed to terminate the SFC #4, 24/12 kV cables from the 25 Hz output transformer. The new open-air bus will contain surge arresters, PTs, CTs, disconnect switches, grounding switches, and a circuit breaker. An exposed rail return bus will be constructed near the SFC #4 output breaker, similar to the SFC #1, #2, and #3 rail return buses, in order to bond the transformer rail return cable to station ground.

A new duct bank will constructed from the SFC #4 output circuit breaker to the 25 Hz traction power substation. The duct bank will contain power and control cables.

All duct banks associated with SFC #1, #2, and #3 will remain in place in the 25 Hz filter yards in order to minimize impact during construction.

The existing 25 Hz, 12 kV, 24 kV, and rail return cables will remain in place bewteen the 25 Hz traction power substation and the SFC disconnect switches located next to the SFC output circuit breakers.

The existing SFC output circuit breakers will be replaced for each SFC. The new circuit breakers are ABB model FSKII. Each is supplied with a CT on both line and load side of each pole. These CTs will replace the existing CTs.

The existing 25 Hz disconnect and grounding switches next to the cable riser on the load side of the circuit breaker will be replaced.

The 25 Hz disconnect and grounding switches, PTs, and surge arresters on the SFC side of the circuit breaker will be relocated and replaced, as requried, based on the size of the new ABB FSKII circuit breakers.

Figure 10 - 25 Hz SFC Filter and Circuit Breaker Yard

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 31 of 87 2.9 25 Hz Traction Power Substation The 25 Hz traction power substation is presently being substantially upgraded under another project. The converter 24 kV feeder, 12 kV trolley, and rail return insulated cables leave the 25 Hz converter filter yard and connect to the 25 Hz traction power substation via an underground duct bank. SFC #2 cables stub-up on the south side of the 25 Hz yard while the SFC #1 and SFC #3 cables stub-up on the north side. A new 24 kV Bus 4 and a new 12 kV Bus 4 will be constructed at the existing substation location.

The SFC #4 duct bank will be built on the east side of the 25 Hz filter yard and extend just north of the SFC #1 and #3 stub-up.

A new mutifuction protective relay will be installed in the 25 Hz traction power substation control house. The location of the relay and associated test switches have been determined under another project.

In the exisitng 25 Hz traction power substation, the new SFC #4 12 kV and 24 kV feeders will be routed to a new two-pole disconnect switch along newly installed cable tray. The new rail return cable will be terminated to the existing rail return bus. The new SFC #4 feeders will be integrated into existing bus work. A new multifunction protective relay and associated equipment will be installed in existing relay panels.

The new 25 Hz traction power substation design drawings show that ammeters and voltmeters receive signals from transducers located on SFC breakers. However, there are no transducers on these breakers. There are transducers in the SFC control room, and these must be the transducers being referenced by the other project (to be confirmed). In any case, any transducers that are being used for supplying signals to the 25 Hz traction power substation will be replaced under the WJSFC project.

Figure 11 - Existing 25 Hz Traction Power Substation

2.10 System Load Demand

2.10.1 60 Hz System Measurements

PECO provided a table of 230 kV load demand and power factor recordings on a monthly basis from August 29, 2013 through August 27, 2015 (Ref. 115). The highest recorded demand was 29,393 kW during between the period of 1/2/14 and 2/3/14. This load demand includes the traction power load as well as the station balance of plant load, i.e., maintenance building, offices, etc. Demand is calculated as the highest 30-minute average during a month. Since Wayne Junction is a HT customer with a standard power factor of 95%, on-peak demands are adjusted by the ratio of standard power factor to measured power factor for billing purposes. For example, if the on-peak demand is 25,000 kW, then the adjusted on-peak demand is 0.95/0.88 x 25,000 kW = 25,119 kW.


Table 7 - PECO Billing Data

From To Power Factor Off Peak kW On Peak kW Max kW Adj On

Peak kW Total kWhr

7/29/2015 8/27/2015 0.880 25,000 23,268 25,000 25,119 8,551,477

6/29/2015 7/29/2015 0.894 24,434 24,516 24,516 26,052 8,990,354

5/29/2015 6/29/2015 0.879 25,436 23,069 25,436 24,932 8,827,397

4/29/2015 5/29/2015 0.877 25,034 24,710 25,034 26,767 8,782,575

3/31/2015 4/29/2015 0.877 24,032 23,760 24,032 25,738 7,949,554

3/2/2015 3/31/2015 0.886 26,996 24,166 26,996 25,912 8,256,913

1/30/2015 3/2/2015 0.886 27,855 24,313 27,855 26,069 9,744,276

12/30/2014 1/30/2015 0.889 26,931 25,199 26,931 26,928 9,344,821

11/25/2014 12/30/2014 0.884 25,086 23,609 25,086 25,372 9,467,878

10/29/2014 11/25/2014 0.885 26,434 24,559 26,434 26,363 7,425,002

9/30/2014 10/29/2014 0.880 25,151 24,494 25,151 26,442 8,168,373

8/29/2014 9/30/2014 0.886 25,302 24,360 25,302 26,120 9,110,634

7/30/2014 8/29/2014 0.881 26,853 23,803 26,853 25,667 9,133,618

7/1/2014 7/30/2014 0.883 26,633 23,656 26,633 25,451 8,649,407

5/31/2014 7/1/2014 0.880 26,529 23,967 26,529 25,873 9,374,478

5/1/2014 5/31/2014 0.883 25,916 24,270 25,916 26,112 8,791,386

4/2/2014 5/1/2014 0.892 25,739 25,328 25,739 26,975 8,293,977

3/4/2014 4/2/2014 0.884 29,065 24,084 29,065 25,882 8,686,770

2/3/2014 3/4/2014 0.893 28,832 25,574 28,832 27,206 9,087,371

1/2/2014 2/3/2014 0.889 29,393 24,697 29,393 26,392 9,873,235

11/27/2013 1/2/2014 0.889 28,784 24,214 28,784 25,875 10,414,956

10/29/2013 11/27/2013 0.881 26,957 24,641 26,957 26,571 7,861,145

9/30/2013 10/29/2013 0.880 25,695 23,306 25,695 25,160 8,172,652

8/29/2013 9/30/2013 0.913 26,179 24,702 26,179 25,703 9,228,786

2.10.2 25 Hz System Measurements

SEPTA continuously measures the total SFC station power output at 100 ms intervals. Individual SFC feeder current and trolley voltage are also measured. Using these values, the station real power and individual SFC apparent power has been tabulated and plotted at one second intervals. Rolling averages have been calculated, plotted, and compared to the cycloconverter ratings. Two days were selected for the analysis: one in July 2014 and one in January 2015. Both were weekdays with one occurring in summer and one in winter.


Figure 12 - SFC #3, July 24, 2014

Figure 13 - SFC #3, July 24, 2014, Measurements vs Ratings


Table 8 - SFC #3, July 24, 2014, Measurements vs Ratings

Rating Limit MVA Measured MVA Percent

2 seconds 48 28.3 59%

30 seconds 30 24.8 83%

6 minutes 24 16.7 70%

1 hour 18 13.8 77%

Continuous 15 8.4 56%

Figure 14 - WJSFC Station Output, July 24, 2014, 30-Minute Average

The maximum 30-minute demand was 23.8 MW at 0.83 pf, compared to a PECO reading of 26.6 MW. The difference of 2.8 MW is the balance of plant demand.


Figure 15 - SFC #3, January 7, 2015

Figure 16 - SFC #3, January 7, 2015, Measurements vs Ratings


Table 9 - SFC #3, January 7, 2015, Measurements vs Ratings

Rating Limit, MVA Measured, MVA Percent

2 seconds 48 28.0 58%

30 seconds 30 23.7 79%

6 minutes 24 17.2 72%

1 hour 18 14.0 78%

Continuous 15 8.6 57%

Figure 17 - WJSFC, Station Output, 30-Minute Average

The maximum 30-minute demand was 24.2 MW at 0.82 pf, compared to a PECO reading of 24.5 MW. The difference of 0.3 MW is the balance of plant demand during the same period.

Based on a comparison of existing station load measurements and the ratings of the cycloconverters, applying the cycloconverter ratings to the new frequency converters seems reasonable.

Also, an output power factor of ≥0.70 lagging appears reasonable for specifying the new converter equipment.


Figure 18 - WJSFC, Station Output, 1-Second Measurement Rate

Figure 18 shows the rapid load cycle of the station, with load demand changing by 43 MVA in 30 seconds, or about 1.43 MVA/s.

The new SFCs shall be able to supply power to the 25 Hz system under the same load conditions as shown above.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 38 of 87 2.11 PECO Customer Requirements Wayne Junction is a HT customer with a standard power factor of 95%. The billing address is:

SEPTA Wayne Junction 4505 Germantown Ave Philadelphia, PA 19144 Account Number 66036-00704

2.12 60 Hz Operating Requirements Specific design requirements for PECO customers are provided in the PECO Electric Service Requirements Manual (Ref. 28). PECO operates within the PJM territory and follows requirements documented in PJM Manual M-03 (Ref. 33).

Table 10 - 60 Hz System Characteristics

Characteristic Value Nominal operating voltage 230 kV Operating voltage range 242 kV normal high




Impulse withstand (BIL) 900 kV (Note: Existing transformers are rated 750 kV BIL) 1.2 x 50 µs (lightning impulse) minimum CFO 1105 kV Minimum distance between conducting parts


Spacing 144 inches @900 kV BIL, phase-to-phase Fault clearing time Normal clearing time for all types of faults = 5 cycles. Fault

clearing due to failed primary line relaying = 33 cycles. Fault clearing due to stuck breaker = 17 cycles.

System grounding Effectively grounded neutral (always) Harmonic voltage distortion limits 1.0% individual frequency voltage harmonic

1.5% THD in 230 kV switchyard Harmonic current distortion limits Must be low enough to meet voltage distortion requirements.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 39 of 87 2.13 60 Hz Short-Circuit Availability PECO prepared a short-circuit model for Wayne Junction and simulated faults at the primary and secondary sides of the Wayne Junction 230-13.2-13.2 kV transformers (Ref. 113).

Figure 19 - PECO 230 kV System Supplying Wayne Junction

Table 11 - 60 Hz Short-Circuit Characteristics

Location and Type Value YWT-XMT1, 230 kV (From PECO Line 220-42) 32,111 A, 3LG

24,109 A, 1LG YWT-XMT2, 230 kV (From PECO Line 220-28) 25,903 A, 3LG

18,630 A, 1LG YWT-XMT1, 13.2 kV, X winding 24,594 A, 3LG

381 A, 1LG YWT-XMT1, 13.2 kV, Y winding 13,000 A, 3LG

380 A, 1LG YWT-XMT2, 13.2 kV, X winding 24,206 A, 3LG

381 A, 1LG YWT-XMT2, 13.2 kV, Y winding 12,867 A, 3LG

380 A, 1LG 2.14 60 Hz Harmonics PECO requires that customers connected to the 230 kV system follow IEEE 519 requirements with respect to harmonic distortion limits (Ref. 28).

2.15 230 kV Substation The Wayne Junction SFC station was upgraded in 1990 for 3 x 15 MVA units, with provision for a future fourth 15 MVA unit. The two incoming PECO 230 kV, 60 Hz supply lines and switchgear were sized and

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 40 of 87 installed to accommodate the initial and the future load of the entire station. The incoming PECO lines are adequate for this project.

There are no planned modifications to the 230 kV switchyard equipment within the scope of this project. The new SFC #4 and its auxiliary equipment will be supplied from these existing transformers.

Neutral grounding resistors are mounted on stands next to the transformers.

The two main transformers convert the 230 kV 60 Hz power to 13.2 kV 60 Hz with a 3 winding transformers rated at 45/60/75 MVA each. With air cooling only, the transformers are rated for 45 MVA each at 55⁰C rise. However, with fan cooling, they are capable of being loaded up to 75 MVA. When the fourth SFC is installed, the total connected load will be 60 MVA for the converters plus the auxiliary loads. Therefore, if all frequency converters are operating, and one transformer is out for maintenance, the transformers fans may be required if the load goes above 45 MVA.

These two transformers feed two separate 13.2 kV switchgear lineups, one for the static frequency converters (NPS-SWGX) and one for the auxiliary loads (NPS-SWGY).

Any modifications to the station load demand or energy usage must comply with PECO requirements and standards.

Table 12 - Existing 230-13.2 kV Substation Transformer 1

Parameter Value Identification YWT-XMT1 (From PECO Line 220-42) Power rating 55⁰C Rise:


Voltage rating 230 kV Δ-13.2 kV GndY-13.2 kV GndY, 3-phase, 60 Hz Impedance H-X: 7.64% at 45 MVA

H-Y: 1.97% at 6 MVA X-Y: 24.9% at 45 MVA





Table 13 - Existing 230-13.2 kV Substation Transformer 2

Parameter Value Identification YWT-XMT2 Power rating 55⁰C Rise:


Voltage rating 230 kV Δ-13.2 kV GndY-13.2 kV GndY, 3-phase, 60 Hz Impedance H-X: 7.69% at 45 MVA

H-Y: 1.98% at 6 MVA X-Y: 25.3% at 45 MVA




Figure 20 - 230-13.2 kV Substation Transformer

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 42 of 87 2.16 13.2 kV, 60 Hz Switchgear The 13.2 kV switchgear NPS-SWGX is located in the 230 kV Control Building and supplies power to the SFCs with a main-tie-main automatic transfer system and a 3000 A bus. The maximum calculated load possible on this switchgear is 68 MVA.

The 13.2 kV switchgear NPS-SWGX has one spare cubicle dedicated to supply the new SFC #4. It contains electromechanical relays for protecting the new SFC #4 feeder. The protective relays will need to be set to the requirements of the new static frequency converter equipment. The types of relays and auxiliary devices are listed below:

1. 50/51 overcurrent, phases 1, 2, 3

2. 50GS overcurrent

3. 0-2000 A ammeter

4. 86 lockout relay

5. Ammeter switch

6. SFC No. 4 breaker control

7. Local/remote key switch

8. 50GS test switch

9. 87BX2 test switch

10. Current circuit test switch

11. PK-2 current circuit

A spare 3000 A circuit breaker, presently used during maintenance activities, is available for use by the future SFC #4. The new SFC #4 will be supplied using this spare 3000 A circuit breaker from the allocated cubicle. All existing protective relays will be used.

A new set of 13.2 kV cables will be run from the existing 13.2 kV cubicle using overhead conduit, then routed from the building through the CMU wall to enclosed cable tray, and then down to conduit stub-ups just outside the 230 kV control building.

The 15 kV switchgear NPS-SWGY supplies power to the auxiliary systems with a main-tie-main automatic transfer system and a 1200 amp bus. The maximum calculated load possible on this switchgear is 27 MVA. The estimated actual load, based on the ammeter reading and verbal conversations with plant personnel is less than 100 amps on this switchgear or about 2.3 MVA.

There are five feeder circuit breakers that originate in switchgear NPS-SWGY. There is a circuit breaker for the feeder to the existing car shop and the estimated load is 250 kVA. There are two feeders for the two 1000/1500 kVA transformers that power the 6.9 kV system with an estimated load of 500 kVA. There are two remaining feeders that power all the auxiliary loads for the static frequency converter building and auxiliary systems with a combined estimated load of 1.6 MVA. These auxiliary loads are connected through 1500/2250 kVA dry-type transformers to convert the voltage to 480 V, 60 Hz. The approximate load on the 480 V switchgear is currently 2.5 MVA.


Table 14 - SFC Input Circuit Breaker Ratings

Parameter Value Identification SFC #4 Input Breaker Manufacturer Siemens Type 15-GM-1000-3000-77 Amps 3000 Frequency 60 Hz Serial No. R-80650B-1 Manufacture Date August 1989 Rated Max. Voltage 15 kV Voltage Range Factor K=1.30 BIL 95 kV Rated Short-Circuit Current 37 kA Close and Latch 77 kA Interrupting Time 5 cycles Motor Voltage and Current 100-140 V dc, 3 A nom. Close Circuit Voltage and Current 100-140 V dc, 5 A nom. Trip Circuit Voltage and Current 70-140 V dc, 5 A nom.

Figure 21 - Spare SFC 15 kV Circuit Breaker

Figure 22 - SFC #4 13.2 kV circuit breaker and relay cabinet (outside and inside)

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 44 of 87 2.17 13.2 kV, 60 Hz Auxiliary Power Transformers There are four auxiliary transformers just outside of the 230 kV Control Building. A fifth transformer is supplied from the 13.2 kV switchgear NPS-SWGY, but is located in the existing car shop. Existing transformers NJS-XAT1 and NJS-XAT2 will be used to supply the new SFC #4 auxiliary systems.

Table 15 - Existing 13.2 kV Auxiliary Power Transformers

Transformer Description NJS-XAT1 1500/2250 kVA, 13.2 kV Δ-480Y/277 V (SFC aux power), 95

kV BIL HV, 10 kV BIL LV, 80 deg C rise, cast coil NJS-XAT2 1500/2250 kVA, 13.2 kV Δ-480Y/277 V (SFC aux power), 95

kV BIL HV, 10 kV BIL LV, 80 deg C rise, cast coil NOS-XAT3 1000/1500 kVA, 13.2 kV Δ-6.9 kV Δ NOS-XAT4 1000/1500 kVA, 13.2 kV Δ-6.9 kV Δ

Figure 23 - Auxiliary Power Transformers

2.18 13.2 kV, 60 Hz System Operating Characteristics All new equipment installed on the 13.2 kV, 60 Hz system shall operate under the following conditions:

Table 16 - 13.2 kV System Characteristics

Parameter Value Reference Nominal operating voltage 13.2 kV Table 12 Operating voltage range 13.86 kV normal high


Ref. 33, 230 kV operating ranges converted to 13.2 kV system



Ref. 33

Rated maximum voltage 15 kV Photograph shown in Figure 21

Power frequency withstand 36 kV Ref. 11 Lightning impulse withstand (BIL) 95 kV BIL indoors

110 kV BIL outdoors Ref. 26

Minimum distance between conducting parts


Ref. 26

Phase spacing - vertical break disconnect switches and bus supports

24 inches @110 kV BIL, centerline-to-centerline Ref. 15

Phase spacing - horizontal break disconnect switches and bus supports

30 inches @110 kV BIL, centerline-to-centerline Ref. 15


Parameter Value Reference Short-circuit availability 381 A 1LG

24,594 A 3LG Ref. 113

Earth fault factor 1.732 (resistive grounded-wye) Conservative assumption

Fault clearing time Approx. 8 cycles at maximum 3-ph fault current (assume 3 cycles for relays, 5 cycles for breaker)

Photograph shown in Figure 21

System grounding Effectively grounded neutral (always), low-resistance grounded (20 ohms per transformer)

Nameplate

2.19 13.2 kV, 60 Hz SFC Supply Circuits

The existing 13.2 kV, 60 Hz supply circuits are (2) 3-1/c, 1000 kcmil cables between the 13.2 kV switchgear and the 60 Hz open-air bus, running in 6" conduit. The circuits transition to (4) 3-1/c, 500 kcmil cables between the 60 Hz open-air bus and the 60 Hz SFC transformers, running in 5" conduit.

The new SFC #4, 60 Hz supply circuits will replicate the existing SFC cable design. New open-air bus will be constructed for SFC #4 similar to SFC #3. It will contain a grounding switch, CTs, PTs, and surge arresters. The instrument transformer ratings will be selected by the SFC vendor.

Parameters for both the 1000 kcmil and 500 kcmil cables are provided below. Table 17 - 13.2 kV, 60 Hz SFC Supply Cables

Parameter Values Reference Rated Voltage 15 kV rms Ref. 25 Voltage withstand 35 kV rms Ref. 25 Size 1000 kcmil stranded 500 kcmil stranded Selected Number of conductors per cable

One (1) Selected

Conductor Soft-drawn bare copper Ref. 25 Insulation type XLPE Ref. 25 Insulation thickness 100% insulation level, 175 mils Ref. 25 Shield 5 mil copper tape, >10% overlap Ref. 25 Jacket type PVC Ref. 25 Jacket thickness >70 mils Ref. 25 Normal Operation Temperature

105°C Ref. 25

Emergency Operation 140°C Ref. 25 Short Circuit Operation 250°C Ref. 25 Load current 676 A rms continuous Calculated Estimated ampacity 640 A each circuit

x 2 circuits x 0.88 correction factor (2 conduits) x (1 - 0.06 x 6 ft)= 721 A rms continuous 3-1/c cable per duct. Burial depth 8.5 ft. Derated additional 6% per foot of burial depth after 30 inches (2.5 ft). Cable operated at 90⁰C.

370 A each circuit x 4 circuits x 0.94 correction factor (4 conduits) x (1 - 0.06 x 6 ft)= 890 A rms continuous 3-1/c cable per duct. Burial depth 8.5 ft. Derated additional 6% per foot of burial depth after 30 inches (2.5 ft). Cable operated at 90⁰C.

Ref. 26, NEC Table 310.77, Details 1 and 2, and Appendix B notes

Installation location Conduits in concrete encased duct bank By design Approximate O.D. 1.71 inches 1.38 inches for 1/c

2.91 inches for 3/c Ref. 123

Minimum bend radius 1.71 x 12 = 21 inches 1.38 x 12 = 17 inches for 1/c 2.91 x 7 = 21 inches for 3/c

Ref. 26, NEC Section 300.34

Allowable pulling tension 8000 lbs 4000 lbs Ref. 127 Allowable sidewall pressure 500 lbs/ft Ref. 127

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 46 of 87 Manholes shall be sized in accordance with NEC 314.71.

Table 18 - 13.2 kV, 60 Hz Manholes

Parameter Value Reference Straight pulls - minimum length of box 48 times outside diameter of shielded cable Ref. 26 Angle or U-pulls - minimum distance between each conductor or conductor entry inside box and opposite wall

36 times outside diameter of shielded cable, increased for additional entries by the amount of the sum of the outside diameters, over sheath, of all other cables or conductor entries through the same wall of the box.

Ref. 26

2.20 13.2 kV, 60 Hz Circuit Breakers All new outdoor circuit breakers on the 13.2 kV, 60 Hz system shall meet the following requirements.

Table 19 - New 13.2 kV Circuit Breakers

Parameter Value Reference Rated maximum voltage 15.5 kV Ref. 12 BIL 95 kV Ref. 12 Current carrying capacity 2000 A rms continuous Ref. 12 Interrupting duty 40 kA Ref. 12 Close-and-latch 104 kA Ref. 12 Rated interrupting time 83 ms Ref. 12

2.21 13.2 kV, 60 Hz Busbars

All new busbars used on the 13.2 kV, 60 Hz open-air substation shall be the following requirements. Table 20 - 13.2 kV Open-Air Substation Busbars

Parameter Value Reference Rated maximum voltage 15.5 kV Ref. 15 BIL New: 110 kV peak

Existing: 150 kV peak Ref. 15 Ref. 109

Current carrying capacity 1100 A minimum Ref. 109 Withstand current 40 kA rms sym Ref. 109 Centerline-to-centerline spacing for rigid buses 24 inches Ref. 15 Minimum metal-to-metal distance for rigid conductors

12 inches Ref. 15

Minimum to grounded parts 10 inches recommended 7 inches minimum

Ref. 15

Size 2 inches nominal, schedule 40 Selected Alloy 6061-T6 Selected Radial thickness of ice 0.5 inches (NESC heavy) Ref. 34 Wind pressure 4 lbs/ft2 Ref. 34 Maximum vertical conductor deflection 1/200 of span length Ref. 34

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 47 of 87 2.22 13.2 kV, 60 Hz Air Disconnect and Grounding Switches

All new air disconnect and grounding switches on the 13.2 kV, 60 Hz system shall be station class and meet the following requirements.

Table 21 - 13.2 kV Disconnect and Grounding Switches

Parameter Value Reference Rated maximum voltage 15.5 kV Ref. 15 BIL 110 kV peak Ref. 15 Minimum 60 Hz withstand 50 kV, dry, 60 seconds

45 kV, wet, 10 seconds Ref. 15

Opening/closing capability 3/4 inch ice Ref. 15 Current carrying capacity Disconnect switch - 1600 A rms continuous

Grounding switch - None Ref. 15

Withstand current 44 kA rms sym 114 kA peak

Ref. 15

Minimum metal-to-metal distance disconnecting switches, bus supports and rigid conductors

12 inches Ref. 15

Ground clearance 10 inches recommended 7 inches minimum

Ref. 15

Centerline-to-centerline spacing 24 inches - vertical break 30 inches - side break 36 inches - horn gap

Ref. 15

2.23 13.2 kV, 60 Hz Surge Arresters All new surge arresters on the 13.2 kV, 60 Hz system shall meet the following requirements.

The nominal system voltage is 13.2 kV.

Maximum continuous line-to-ground voltage = 13.2 kV / 1.732 x 1.05 = 8.0 kV

During a line-to-ground fault, with the system being grounded through a 20 ohm neutral grounding resistor, the temporary overvoltage (TOV) between line-to-ground is:

TOV = 13.2 kV x 1.05 = 13.9 kV

Selecting an MCOV rating of 8.4 kV, the highest corresponding station class duty cycle rating is 15 kV per IEEE C62.22. This will adequately protect the solid-dielectric cable and converter input transformers.

Table 22 - 60 Hz Surge Arresters Connected Line-to-Ground

Parameter Value Reference Type Gapless metal-oxide Selected Maximum line-to-ground 8.0 kV rms Calculated TOV rms 13.9 kV rms Calculated MCOV rating 8.4 kV rms Ref. 19 Duty cycle 15 kV rms Ref. 19 Class Station Ref. 19

For surge arresters connected line-to-line, the maximum continuous voltage between phases is:

Maximum continuous line-to-line voltage = 13.2 kV x 1.05 = 13.9 kV Table 23 - 60 Hz Surge Arresters Connected Line-to-Line

Parameter Value Reference Type Gapless metal-oxide Selected Maximum line-to-line 13.9 kV rms Calculated TOV rms 13.9 kV rms Calculated MCOV rating 15.3 kV rms Ref. 19 Duty cycle 18 kV rms Ref. 19 Class Station Ref. 19


2.24 13.2 kV, 60 Hz Instrument Transformers Table 24 - 13.2 kV, 60 Hz Current Transformers

Parameter Value Reference Ratio 2000:5 A multiratio Ref. 18 Accuracy class C400 Ref. 18 Secondary thermal overload 2.0 Ref. 18 Insulation class 15.5 kV Ref. 18 BIL 110 kV Ref. 18 Power frequency withstand 34 kV Ref. 18

Table 25 - 13.2 kV, 60 Hz Potential Transformers

Parameter Value Reference Nominal voltage 13.2 kV Ref. 18 Insulation class 15.5 kV Ref. 18 Primary voltage 8400 V Ref. 18 Secondary voltage 120 V Ref. 18 Ratio 70:1 Ref. 18 Burden Z, 200 VA Ref. 18 Accuracy class Relaying - 0.3

Metering - 0.15 Ref. 18

BIL 110 kV Ref. 18

2.25 13.2 kV, 60 Hz Insulators Table 26 - 60 Hz Insulators

Parameter Value Reference Nominal voltage 13.2 kV Given BIL 110 kV Ref. 20 Low-frequency wet withstand 45 kV Ref. 20

2.26 6.9 kV, 60 Hz Switchgear The 6.9 kV switchgear NOS-SWGY is located in the 230 kV Control Building and has a main-tie-main automatic transfer system. The 6.9 kV switchgear originally had four feeder breakers, but with time, it has been reduced to just two operating circuit breakers. The wheel turn building and the 100 Hz motor-generator signal feeders are no longer used. The main function is to supply power to the Delta East and Delta West part of the Septa system. The load is estimated to be 250 kVA.

2.27 480 V, 60 Hz Switchgear

The 480 V switchgear is located in the 230 kV Control Building. It was designed to supply two redundant power feeders to each of the four SFCs with a main-tie-main automatic transfer system. Additionally, this switchgear supplies power to MCC1 and MCC2, which powers the 230 kV Control Building and the SFC Building, respectively. In time, other loads were added for the Power Distribution (PD) Building and the old Tempco Building (old rotary converter building).

The 480 V switchgear has two spare cubicles dedicated to supply the new SFC #4. New 480 V feeders will be routed from the 230 kV Control Building to the SFC Building for SFC #4. Existing feeders for SFC #1, #2, and #3 will remain routed from the 230 kV Control Building, but will be spliced at the SFC Building to new feeders supplying the SFC auxiliary power system equipment.

SFC #4 auxiliary power feeders are required to be 500 kcmil with a higher trip setting, since they will also carry the SFC Control Building Roof Top Unit air-conditioning/heating load.


Table 27 - 480 V Distribution Feeder Data

Parameter Values for SFC #1, #2, #3 Values for SFC #4 Reference Nominal voltage 480 V 480 V Ref. 111 Insulation 600 V 600 V Cable size 3-1/c, 350 kcmil 3-1/c, 500 kcmil Ref. 111 Breaker type Siemens Static Trip II Siemens Static Trip II Ref. 111 Frame size 800 A 800 A Ref. 111 Trip coil range 400 A 400 A Ref. 111 Long-time delay pickup 250 A 400 A Ref. 111 Short-time delay pickup 3000 A 3000 A Ref. 111 Ground sensor pickup 200 A 200 A Ref. 111

Equipment grounding is accomplished by running ground wires, bonded to metallic conduits, cable trays, and embedded in concrete encased duct lines, along with the circuit conductors.

2.28 Low-Voltage Distribution System The existing 480 V-208Y/120 V transformers and 208Y/120 V ac power distribution panels in the SFC Building will remain, but SFC Room lighting circuits will be removed from these panels and placed on the new SFC distribution panels supplied by the SFC Contractor.

Roof-top air-conditioning and heating units (RTUs) will be powered from the new SFC distribution panels supplied by the SFC Contractor.

2.29 125 V dc Power System The existing 125 V dc battery and charger systems may be required to operate the new SFC equipment. The batteries are presently used for the existing SFC system and 25 Hz circuit breaker control. Per SEPTA's request, the existing battery system will be replaced with a new 120 V dc, 190 A-hr pure lead VRLA (valve-regulated, lead-acid) AGM (absorbent glass mat) stationary battery of flat plat construction, comprised of ten (10) monoblocks (a.k.a. multi-cell unit or monoblock) at 12 V dc each. Using new VRLA batteries will require replacing the battery charger system as well.

2.30 Lighting

Lighting levels are adequate in all building areas. The existing lighting systems in the converter building consist of standard 4-foot fluorescent lighting fixtures. In the corridors, the lighting fixtures are suspended from the ceiling. In the control room, the fixtures are integrally fitted into the ceiling.

All fixtures within the SFC Building will be upgraded to LED-type fixtures. LED exit lights and emergency egress lights will be added where required by NFPA 101 life safety code.

The existing yard lighting is adequate. Lighting fixtures are mounted on poles and on the sides of buildings. Lighting fixtures on the side of SFC #3 building will be removed with the construction of SFC #4 building. New LED-type lighting will be specified for SFC #4 building exterior to replace the lighting removed from the side of SFC #3 building.


Figure 24 - Control Room lighting fixtures

Figure 25 - Suspended fixtures in the SFC building corridor

2.31 Grounding

All outdoor switchyard grounding grids shall be constructed to meet the requirements of IEEE 80, the IEEE Guide for Safety in AC Substation Grounding. A grounding grid study, which demonstrates compliance with the requirements of IEEE 80, is required, and the resistance to remote earth of the completed ground grid shall be tested. It is anticipated that grounding grids will only be required in the SFC 25 Hz switchyard.

All switching and substation grounding grids shall be constructed with a minimum of 4/0 AWG copper conductor and shall be installed a minimum of 18 inches below grade. All pigtail connections to equipment and structures shall be made with 350 kcmil copper and all equipment and structures shall be connected by at least two connections to the ground grid.

All below grade connections shall be exothermically welded. All equipment and structure grounding connectors shall meet the requirements of IEEE 837-2002, IEEE Standard for Qualifying Permanent Connections for use in Substation Grounding. All metallic fences, platforms, and railings within a station shall be grounded by cable connections and not rely on mechanical contact with supporting structures, all discontinuous pieces shall have two connections to the ground grid.

All feeder and branch circuit wiring shall be specified with dedicated copper ground wires. Conduit systems shall not be used for equipment grounding.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 51 of 87 2.32 Lightning Protection The existing building and switchyards are protected from lightning strikes utilizing the static wire above the tracks. There is no equipment mounted on either the 230 kV building or the converter building for lightning protection.

All equipment located between the 230 kV control building and the 25 Hz traction power substation, including the SFC filter yards and building, shall be protected against lightning in accordance with IEEE-998.

2.33 Power and Control Cable

2.33.1 General

The design of wire and cable for continuous operating current shall be based on a maximum ambient temperature of 40°C and continuous conductor temperatures of 60°C for conductor sizes No. 1 AWG and smaller and 75°C for conductor sizes 1/0 AWG and larger (in accordance with UL terminal temperature ratings).

Where UL terminal temperature ratings do not apply, conductor temperatures may be 90°C unless otherwise required by the NEC.

In areas where the ambient temperature exceeds 40°C, the wire and cable shall be derated in accordance with the NEC.

Design of wire and cable which shall be installed in underground duct lines shall be based on an ambient earth temperature of 20°C with the thermal resistivity of the earth at RHO-90 (°C-cm/watt).

All conductor insulation for cables installed indoors shall be 90°C thermosetting material (Type XHHW). Cable jackets also shall be of a thermosetting material (thermoset CPE). This applies to SFC vendor power, control, and instrumentation wire as well as all building wire.

All conductors, with the exception of thermocouple extension and fiber-optic cables, shall be Class B concentric strand copper in accordance with ASTM B8.

Conduit within the buildings shall be either RGS conduit or EMT. Underground conduits shall be Schedule 40 PVC encased in concrete. Outdoor areas which transition to above grade or are subject to physical damage will transition with RGS conduit.

2.33.2 15 kV Power Cable All 15 kV cable used for the 13.2 kV, 60 Hz system shall be single-conductor, multiple-stranded copper, type MV-105, suitable for TC use, 105°C rating, 100% percent insulation, shielded bare copper tape with 12.5 percent minimum overlap, ethylene propylene rubber (EPR) insulation, extruded semiconducting strand screen, with a PVC jacket. All cables must be suitable for wet or dry locations, indoors or outdoors, in any raceway or underground duct, and direct buried. Conductors shall be 98 percent conductive (minimum) copper. All cables must be sunlight resistant. Cables must meet the requirements of NEMA WC 74/ICEA S-93-639, UL1072, IEEE 383 (Vertical Flame Test).

2.33.3 600 V Cable

All multiconductor 600 V power and control cable shall be UL type TC with flame-retardant cross-linked polyethylene (XLPE) and thermoset CPE jacket, suitable for wet or dry locations, in any raceway or underground duct. All cables must be sunlight resistant.

All single conductor 600 V power cable shall be type RHH or RHW with flame retardant ethylene propylene (FREP) insulation. It shall be manufactured and tested in accordance with the requirements of NEMA WC 70, UL44, UL1581, and IEEE 383 (Vertical Flame Test). All cables must be suitable for wet or dry locations indoors or outdoors, in any raceway or underground duct. All cables must be sunlight resistant.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 52 of 87 Instrumentation cable shall be 600 V UL type TC with XLPE insulation and thermoset CPE jacket. It shall be manufactured and tested in accordance with the requirements of NEMA WC 53, UL 1277, and IEEE 383 (Vertical Flame Test).

Thermocouple extension wire shall be 600 V, with XLPE insulation and thermoset CPE jacket. It shall be manufactured and tested in accordance with the requirements of NEMA WC 57, UL 1277, and IEEE 383 (Vertical Flame Test).

Data highway wire shall be 600 V, UL type PLTC plenum rated coax with thermoset insulation. It shall be manufactured and tested in accordance with the requirements of NEMA WC 63.2, UL 1277, and IEEE 383 (Vertical Flame Test).

2.34 Cable Installation Criteria Table 28 - Cable Installation Parameters

Parameter Value Reference Maximum allowable conductor stress 0.008 lb/cmil for soft-drawn copper conductor Ref. 122 Coefficient of Dynamic Friction 0.35 for PVC jacketed cables in PVC conduit

0.40 for PVC jacketed cables in metallic conduit 0.50 for CPE jacketed cables in metallic or PVC conduit

Ref. 122

Maximum sidewall pressure 300 lbs/ft for 600 V nonshielded control cable 500 lbs/ft for 600 V power cable 500 lbs/ft for 15 kV power cable

Ref. 122

Minimum bending radii 12 times cable O.D. for shielded cable 600 V and greater 8 times cable O.D. for non-shielded cable 600 V and greater

Ref. 122

2.35 Underground Installation Criteria

Underground conduit systems shall be installed per NESC requirements (Ref. 11).

Conduit systems to be occupied by instrumentation, communication, and/or control conductors shall be separated from conduit systems to be used for power supply systems by not less than 3 inches of concrete, 4 inches of masonry, or 12 inches of well-tamped earth (Ref. 11, Section 320).

Conduit systems shall be installed with a minimum of 36 inches of cover so that impact loading need not be considered (Ref. 11, Section 322).

A warning ribbon shall be placed at least 12 inches above underground conduit systems.

2.36 Medium-Voltage Cable Terminations

Medium-voltage cable terminations shall comply with IEEE 48.

Aerial connector lugs shall be provided for each termination. The connectors shall have NEMA four hole spacing and be capable of carrying the emergency operating current for 40°C ambient air temperature, with sun and no wind.

2.37 Control Circuit Voltage Ranges Table 29 - Control Circuit Voltages

Rated Voltage Required Voltage Range Reference 125 V dc 90-140 V dc, operating and auxiliary function

70-140 V dc, tripping function Ref. 15, Table 17

120 V ac 104-127 V ac, operating and auxiliary function Ref. 15, Table 17 480 V ac 416-508 V ac, operating and auxiliary function Ref. 15, Table 17

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 53 of 87 2.38 Conduit Bends and Fill Conduit bend radius and fill capacity shall follow Tables 1 and 2 of NEC Chapter 9.

Table 30 - Conduit Fill Capacity

Number of Conductors Maximum Fill Reference 1 53% Ref. 26 2 31% Ref. 26

Over 2 40% Ref. 26

Table 31 - Conduit Minimum Bend Radius

Conduit Size Minimum Bend Radius Reference 4 24 in Ref. 26 5 30 in Ref. 26 6 36 in Ref. 26

2.39 25 Hz, 24/12 kV System Characteristics Table 32 - 13.2 kV, 25 Hz System Characteristics

Parameter 12 kV trolley system 24 kV feeder system Nominal operating voltage 12 kV 24 kV Operating voltage range -5% to +10% (due to train regenerative braking) Phase number Single-phase, two-pole Frequency 25 Hz Insulation class 27 kV 46 kV Impulse withstand (BIL) 150 kV 250 kV

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 54 of 87 2.40 25 Hz, 24/12 kV Circuit Breakers A new circuit breaker will be installed for each SFC. The breaker shall follow all applicable IEEE C37 requirements except as required by Table 33.

Table 33 - 25 Hz, 46 kV, Two-Pole Circuit Breaker

Parameter Value Rated insulating voltage 46 kV Rated operating voltage 36 kV pole-to-pole Number of poles 2 Rated frequency 25 Hz Normal frequency withstand voltage, dry/wet 95 kV Rated full wave impulse withstand voltage - Basic insulation level (BIL) across contact gap and to ground

250 kV

Rated transient recovery voltage (TRV) 57 kV Rated voltage range factor K 1.0 Rated standard operating duty CO – 15 s - CO Rated continuous current 2,000 A Overload rating Compatible with SFC rating Rated short circuit current 25 kA Closing time, maximum 65 milliseconds Opening time, maximum 22 milliseconds Break time, maximum 33 milliseconds Dead time, maximum 300 milliseconds Rated permissible tripping delay 3 seconds Mechanical switching capability 20,000 operations Continuous current switching capability 10,000 operations Short circuit current switching capability for 12 kV circuit breakers at 25 kA

60 operations

Short circuit current switching capability for 24 kV circuit breakers at 12 kA

100 operations

Short circuit current switching capability for 24 kV circuit breakers operating at 36 kV and 8 kA

150 operations

Rated AC control voltage, nominal 120 V ac, 60 Hz Rated DC control voltage, nominal 130 V dc Arc chamber service life, minimum 20 years Design service life, minimum 30 years

2.41 25 Hz Busbars All new busbars used on the 25 Hz open-air substation shall be the following requirements.

Table 34 - 25 Hz Open-Air Substation Busbars

Parameter Value Reference Rated maximum voltage 48.3 kV Ref. 15 BIL New: 250 kV

Existing: 250 kV Ref. 15 Ref. 110

Current carrying capacity 1000 A Ref. 110 Withstand current 12 kA Ref. 110 Centerline-to-centerline spacing for rigid buses 48 inches Ref. 15 Minimum metal-to-metal distance for rigid conductors

21 inches Ref. 15 Ref. 110

Minimum to grounded parts 18 inches recommended 17 inches minimum

Ref. 15 Ref. 110

Size 2 inches nominal, schedule 40 Selected Alloy 6061-T6 Selected Radial thickness of ice 0.5 inches (NESC heavy) Ref. 34 Wind pressure 4 lbs/ft2 Ref. 34 Maximum vertical conductor deflection 1/200 of span length Ref. 34

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 55 of 87 2.42 25 Hz Air Switches All new air disconnect and grounding switches on the 25 Hz system shall be station class and meet the following requirements.

Table 35 - 25 Hz Disconnect and Grounding Switches

Parameter 12 kV Circuits 24 kV Circuits and Two-Pole Circuits

Reference

Rated maximum voltage 27 kV 48.3 kV Ref. 15 BIL 150 kV peak 250 kV peak Ref. 15 Minimum 60 Hz withstand 70 kV, dry, 60 seconds

60 kV, wet, 10 seconds 120 kV, dry, 60 seconds 100 kV, wet, 10 seconds

Ref. 15

Opening/closing capability 3/4 inch ice 3/4 inch ice Ref. 15 Current carrying capacity Disc - 2000 A rms continuous

Gnd - None Disc - 2000 A rms continuous Gnd - None

Ref. 15

Withstand current 44 kA rms sym (60 Hz) 114 kA peak (60 Hz)

44 kA rms sym (60 Hz) 114 kA peak (60 Hz)

Ref. 15

Minimum metal-to-metal distance disconnecting switches, bus supports and rigid conductors

15 inches 21 inches Ref. 15

Ground clearance 12 inches recommended 10 inches minimum

18 inches recommended 17 inches minimum

Ref. 15

Centerline-to-centerline spacing

30 inches - vertical break 36 inches - side break 48 inches - horn gap

48 inches - vertical break 60 inches - side break 72 inches - horn gap

Ref. 15

For 25 Hz two-pole circuits use the 48.3 kV maximum voltage, 250 kV BIL ratings.

2.43 25 Hz Surge Arresters

All new surge arresters on the 12 kV and 24 kV, 25 Hz system shall meet the following requirements.

The highest voltage on the 25 Hz system is 110% of nominal due to train voltage regeneration.

The nominal catenary voltage is 12 kV.

Maximum continuous line-to-ground voltage = 12 kV x 1.10 = 13.2 kV

The nominal feeder voltage is 24 kV.

Maximum continuous line-to-ground voltage = 24 kV x 1.10 = 26.4 kV

During a line-to-ground fault, with the system being solidly grounded, the temporary overvoltage (TOV) between line-to-ground is no higher than the maximum continuous line-to-ground voltages, respectfully. Arrester ratings are based on existing SEPTA requirements.

Table 36 - 25 Hz Surge Arresters

Parameter 12 kV Circuits 24 kV Circuits Reference Type Gapless metal-oxide Gapless metal-oxide Selected BIL 150 kV 250 kV Selected Maximum line-to-ground 13.2 kV 26.4 kV Calculated TOV rms 13.2 kV 26.4kV Calculated MCOV rating 15.3 KV 29 kV Ref. 14 Duty cycle 18 kV 36 kV Ref. 14 Class Station Station Selected

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 56 of 87 2.44 25 Hz Instrument Transformers

Table 37 - 25 Hz Current Transformers

Parameter 12 kV Circuits 24 kV Circuits Reference Ratio 1200:5 A 600:5 A Ref. 93 Accuracy class C400 C400 Ref. 18 Secondary thermal overload 2.0 2.0 Ref. 18 Insulation class 25 kV 46 kV Ref. 18 BIL 150 kV 250 kV Ref. 18 Power frequency withstand 50 kV 95 kV Ref. 18

Table 38 - 25 Hz Potential Transformers

Parameter 12 kV Circuits 24 kV Circuits Reference Nominal voltage 12 kV 24 kV Ref. 93 Insulation class 25 kV 46 kV Ref. 18 Primary voltage 12 kV 24 kV Ref. 18 Secondary voltage 120 V 120 V Ref. 18 Ratio 100:1 200:1 Ref. 93 Burden Z, 200 VA Z, 200 VA Ref. 18 Accuracy class Relaying - 0.3

Metering - 0.15 Relaying - 0.3 Metering - 0.15

Ref. 18

BIL 150 kV 250 kV Ref. 18

2.45 25 Hz Insulators

For two-pole arrangements, use 24 kV values for both 12 kV and 24 kV circuits. Table 39 - 25 Hz Insulators

Parameter 12 kV Circuits 24 kV Circuits Reference Nominal voltage 12 kV 24 KV Given Insulation Class 27 kV 46 kV Selected BIL 150 kV 250 kV Ref. 20 Low-frequency wet withstand 60 kV 100 kV Ref. 20

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 57 of 87 2.46 25 Hz Power Cables The selection of 12 kV, 24 kV, and rail return cables is based on recently purchased cables for the Wayne Junction Traction Power Substation (WJTPSS) project. The cable construction is for a 46 kV, 133% insulation cable. It is suitable for 12 kV, 24 kV, and rail return single-phase cables. This insulation level is similar to that which is existing, 63 kV, supplied by ASEA (46 kV x 1.33 = 61 kV).

Table 40 - 25 Hz Power Cables

Parameter 12 kV trolley 24 kV feeder Rail Return Reference Nominal Voltage 12 kV rms 24 kV rms 0 kV rms Given Nominal insulation rating 46 kV 46 kV 46 kV Selected Basic impulse level 250 kV 250 kV 250 kV Selected Size 1000 kcmil stranded

(61 strands) 1000 kcmil stranded (61 strands)

1000 kcmil stranded (61 strands)

Selected

Number of conductors per cable

One One One Selected

Conductor Soft-drawn bare copper

Soft-drawn bare copper

Soft-drawn bare copper

Selected

Insulation type Ethylene propylene rubber (EPR)

Ethylene propylene rubber (EPR)

Ethylene propylene rubber (EPR)

Selected

Insulation thickness 133% level, 550 mils min, 630 mils max

133% level, 550 mils min, 630 mils max

133% level, 550 mils min, 630 mils max

Ref. 25

ac test voltage 116 kV 116 kV 116 kV Ref. 25 Shield 8 x 0.175" x 20 mil

tinned CU flat straps 8 x 0.175" x 20 mil tinned CU flat straps

8 x 0.175" x 20 mil tinned CU flat straps

Jacket type Crosslinked polyolefin (XLPO)

Crosslinked polyolefin (XLPO)

Crosslinked polyolefin (XLPO)

Jacket thickness 100 mils 100 mils 100 mils Ref. 25 Normal Operation Temperature

105°C 105°C 105°C Ref. 25

Emergency Operation 140°C 140°C 140°C Ref. 25 Short Circuit Operation 250°C 250°C 250°C Ref. 25 Load current 1316 A rms

continuous (Assumes full SFC load on trolley conductor)

658 A rms continuous (Assumes full SFC load on feeder conductor)

Calculated

Estimated ampacity 658 A each conductor x 2 conductors = 1316 A 2-1/c cable in one duct. Burial depth 10 ft. Cable operated less than 105⁰C. Includes rail return conductors in another other duct.

658 A each conductor x 1 conductors = 658 A 1-1/c cable in one duct. Burial depth 10 ft. Cable operated less than 105⁰C.

ETAP simulation

Installation location Conduits in concrete encased duct bank, 1/c per duct

Conduits in concrete encased duct bank, 1/c per duct

Conduits in concrete encased duct bank, 1/c per duct

Selected

Approximate O.D. 2.748 inches 2.748 inches 2.748 inches Refs. 126 Minimum bend radius 33 inches 33 inches 33 inches Ref. 26, Section

300.34 Allowable pulling tension 8000 lbs 8000 lbs 8000 lbs Ref. 127 Allowable sidewall pressure 500 lbs/ft 500 lbs/ft 500 lbs/ft Ref. 127

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 58 of 87 2.47 Interlocking Disconnect switches on the 13.2 kV, 60 Hz system and 24/12 kV, 25 Hz system are interlocked so that they cannot be operated if their respective circuit breaker is open.

Ground switches on the 13.2 kV, 60 Hz system and 24/12 kV, 25 Hz system are interlocked so that they cannot be operated if their respective disconnect switches are closed.

2.48 SFC Protective Relaying

The SFC system shall have the following protective relaying schemes as a minimum. Table 41 - 13.2 kV, 60 Hz Protective Relaying

Parameter Description Reference Bus overvoltage protection Three-phase definite time overvoltage detection Ref. 105 Overcurrent protection Three-phase overcurrent and ground fault detection using

time-overcurrent and instantaneous settings Ref. 105

Transformer differential protection Three-phase instantaneous percentage differential protection Ref. 105 Transformer supervision Gas relay, oil level, oil temperature, winding temperature,

relief vent, and pressure relay. Ref. 105

Table 42 - 24/12 kV, 25 Hz Protective Relaying

Parameter Description Reference Overcurrent protection Single-phase overcurrent and ground fault detection using

time-overcurrent and instantaneous settings Ref. 105

Reverse power protection Detects current flowing in the wrong direction. Ref. 105 Transformer differential protection Single-phase instantaneous percentage differential protection Ref. 105 Transformer supervision Gas relay, oil level, oil temperature, winding temperature,

relief vent, and pressure relay. Ref. 105

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 59 of 87 3.0 Fire Detection and Annunciation

3.1 Introduction

There are three existing Pyrotronics fire alarm detection and annunciation panels that monitor the fire alarm devices in the static frequency converter building and the 230 kV substation. These FACPs monitor and control eight deluge fire suppression sprinkler systems that protect the exterior transformers and six Halon fire suppression systems that protect four converter rooms, two battery rooms and a control room. Included is smoke detection and manual pull stations. These panels are near the end of life and will be replaced.

Figure 26 - Existing Fire Alarm and Halon System Control Panel in SFC building

3.2 Design Criteria

The entire system will be replaced with new addressable components. The new panels will monitor the new FM-200 systems, which replace the Halon system in the SFC Building, the new deluge system panel for the outdoor transformers, and the buildings that have smoke detection and manual pull stations. All detection devices and notification devices will be replaced as well. This system will be designed for remote monitoring by SEPTA's TycoIS contractor.

For the 230 kV control building, the new fire alarm control panel will control the existing deluge systems, which are not being modified, and control/monitor the existing fire alarm devices. The new FACP in the 230 kV switchgear building will also control the existing Halon system.

For the SFC building, the new FACP will monitor and control the FM-200 system, the new deluge system panel, and control/monitor the new addressable fire alarm system detectors and pull stations, which are not controlled by the FM-200 or deluge system panels.

These panels will communicate with each other and report to the communications RTU, which reports to 1234 Market Street. Individual points will be reported to the RTU.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 60 of 87 4.0 Communications and Control

4.1 Introduction

There are two components that make op the communications and control system. The first component is the network connectivity to the SFC building. The SFC building is connected to a SONET network that provides redundant, fault tolerant connectivity to the main control center located at 1234 Market Street, Philadelphia, PA. The second component is the SCADA system that monitors and controls the 230 kV substation and associated monitor and control points. The SCADA system is currently a QEI system, now supported by CG Automation.

The current telephone service for the SFC building is standard POTS lines. A typical POTS system provides five 9's of reliability (99.999%).

Figure 27 - Existing QEI Cabinet located in the SFC building Control Room

4.2 Design Criteria

The current SONET network is relatively new and does not require upgrades or modifications. Given the age of the current SCADA system, the system will be upgraded to the ePAQ-9410 Multifunction Gateway. This will allow the integration of the current analog inputs, status inputs, accumulator inputs, and control outputs in to a common control system that is Ethernet capable. The current telephone service will remain.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 61 of 87 5.0 Security

5.1 Introduction

The current security for the SFC building consists of occupancy sensors and entry door alarms that are monitored remotely by SEPTA’s existing Master SCADA system.

Figure 28 – Existing occupancy sensor located in SFC building corridor

5.2 Design Criteria The current configuration will be maintained. This consists of remotely monitoring local intrusion detection alarms by SEPTA's Master SCADA system located at 1234 Market Street. The local intrusion alarms will be collected via the local SCADA/RTU system and transmitted to the head-end via the existing SONET network.

A new security system will be installed per SEPTA's request.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 62 of 87 6.0 Heating, Ventilation, and Air-Conditioning

6.1 General Design Criteria

Outdoor air design conditions for heating, ventilation, and air-conditioning (HVAC) will be based on the 2009 ASHRAE Handbook of Fundamentals for North East Philadelphia, PA.

Table 43 - Outdoor Design Temperatures

Parameter Value Winter Design Temperature

(ASHRAE 99.6% winter design condition) 11.6⁰F

Summer Design Conditions (ASHRAE 0.4% summer design condition)

92.7⁰F dry bulb

Table 44 - Indoor Design Temperatures

Parameter Value SFC Rooms & Corridors 77ºF cooling, 55ºF heating*

Other spaces 75ºF cooling, 70ºF heating * SFC equipment only requires the SFC Rooms and Corridors to be maintained at 41ºF. These spaces will have a setpoint of 55ºF to provide thermal comfort during maintenance. Note that corridors #1 and #4 would not meet the setpoint during a design heating condition (typically occurs before sunrise on coldest days of winter) during which time the EUH would be able to maintain the corridor at 51 ºF.

Table 45 - Internal Loads

Parameter Value SFC Rooms 30 kW of heat dissipation

Typical Spaces 0.5 kW/ft2 of receptacle load All Spaces 1.5 kW/ft2 of interior lighting

6.2 Roof Top Units

The existing roof-top unit (RTU) serving the control building is planned to be replaced in kind.

The existing control room only has a fire damper on the supply ductwork and none in the return ductwork. The system will be updated to meet current code requirements.

All RTU systems will be designed to accommodate the fire protection systems installed.

The existing RTUs serving the three SFC buildings will not be reused.

6.3 Make-Up Air Units

The existing make-up air units (MAUs) serving SFC #1 and #3 buildings will not be reused, since climate controlled air conditioning is required in the SFC buildings.

6.4 Ductwork

The existing ductwork systems will be reused to best extent possible. However, the existing ductwork insulation in the SFC building is in poor condition and will need to be replaced. The ductwork insulation in the SFC control building will not be replaced on any insulated ductwork that is existing to remain. Ductwork in the SFC buildings is to be demolished and replaced with new ductwork serving the new systems.

6.5 Exhaust Fans

The restroom/housekeeping fan will be replaced in kind. The battery room fan and associated ductwork will be replaced and sized appropriately for the new requirements of the battery room.

6.6 Outdoor Air Intakes

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 63 of 87 The existing outdoor air intake ventilator that serves the battery room will be replaced.

The existing outdoor air intake louvers that serve the SFC rooms will be removed. The wall openings will be patched to match existing.

6.7 New Control System A new direct digital control (DDC) building automation system will be provided. This DDC system will communicate with new HVAC mechanical systems, providing for occupancy scheduling, setpoint adjustment, and alarm monitoring at a minimum. Additional control options will be considered as required by the project, including monitoring of the associated SFC cooling systems and any additional points as requested by SEPTA and/or the SFC Contractor.

6.8 New HVAC Systems for SFC Rooms A new RTU will be provided for each SFC room. These RTUs will provide the climate control required by the new SFCs and thermal comfort for maintenance activities. A new insulated ductwork system will be provided for each RTU system.

6.9 New HVAC Systems for SFC Corridors

A new split-system heat pump will be provided for each SFC corridor. These heat pumps will provide thermal comfort for the corridors. A new electric unit heater will also be provided for each SFC corridor.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 64 of 87 7.0 Plumbing

7.1 Introduction

The existing building is served by a 3" domestic water service fed from a metered site fire/domestic water service main. The 3" service enters the building beneath the workshop floor in a concrete enclosure. The 3" domestic water service was recently replaced and includes a code-required backflow preventer. The domestic water system feeds a domestic water heater and plumbing fixtures throughout the building.

The existing building is served by a 4" sanitary drainage lateral that conveys wastes from interior plumbing fixtures and floor drains to a site combination sanitary/stormwater drainage system. The sanitary drainage system includes required vents and traps.

The existing building is served by several 4" storm laterals that convey stormwater from perimeter roof drains.

The building plumbing fixtures includes a water closet, a lavatory sink, mop sink, an electric water cooler and emergency shower. The fixtures are supplied with hot water through an electric water heater located in the janitor’s closet.

The emergency shower is not fed with tempered water, which is required under current code.

7.2 Design Criteria The existing water closet, lavatory sink, and electric water cooler will not be replaced. The existing safety shower and eyewash will be upgraded, since the batteries will be maintained. The emergency shower and eyewash is required to have tempered water supplied to the unit, therefore a dedicated electric water heater with emergency fixture mixing valve will be provided to serve the unit.

New roof drains and rainwater piping will be provided for the new addition. The rainwater piping will be routed underground to site laterals. Any existing rainwater piping beneath the building addition will be modified to allow construction of the addition.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 65 of 87 8.0 Fire Protection

8.1 Introduction

The interior converter rooms, control room, switchgear room and battery room are protected by existing Halon systems. Each converter room is protected by two Halon tanks, and the control room, switchgear room and battery room are protected by a single tank. The seven Halon tanks and equipment are located in the fire protection equipment rooms on the west and east sides of the building. Halon discharge for the systems is initiated by heat detectors located within each room. The discharge of Halon is detrimental to the environment and is being phased out for use as a gaseous suppression system and therefore will be replaced. In addition, the control system serving the Halon system is extremely old technology and is being replaced as part of the scope.

The exterior transformers are protected by dedicated dry deluge sprinkler systems. Water service for the deluge sprinkler systems enter the fire protection equipment rooms on the west and east sides of the building. Upon service entrance, a code-required backflow preventer is installed. The west service feeds one deluge valve and the east service feeds six deluge valves. A single spare connection for a future deluge valve is included within the room. Water flow for the systems is initiated by heat sensors local to the transformers.

Spaces other than listed above are currently not served by a sprinkler system. Due to the construction and size of the building, a sprinkler system is not required to be provided in the remaining spaces.

8.2 Design Criteria

8.2.1 Proposed FM-200 System

Due to the phasing out of Halon systems, the replacement of the Halon control system, and space modifications within the converter rooms, new FM-200 clean-agent systems will replace the existing Halon systems. A dedicated FM-200 system will be provided for each existing converter room and an FM-200 system will be provided to serve the existing control room, switchgear room, and battery room. An FM-200 system will also serve the new converter room in the building addition. The existing Halon system will remain in the 230 kV switchgear building, but the control panel is being replaced.

FM-200 system tanks and control panels serving converter rooms will be located in the equipment corridor outside each of the converter rooms. Piping will be extended from the FM-200 system tanks to nozzles within the converter rooms and crawlspaces, where applicable. It is anticipated that two FM-200 system tanks are required for each converter room.

The FM-200 system tank and control panel serving the control room, switchgear room, and battery room will be located within the east fire protection equipment room. Piping will be extended from the FM-200 system tanks to nozzles within these spaces. It is anticipated that one FM-200 system tank is required to serve these spaces.

New, dedicated, cross-zoned fire detection systems consisting of photoelectric smoke detectors will be provided to serve each FM-200 system. The smoke detectors will be directly monitored by the associated FM-200 system control panel. Each FM-200 control panel will be monitored by the building fire alarm system.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 66 of 87 8.2.2 Deluge System The water service and backflow preventers serving the building are adequate and will therefore be reused under this project.

Water flow test data provided by SEPTA, dated 6/13/2015 indicates the following: Table 46 - Water Flow Test Data from 6/13/15

Parameter Value Flow Hydrant Location 230 kV Transformer #2 Front Residual Hydrant Location 18th Street Gate Entrance Static Pressure 105 psi Residual Pressure 94 psi Flowrate 750 gpm

The water flow test data provided indicates that there is sufficient pressure and flow to serve the proposed deluge systems.

The existing deluge valves, trim, piping, and accessories are over 30 years old and will therefore be replaced. All fire water mains are in good working condition and will remain for reuse.

At the existing transformers, exterior piping and nozzles around the transformers will be removed to allow the removal of the transformers. New piping and nozzles will be provided around new transformers. Existing branch main piping from the existing deluge valve to the transformer location will be used to the greatest extent possible.

New deluge valves, trim and accessories is to be provided to serve the transformers at the building addition. The deluge valves will be installed within the east fire protection room. Piping will be extended from the existing water service manifold to the new deluge valves. A single dedicated multi-zone deluge control panel will be provided for the deluge systems.

If the final converter system selected does not include 60 Hz transformers, then the existing deluge system valves, trim, accessories, and piping serving the existing transformer location will be removed in their entirety.

Open head sprinkler nozzles will be provided around exterior transformers to allow complete coverage over the surface of the transformers. Sprinkler water flow at a rate of 0.25 gallons per minute for each square foot of transformer surface area will be provided as required by NFPA.

New dedicated fire detection systems consisting of linear heat detection wire are to be provided to serve each deluge system. The heat detectors are to be attached to the transformers and will be monitored by the deluge system control panel. The deluge system control panel will actuate the applicable deluge valve upon signal from the associated heat detector. The deluge system control panel will be monitored by the building fire alarm system.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 67 of 87 9.0 Architectural

9.1 Introduction

The existing facility houses three SFC's and a control room, which was constructed in two stages. According to as-built drawings, Phase I design drawings are dated 1984 and Phase II design drawings are dated 1987, placing construction within proximity to these years. The initial phase included construction of the SFC control room and one single SFC bay (SFC #2) to the southeast. The second phase involved construction of SFC #1 (attached to the southeast wall of the existing converter bay) and SFC #3 (attached to the northwest wall of the control room). As part of the second phase, a deluge room was constructed at the northeast end of the existing SFC control room.

9.2 Building Classification Table 47 - Preliminary Code Review - 2009 IBC

Code Section Section Title Required Existing Provided Remark

Chapter 3 - Use and occupancy Classification

306 Use group F-1 F-1 F-1

Chapter 5 - General Building Heights and Areas Table 503 Height/area

2 (55 ft) st. / 15,500 s.f. 1 st. / 6,950 1 st. / 8,382

Chapter 6 - Types of Construction

Table 602 Construction Type IIB IIB IIB Non Combustible

Table 601 Fire resistance rating

primary structure 0 0 0 bearing walls exterior 0 0 0 Bearing walls interior 0 0 0 Non bearing exterior walls See table 602 Non bearing interior walls 0 0 0 Floor construction 0 0 0 Roof construction 0 0 0

Chapter 7 - Fire and Smoke Protection

708.4 Shaft enclosure, fire rating Less than 4 stories 1 NA NA

Chapter 8 - Interior Finishes

Table 803.5

Interior wall and ceiling finish (NS) Class Class Class

Passageways B NA B Corridors C NA C Rooms and enclosed spaces C NA C



Interior wall and ceiling finish (S)

Passageways C NA C Corridors C NA C Rooms and enclosed spaces C NA C

Chapter 9 - Fire Protection Systems

903.2.4

Automatic Sprinkler system - Group F-1 required if all three conditions exist

Area exceeds 12,000 s.f. 6,950 8,382 Not Required

fire area located more than 3

stories above grade 3 stories 1 story 1 story Not Required Combined Fire Area 24,000 s.f. 6,950 8,382 Not Required

Chapter 10 - Means of Egress

Table 1004.1.1 Occupant load

Industrial 100 sf per

person 70 84 1005.1 Egress width

Stairs 0.3 inches / pp 21 inches 25.2 inches other components 0.2 inches / pp 14 inches 16.8"

1009.1 Stair width 44" min. NA 44" min. 1009.2 Headroom at stair 80" min. NA 80" min.

1009.4.2 Stair treads and risers Treads 11" min. - -

Riser 7" max / 4"

min - -

1009.4.4 Stair - Dimensional Uniformity tolerance .375" per flight - -

1009.5 Stair Landing Width Stair width - -

Depth Stair width - - Need not to exceed 48"

1009.6.1 Stairway walking surface 1:48 max. - -

1009.6.3 Enclosure under stairs 1 hour

enclosure - - 1009.7 Vertical rise (between levels) 12'-0" max. - -

1009.12 Handrail Each side of stair comply with

1012 1012 Handrails

Height (Min. / Max.) 34" - 38" - - Graspability (Min. / Max.) 1 1/4" - 2" - - Continuity continuous - -



Extensions (top/bottom) 12"/ tread

depth - -

Chapter 29 - Plumbing Fixtures Table

2902.1 Min. required plumbing fixtures

Water closet (Male/female) 1 per 100

persons = 2 1 1 Existing non-compliant

Lavatories (Male/female) 1 per 100

persons = 2 1 1 Existing non-compliant

Drinking Fountain 1 per 400

persons = 1 1 1 Water cooler in control room

Other (service sink) 1 1 1

9.3 Repairs and Upgrades

Existing building damage will be repaired as identified in this design criteria. Table 48 - SFC #1 Repairs and Upgrades

Location Repairs and Upgrades Interior Walls • Install CMU wall with double doors between

SFC equipment and main corridor • Repair cracks and re-paint

Doors & Louvers • Replace door weather-stripping with air tight seal

• Replace louvers with automatic airtight closing louvers

Floor None Ceiling None Basement None Roof • Replace roof with EPDM roofing system

• Replace all parapet coping • Provide OSHA compliant fall protection at

HVAC units. Exterior Walls • Repair spalling brick

• Repair cracks at east and west parapet • Repair cracked CMU base • Clean façade to remove efflorescence • Fill hole in CMU base • Provide weep holes to allow water to exit the

wall. Exterior East Transformer Bay • Repair CMU Base

• Clean façade to remove efflorescence • Seal open penetrations • Modify existing bus openings to accommodate

new transformers or reactors Exterior West Transformer Bay • Replace spalled brick

• Repair CMU Base


Location Repairs and Upgrades • Clean facade to remove efflorescence and

staining • Repair sealant at east and north wall • Modify existing bus openings to accommodate

new transformers or reactors

Table 49 - SFC #2 Repairs and Upgrades

Location Repairs and Upgrades Interior Walls Install CMU wall with double doors between SFC

equipment and main corridor Doors & Louvers Replace door weather-stripping with air tight seal Floor None Ceiling None Basement None Roof • Replace roof with EPDM roofing system

• Replace all parapet coping • Provide OSHA compliant fall protection at HVAC

units. • Add tread to existing stair

Exterior Walls • None Exterior East Transformer Bay • Re-paint areas of peeling paint

• Clean walls to remove staining • Scrape and paint steel support members if they

are to remain • Modify existing bus openings to accommodate

new transformers or reactors Exterior West Transformer Bay • Repair cracks and open mortar joints

• Repair CMU Base • Modify existing bus openings to accommodate

new transformers or reactors

Table 50 - SFC #3 Recommended Repairs and Upgrades

Location Recommended Repair and Upgrades Interior Walls • Repair cracks and re-paint

• Install CMU wall with double doors between SFC equipment and main corridor

Doors & Louvers Replace door weather-stripping with air tight seal Floor None Ceiling None Basement None Roof • Replace roof with EPDM roofing system


units Exterior Walls • Repair cracks/shifts at east and west parapet

• Repair cracked CMU base • Repair bulged CMU base • Clean façade to remove efflorescence


Location Recommended Repair and Upgrades • Fill hole in CMU base • Provide weep holes to allow water to exit the

wall. Exterior East Transformer Bay • Clean walls to remove efflorescence

• Repair cracks in brick and CMU base • Repair spalled penetrations • Modify existing bus openings to accommodate

new transformers or reactors • Repair stone subsidence

Exterior West Transformer Bay • Clean walls to remove efflorescence • Repair cracks in brick and CMU base • Modify existing bus openings to accommodate

new transformers or reactors • Repair stone subsidence

Table 51 - Control Building Repairs and Upgrades

Location Recommended Repairs and Upgrades Fire Pump Room Repair wall cracks and paint East Deluge Room None Main Corridor • Repair detached linear ceiling panels

• Remove non-working water fountain • Address the tripping hazard in the middle section

of the interior floor slab in the switchgear room and in the corridor between the battery room and the workshop storage room.

Battery Room • Paint ceiling • Replace missing HVAC register

Control Room Replace ceiling Workshop None Switchgear Room None Toilet Room Replace paper towel dispenser Custodial Closet Repair wall crack Doors and Louvers Replace door weather-stripping with air tight seal Roof • Replace roof with EPDM roofing system


units. • Add tread to existing stair

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 72 of 87 9.4 SFC #4 Building Design

9.4.1 General Description

The new building addition shall match the general look of the existing building.

9.4.2 Exterior Walls 1. Brick veneer (upper wall)

2. Ground face CMU base

3. 8" CMU backing course

4. Cavity filled with rebar and grout

9.4.3 Interior Walls

1. Painted interior CMU walls between SFC equipment and the main corridor.

2. The SFC equipment will be accessed via double doors with removable insulated transom for equipment access.

9.4.4 Roof 1. Metal roof deck.

2. rigid building insulation and tapered insulation to provide positive pitch to roof drains

3. EPDM roofing system

4. Factory finished metal coping

9.4.5 Floors and Foundation 1. Concrete floor with epoxy coating

2. Cast in place foundation walls

3. Crawl space provided with exterior access

9.4.6 Doors

1. Exterior doors and frames - 16 gauge, galvanized insulated hollow metal. Smoke tight seals for FM200 fire protection system

2. Interior doors and frames - 18 gauge hollow metal.

3. All doors will be provided with a removable insulated transom for equipment access

9.4.7 Louvers 1. Factory finished aluminum louvers with automatic dampers. Provide smoke tight seal for

FM200 Fire protection system.

2. Provide free air per ventilation requirements.

9.4.8 Stairs

1. Factory finished galvanized steel grated stair and landing.

2. Factory finished galvanized steel guard and handrails.

9.4.9 Painting

1. Interior: CMU: 1 coat interior enamel undercoat, 1 coat interior low luster (eggshell) alkyd enamel.


2. Hollow metal doors and frames: Factory primed, 2 coats interior semi-gloss alkyd enamel.

3. Exposed concrete floors: 2 coats of sealer.

4. Exposed construction – roof deck and support steel.

5. Color: White.

10.0 Structural

10.1 Introduction

10.1.1 Overall Building Construction and Layout

The general construction of the three buildings consists of steel roof framing, masonry load bearing walls, and concrete foundation walls. Steel columns are used in the middle building (SFC #2) in place of load bearing masonry wall. The floor construction for SFC #1 and #3 buildings consists of cast-in-place concrete beam and girder floor systems supported on timber pile foundations. The floor system in SFC #2 room differs in that it is designed as a cast-in-place concrete slab on grade that is built independent of pile support concrete grade beams and column pile cap foundations. This type of floor system is commonly referred to as a "floating slab," which means that it is not monolithically poured with the supporting grade beams.

The general condition of the three buildings and equipment support foundations are relatively sound. The existing drawings indicate that the major structural elements of the three buildings and the major equipment were built on concrete grade beams all supported on 12" diameter timber piles. The areas that are pile supported have little deficiencies in their existing state.

10.1.2 Repairs

10.1.2.1 Interior - floor drop/CMU wall cracks A structural repair is not required for the dropped slab in the Unit 2 switchgear room and adjacent corridor. The original design of the floor slab did not have these floors physically connected to the foundation grade beams and, therefore, is not part of the structural stability of the building. However, the dropped floor area does create a "tripping" hazard for the plant personnel as they travel from one area to another. The tripping hazard will be repaired.

The repairs for the CMU wall cracks in the switchgear room and corridor are not a necessity to maintain the overall structural stability of the SFC buildings. However, these walls are building components and, since there is no longer the overall continuity of the wall element, cracks will be repaired.

10.1.2.2 Exterior The end connections of the steel support beams over the transformer bays show minor rust on areas of the beam and the end connections. This is evident by the rust stains on the CMU wall below the connection. While there does not appear to be any significant loss of material section, these areas are to be cleaned and coated with a rust inhibitor and repainted to prevent any further possible deterioration.

In the 60 Hz and 25 Hz transformer bays, there appears to be a small amount of ground subsidence at the exterior fire walls partitions. These area are to be excavated, backfilled, and compacted to project specifications.

10.1.3 230 kV Control Building Openings in the existing building walls may need to be modified to adjust for new or additional duct work or piping. This may include new steel or masonry lintels.

10.1.4 60 Hz and 25 Hz Transformer Bay Areas A new oil containment pit may need to be installed for the SFC #2 transformer. The requirements (size, depth, construction type) will be similar to the existing containment pits in the SFC #1 and #3 rooms.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 74 of 87 Additional consideration should be given to the installation of the new transformers for SFCs #1 and #3. It is possible that existing transformer foundations will need to be modified or rebuilt for the new transformers, which will most likely affect the integrity of the existing oil containment structures in these bays and may require repair or possible rebuilding to accommodate new containment requirements.

Also, openings in the existing building walls may need to be modified to adjust for new or additional electrical bus ducts or piping. This may include new steel or masonry lintels.

10.1.5 SFC Building Roof It is an OSHA requirement to provide fall protection for maintenance personnel that will be working on roof equipment that is within ten feet of the roof edge. A fall protection system will be installed in the areas where personnel will be within this requirement. Engineered tie-off locations where personal will be equipped with safety harnesses and lanyards will be designed.

The upgrades for the SFCs will require mechanical equipment to be installed on the roof. Additional framing will be designed to support the new equipment, as well as the need to reinforce the existing steel to support the additional loading.

10.2 Building Design Criteria

10.2.1 Materials The building envelope for the new addition will be based on CMU load bearing construction. The floor inside the addition will be constructed using a steel supported concrete floor and the roof will be built using conventional steel construction.

The project shall be designed and constructed using materials with the following minimum property requirements.

Table 52 - Structural Steel

Structural steel W-shapes ASTM A 992, Grade 50 Miscellaneous steel shapes and plates ASTM A 36 Hollow Structural Shapes (HSS) ASTM A 1085-13 Structural steel pipe ASTM A 53, Grade E High strength bolts ASTM A 325 Welding AWS D1.1 Welding electrodes AWS A5.1 (E70XX) Anchor rods ASTM F 1554, Grade 50

Table 53 - Concrete 28-Day Compressive Strength

Foundations, normal weight concrete, air entrained f’c = 4,500 psi Slab-on-grade, normal weight, air entrained (exterior) f'c = 4,500 psi Slab-on-grade, normal weight, non-air entrained (interior) f’c = 4,000 psi Suspended slabs f’c = 4,000 psi

Table 54 - Reinforcing Steel

Bar reinforcing ASTM A 615, Grade 60 Welded Rebar, Threaded Rebar ASTM A 706, Grade 60 Welded wire reinforcement (WWR) ASTM A 1064, flat mesh

Table 55 - Masonry

Concrete Masonry Unit (CMU) ASTM C90 Grade N-1 f’m = 1500 psi partition f’m = 2000 psi load bearing/shear wall

Grout ASTM C476 –3000 psi Mortar ASTM C270 –Type M or S

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 75 of 87 10.2.2 Design Loads

10.2.2.1 Dead loads

Unit weights will be in accordance with the commentary to ASCE 7-05, for various construction materials and assemblies.

Table 56 - Dead Loads

Material Weights Concrete 150 pcf Steel 490 pcf Walls 12” Concrete Masonry Unit- grouted solid 126 psf 12” Concrete Masonry Unit- grouted 24” oc 78 psf 12” Concrete Masonry Unit- grouted 32” oc 72 psf 12” Concrete Masonry Unit- grouted 48” oc 66 psf 8” Concrete Masonry Unit- grouted solid 83 psf 8” Concrete Masonry Unit – grouted 24” oc 54 psf 8” Concrete Masonry Unit – grouted 32” oc 50 psf 8" Concrete Masonry Unit – grouted 48” oc 47 psf Roof Dead Loads Roofing membrane 2 psf Sheathing 3.5 psf 1 1/2” 20 gauge Type B Metal Roof Deck 2 psf Roof Insulation 8 psf Ancillary Loads (Lights/HVAC/Etc.): 10 psf

10.2.2.2 Live Loads Table 57 - Floor and Roof Live Loads

Live loads Roof 20 psf Suspended Floor 150 psf Basement Floor 60 psf

Table 58 - Wind Loads

Wind loads Basic Wind Speed V = 90 mph Exposure Category Main Wind Resisting System C Components and Cladding C Topographic Factor Kzt= 1.0 Directionality Factor Kd= 0.85 Wind Occupancy Category III Wind Importance Factor I= 1.15 Fm Global I= 1.15 Enclosure Classification (UNO) Enclosed Gust Effect Factor G = 0.85 Internal Pressure Coefficient (UNO) GCpi = +/- 0.18

Table 59 - Snow Loads

Snow loads Ground Snow Load Pg = 25 psf Flat Roof Snow Load Pf = 22 psf Snow Importance Factor I = 1.1 FM Global (component and cladding) I = 1.1 Snow Exposure Factor Ce =1.0


Thermal Factor Ct=1.1 FM Global (component and cladding) Ct = 1.1

Table 60 - Seismic Loading

Methodology ASCE 7-05 Site Location Philadelphia, Pennsylvania Seismic Occupancy Category III Seismic Importance Factor 1.25 Maximum Considered Earthquake (MCE) Ground Motion 0.2 Second Spectral Response Ss = 0.274 1.0 Second Spectral Response S1 = 0.060 Seismic Site Classification D Short Period Site Coefficient Fa = 1.581 Long Period Site Coefficient Fv = 2.4 Maximum Considered Earthquake Short Period, Fa * Ss SMs = 0.433 1s Period, Fv * S1 SM1 = 0.145 Design Spectral Acceleration Short Period SDs = 0.289 1s Period SD1 = 0.096 Other Seismic Design Category B Basic Seismic Force Resisting System Intermediate Response Modification Factor, R 3.5 System Overstrength Factor, WO 2.5 Deflection Amplification Factor, Cd 1.75 Seismic Response Coefficient, Cs 0.144 Analysis Procedure Equivalent Lateral Force

Table 61 - Allowable Deflections

Roof (Live Loads) L/360, 1” max Roof (Total Load) L/240, 1.5” max Floor (Live Loads) L/360, 1” max Floor (Total Load) L/240 Wall Assemblies (Horizontal deflection) L/240

Table 62 - Allowable Building Story Drifts

Wind at eave height (10 year wind) H/400

10.2.3 Global Stability

The stability analysis shall consider the overall global stability of the SFC building, bearing capacity analysis of the foundation soils, and settlement analysis of the proposed structure. The soil parameters used in the design of the structure shall be based on the project geotechnical report.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 77 of 87 11.0 Geotechnical

11.1 Introduction

The geotechnical design criteria presented herein shall govern the design of the following project elements:

• Shallow foundations (bearing capacity, settlement, stability)

• Deep foundations (timber piles, vertical and lateral capacity)

• Site Earthwork (subgrade preparation, compaction)

• Seismic design parameters

11.2 Design Criteria

11.2.1 Geotechnical Investigation

A geotechnical investigation was conducted by STV Incorporated in 2015 to supplement the subsurface data from a previous investigation conducted in 1992. The boring logs from both investigations are presented in the Contract Drawings for information and use by the Contractor.

The Geotechnical Engineering Report for the project presents a more detailed site subsurface characterization along with all available field and laboratory data.

11.2.2 Excavations Temporary excavation support for construction is the responsibility of the Contractor and shall be designed by a Professional Engineer licensed in the Commonwealth of Pennsylvania.

Excavation for any purpose shall not remove lateral support from any existing foundation without first underpinning or protecting the foundation against settlement or lateral translation.

11.2.3 Foundations

The existing SFC facility is to remain in service during earthwork and foundation construction. The proposed construction methods are required to minimize vibrations during construction to reduce impacts to the existing SFC facility.

Foundation depths must consider the final site grading and frost penetration. The frost depth for Philadelphia County is 36 inches.

Spread footing foundations and earth retaining structures are to be designed in accordance with IBC 2009, Section 1809.

Applied foundation pressures for each column and wall footing shall be computed as the resultant vertical load acting the effective width and length of the foundation, and shall not exceed the following allowable bearing pressures:

All Footings – 1,000 psf

In cases where a footing is subjected to moments in addition to vertical loads, the line of action of the resultant force shall have a maximum eccentricity from the centerline of the footing equal to B/6, where B is defined as the width of the footing in the corresponding direction of applied moment.

The structural design of floor slabs-on-grade is normally based on the theory of slabs on elastic foundations. The design value for the modulus of subgrade reaction to be used for structural design may be taken as 150 pci.

Where shallow footings are not feasible due to exceedance of allowable bearing, settlement, or eccentricity, timber piles may be used for foundation support.

Timber piles shall have a minimum butt diameter of 13 inches and a minimum tip diameter of 8 inches. The allowable single pile vertical capacity shall be 25 tons in compression and 2.510 tons in uplift with a required ultimate driving resistance of 57 tons based on factor of safety of 2.25 and verification of the pile capacity

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 78 of 87 via dynamic testing. In order to be considered braced, the minimum pile group size shall be three piles connected by a rigid cap.

The single pile lateral capacity shall be taken as 1 ton. Where piles are utilized in groups, the following P-Multipliers shall be used to reduce the single pile lateral capacity due to group effects:

Table 63 - P-Multipliers

Pile CTC spacing (in the direction of loading)

P-Multipliers, Pm Row 1 Row 2 Row 3 and higher

3B 0.8 0.4 0.3 5B 1.0 0.85 0.7

11.2.4 Subgrade Penetration Subgrade preparation for the support of structure foundations and slabs-on-grade shall consist of scarifying the upper 8 inches to 12 inches of the subgrade, moisture conditioning as needed to achieve a moisture content within plus or minus 2 percent of optimum, and recompaction to a minimum of 95% maximum Standard Proctor (ASTM D698) dry density.

11.2.5 Seismic Design Parameters

Seismic loads are based on the methodology outlined in IBC 2009 and ASCE 7-05 and the recent soil boring standard penetration data.

Table 64 - Seismic Design Parameters

Site Location

40.02578o N -75.15581o W

Ss 0.274 g S1 0.060 g

Site Class D Fa 1.581 Fv 2.400

SMS 0.433 g SM1 0.145 g SDS 0.289 g SD1 0.096 g

Occupancy Category III Seismic Importance Factor 1.25 Seismic Design Category B

*Based on 2% Exceedance in 50 years

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 79 of 87 12.0 Civil

12.1 Introduction

Plans and specifications will be developed for the preparation of the site and the arrangement and layout of the equipment, including modifications to existing facilities and structures that will remain as a necessary part of the Project and impact of excavation on existing facilities and structures which are to remain. This work shall include, but not be limited to:

1. The Consultant shall perform all activities necessary to obtain all applicable municipal and agency approvals. The Consultant shall prepare application(s) for land development and zoning approvals. This includes any and all plans, exhibits, studies and reports that are needed for municipal review. The Consultant shall pay all fees for this task. SEPTA shall review and receive copies of all submissions prior to release.

2. Site plans, including grading and layouts for all future specified facilities and their access-ways.

3. Flood plain, drainage and storm water runoff.

4. Excavation, clearing and grubbing, paving and grading.

5. Locating of foundations, equipment pads, duct lines, manholes, underground and overhead utilities.

6. Security, encompassing fencing.

7. Locate on site drawing all existing underground and overhead utilities occupying or affecting the work area and relocate existing utilities where required. Coordinate the design with those utilities, in compliance with the laws of the Commonwealth of Pennsylvania. Locate appropriate water supply and sewer system for connections if needed.


12.2.1 Survey and Subsurface Utility Investigation

A topographic survey was conducted by Matrix New World in 2015 and utilized existing as-built drawings provided by the owner and additional supplemental information of the subsurface utility investigation provided by American Geotech Inc (AGI). AGI has supplied the locations, dimensions and depths of subsurface obstructions found during their investigation. The surface and subsurface features are displayed on the existing conditions Contract Drawings for information and use by the Contractor. The Contractor is to field verify the existing conditions as it relates to the proposed elements of the project and alert the owner/engineer of any potential conflicts.

12.2.2 Demolition and Phasing A demolition plan has been prepared to identify to the Contractor those site/civil items which are deemed necessary for removal due to the implementation of the proposed project elements. Features beyond those shown on the plan may require removal due to the existing site conditions. A project phasing criteria will be established per the traction power project requirements and facility operational needs. The Contractor will be responsible for preparing a demolition schedule which meets the project phasing requirements.

12.2.3 Paving and Grading Improvement

The paving and grading areas are designed to meet the existing conditions as closely as possible. Existing paved areas disturbed by the proposed project elements will be replaced in kind in the same location and have a 13” minimum pavement section comprising of a 2” bituminous wearing course, 5” bituminous base course, and a 6” subbase course No. 2A modified course. The proposed grading will allow for positive drainage to the existing stormwater inlets located throughout the project area.

12.2.4 Drainage, Stormwater Management, and Erosion & Sediment Control

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 80 of 87 A stormwater analysis will be prepared to gauge the need for the installation of new stormwater inlets and piping or if the capacity of the existing system is sufficient for this project. Any design inlets, manholes, or pipes are to accommodate the 10-year storm.

The drainage system and stormwater management facilities shall accommodate the entire area of WJSFC rehabilitation project. Coordination with SEPTA to obtain information pertaining to future aspects of the expansion not included in this contract.

Matrix will review the need for an NPDES permit to cover this WJSFC rehabilitation project. Coordination with SEPTA to obtain information pertaining to future aspects of the expansion not included in this contract.

All erosion & sediment control measures shall be in accordance with PA DEP requirements.

12.2.5 Fences All new substation fences shall meet or exceed the requirements of National Electric Safety Code (NESC) IEEE-C2, IEEE-80, and IEEE-1119. In general, fences shall be at least 6 feet high made of tight mesh galvanized steel or aluminum chain link with an applicable top structure to discourage climbing. Fences shall be equipped with both top and bottom rails to discourage entry. Fences shall be grounded in accordance with the above listed codes and all gates shall utilize woven mesh straps to insure continuity at all hinged joints.

The two existing gates will remain utilized for vehicular access.

SEPTA fencing requirements shall be followed if more stringent than PECO requirements.

13.0 Survey

13.1 Introduction

All necessary field surveying, site investigation, structural analysis, and soil testing shall be performed prior to construction.

13.1.1 Site Access

Prior to doing any existing condition site work, all personnel who will perform work on the site will require Safety Training.

13.1.2 Topographical Field Property Survey

Conventional topographical surveys will be performed to verify and/or determine the property line and condition as well as the nature, dimensions, elevations, grades and locations of all existing natural and man-made physical features and facilities within the limits of the proposed work or adjacent thereto as may be affected by the proposed work.

13.1.3 Survey Notes

All survey notes shall be kept in standard notebooks and the originals shall be delivered to SEPTA, as its property, at the completion of the design. They shall be accurately and neatly kept, fully indexed, dated with the names and signatures of personnel compiling the data. Survey data collected by electronic devices shall be transferred onto electronic media with a copy submitted to SEPTA by the Consultant.

13.1.4 Analysis of Project Site Analysis of the project site shall include drainage, structural, civil, electrical, utilities, access and other elements of the site. Existing field conditions and problems which could affect the construction of the project facilities will be identified.

13.1.5 Soil Testing

Soil testing will include:

1. Sufficient number of core borings on site at a depth of 30' to 40'.


2. Full soil analysis using a photo ionization detector.

3. Screening for hazardous material.

4. Testing for electrical characteristics necessary to design the substation ground grid.

13.2 Site Survey Two monuments were located on September 8, 2015, along the railroad tracks near Wayne Junction SFC Station. The drawing files are referenced to the site horizontal and vertical datum. Property boundary information has been shown based on the existing site mapping.

On-site mapping of the existing utilities, as shown on the project base map, have been plotted based on a combination of surveyed field observations, review of available referenced mappings, the use of ground penetrating radar (GPR) utility mark-outs. The field mark-outs have been correlated to the referenced mapping to the highest extent possible.

The existing SFC and Control Building structure is about 12,400 square feet and includes six transformers, each on individual concrete pads and isolated by fire walls on a gravel surfaced open space. The fenced SFC station consists of impervious pavement and gravel surface without any vegetation.

The existing project area is surrounded by a 12" and 15" diameter stormwater reinforced concrete pipe (RCP) conveying surface stormwater and roof stormwater runoffs via inlets and roof leaders. The roof leader downspouts run inside of the building and connect perpendicular to the existing RCP on the west and east sides of the site. Open grate roof leader clean-outs were observed on the access pavement surface between the SFC and Control Buildings and existing stormwater RCP alignments. The site topography survey, stormwater inlets, and manhole elevation measurements indicate that the overall site stormwater flows east towards North 18th Avenue.

The proposed building expansion from the north side of the existing SFC #3 building may include additional transformers isolated by wing walls. The north side of SFC #3 consists of compacted gravel that has been utilized as a loading and storage area for metal containers. By replacing some of the existing gravel surface with the newly proposed building expansion, the stormwater surface runoff volume per unit area of the compacted existing gravel will slightly increase as compared with existing conditions.

The Pennsylvania One Call System shall be used to confirm interfaces and obstructions of all utilities.

14.0 Environmental

14.1 Introduction

An environmental overview report has been prepared to identify environmental resources and potential impacts and/or hazards. This report meets requirements of all applicable environmental regulations. Samples have been taken from all core borings and several other locations on the site to be used for analytical testing to determine whether the material meets all the requirements of clean fill, and to determine if there are hazardous materials present.


14.2.1 Phase I Environmental Site Assessment (ESA) A Phase I ESA assessment shall be performed to identify recognized environmental conditions (RECs) and environmental concerns that may affect the suitability of the Site for the proposed development. Recognized environmental conditions are defined in ASTM International (ASTM) Standard Practice E 1527-13 as the presence or likely presence, use, or release on the Site of hazardous substances or petroleum products. In addition, other environmental issues and conditions that, in the opinion of the environmental professional conducting the assessment, would not be considered recognized environmental conditions are identified in this assessment. These may include historical recognized environmental conditions and/or de minimis conditions. The Phase I ESA also includes a preliminary evaluation of specific potential environmental issues or conditions that are, according to ASTM E 1527-13 considered non-scope considerations. These issues include potential vapor encroachment conditions (VECs) as per ASTM

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 82 of 87 E2600-10, radon, asbestos-containing material (ACM), polychlorinated biphenyl (PCB)-containing light ballasts and caulking materials, lead-containing paint (LCP), chemical storage, wetlands, regulatory compliance issues, dry cleaner and other industrial emissions, biological agents, electromagnetic fields, and methane. The Phase I ESA shall include a review of federal, state, and local records, previous reports (if available) and historical documents; visual observation of the Site and adjoining properties; and interviews with selected Site representatives.

The assessment shall identify conditions that may have the potential to impact the decommissioning of the Site. The assessment will be conducted for purposes of environmental due diligence in order to qualify for the innocent landowner, a bona fide prospective purchaser or a contiguous property owner defense under the Comprehensive Environmental Response Compensation and Liability Act (CERCLA). The Phase I ESA includes, but is not limited to, an assessment of the following potential environmental issues: current and historical Site usage; current and historical usage of adjoining properties; regulatory agency records review; on-site solid waste management and disposal practices; on-site hazardous materials and petroleum products management; chemical storage, ACM, PCBs and LCP management; wetlands; regulatory compliance issues; dry cleaner and other industrial emissions; radon; biological agents; electromagnetic fields; and potential for methane generating materials. The Phase I ESA shall be performed in conformance with the scope and limitations of ASTM Practice E 1527-13.

14.2.2 Environmental Testing - Phase II Drilling and collecting environmental soil and water samples shall be taken from the geotechnical borings, test pits, and geoprobe borings. The boring cutting waste will be drummed, left onsite, and managed by SEPTA at their direction. Upon completion of the borings, collection of samples and receipt of lab results, The Consultant shall prepare the environmental testing final report, including conclusions, recommendations, and a soil management plan, if required.

14.2.3 Asbestos Testing A pre-renovation hazardous materials survey shall be performed for asbestos-containing materials (ACM), lead-containing paint (LCP), and universal waste at the WJSFC. The purpose of the survey is to identify, locate, sample, and assess the condition of accessible building materials that were suspected of containing asbestos-containing materials, lead-containing paint, and universal waste that may impact the proposed facility renovation.

14.2.4 Lead Testing Results Samples of suspect lead-containing materials shall be collected and submitted to an EMSL Analytical for lab analysis. Any work that affects lead-containing materials should be performed in strict accordance with SEPTA specifications, Occupational Safety and Health Administration (OSHA) Lead in Construction Standard 29 CFR 1926.62, federal, state, and local laws.

A limited visual universal and regulated waste survey shall be performed to determine what equipment or devices present at the Site may contain mercury, oils, PCBs and/or other waste products requiring proper handling and disposal in the event that construction should come in contact herewith.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 83 of 87 15.0 Regulatory Compliance and Permits

15.1 Wetlands

Based on a field review of the USFWS NWI mapping, information available on PADEP's eMapPA GIS database and a site visit conducted on August 20, 2015, there are no wetlands or waterbodies within the project limits.

15.2 100-year Floodplains

Based upon information available on PADEP's eMapPA GIS database and a review of the FEMA Preliminary FIRM map for the City of Philadelphia (Panel #4207570095G dated February 20, 2014), no portion of the project site is located in a 100-year floodplain.

15.3 Threatened and Endangered Species Habitat Based on information obtained from the Pennsylvania Natural Heritage Program's on-line PNDI Environmental Review Tool, no impacts are anticipated to threatened and endangered species and/or special concern species and resources under the jurisdiction of the PA Game Commission, PA Fish and Boat Commission, the PA Department of Conservation and Natural Resources or the USFWS.

15.4 Permitting Requirements

15.4.1 PADEP Erosion & Sediment Control Permit A PADEP Erosion and Sediment Control Permit will be required if the proposed construction will disturb 5,000 square feet or more of soil. It is anticipated that this permit will be required.

15.4.2 City of Philadelphia Water Department Storm Water Approval

City of Philadelphia Water Department review of stormwater management plans will be required if soil disturbance is 5,000 square feet or more. However, within the watershed where the project is located, the Department's post-construction stormwater management requirements only apply to projects that disturb 15,000 square feet or more of soil. Based on the scope of the project, it is anticipated that the 5,000 square feet threshold will be exceeded, but the 15,000 square feet threshold will not be exceeded. Therefore, an application for a development exemption will be required.

15.4.3 PADEP General NPDES Permit for Stormwater Discharges from Construction Activities

PADEP General Permit PAG-02 for stormwater discharges from construction activities will be required if soil disturbance of one acre or more is required. It is unlikely that this permit will be required.

15.4.4 City of Philadelphia Zoning Permit

A Zoning Permit is required for any new construction or building an extension to an existing structure. No variances are anticipated at this time.

15.4.5 Pennsylvania Historical and Museum Commission Review

As part of the application to PADEP for an Erosion and Sediment Control Permit, it will be necessary to submit Cultural Resource Notice Form 0120-PM-PY0003 to the Pennsylvania Historical and Museum Commission for confirmation that no impacts to known historic or archaeological resources will occur as a result of the project.

15.5 Buy America

SEPTA has stated that this project will be subject to "Buy America" requirements. The United States Code Title 49 (49 U.S.C.), Section 24405(a) "Buy America," (1), states:

"The Secretary of Transportation may obligate an amount that may be appropriated to carry out this chapter for a project only if the steel, iron, and manufactured goods used in the project are produced in the United States."

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 84 of 87 However, a waiver may be possible to obtain relief from the conditions as stipulated in the Buy America documents. Under 49 U.S.C, Section 24405(a)(2), the following direction is given regarding waivers:

"(2) The Secretary of Transportation may waive paragraph (1) of this subsection if the Secretary

finds that—

(A) applying paragraph (1) would be inconsistent with the public interest;

(B) the steel, iron, and goods produced in the United States are not produced in a sufficient and reasonably available amount or are not of a satisfactory quality;

(C) rolling stock or power train equipment cannot be bought and delivered in the United States within a reasonable time; or

(D) including domestic material will increase the cost of the overall project by more than 25 percent."

Based on this, it appears that even if the project is subject to "Buy America" requirements, a waiver appears reasonable for static frequency converter equipment, such as the power block equipment, control systems, and converter transformers, which have special winding arrangements only compatible with their associated converter design.

16.0 Site Construction Phasing

16.1 General Construction Sequence The main priority in developing a construction sequence will be to keep at least two SFCs in operation at all times with a third in stand-by.

The second priority is to avoid construction traffic exposure to any unit while in operation. Presently, the SFC rooms function strictly to contain power block equipment and associated buswork. Walking through a room while the SFC is functioning, is kept to a minimum. However, during construction, it is strongly discouraged to keep SFC room doors open or allow construction materials to be transported through the room while the SFC is operating. In order to avoid exposure to construction traffic, a wall and doors will be constructed in front of the SFC power block equipment in order to isolate the sensitive equipment from dust and debris, as well as personnel.

With these two main concepts in mind, the following general sequence will be followed:


2. Construct the new SFC #4 building, including 60 Hz and 25 Hz power feeder duct banks, open-air bus work and associated equipment, 25 Hz output circuit breaker, and make connections to the existing Wayne Junction 25 Hz traction power substation. The new SFC #4 converter room will have a wall with doors between the SFC power electronics and the power distribution/control equipment.

3. Establish a new station computer in the existing Control Room. Depending on SFC vendor options, the existing computer equipment will need to be removed one unit at a time or it can be left in place until the final new SFC is commissioned.

4. Demolish the SFC #3 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz duct banks and filter yards, as required.


6. Demolish the SFC #1 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz duct banks and filter yards, as required. Note that the reason that SFC #1 is selected to be demolished after the


construction of SFC #3 is so that all debris to be carried from SFC #2 demolition will only occur after constructing a wall in front of SFC #1 power electronics equipment.


8. Demolish the SFC #3 cycloconverter cubicles and buswork, remove 25 Hz and 60 Hz SFC transformers, and modify existing 25 Hz and 60 Hz duct banks and filter yards, as required.


10. After all new SFCs are commissioned, the existing computer system can be removed. The final Control Room will either have a complete new computer system or a HMI interface that coordinates control of all new SFCs.

16.2 Construction of New SFC building

The construction of the new proposed building for SFC #4 will be performed prior to any other building-related work at Wayne Junction. As part of the construction sequence, installing and commissioning the SFC #4 building will be performed prior to decommissioning any other SFCs in order to keep at least two SFCs available for operation at all times.

The new SFC #4 building construction requires building the entire structure using conventional steel construction with columns, girder and beams. A brick veneer with an 8" CMU backup is utilized for the building enclosure.

The SFC #4 building is located closest to the existing parking lot on the north side of the existing SFC #3 building. Its construction should not affect the continued operations of SFCs #1, #2, and #3. However, connections to electrical utilities will come from the existing Control Building and be routed under SFC #3, through existing conduits, trays, and openings in the SFC #3 basement walls. When working in the SFC #3 basement, SFC #3 would need to be de-energized and tagged out.

There are no overhead lines that would impair the construction of the new building. Review of existing drawings and results of site investigations show that there are no major utilities running under the proposed new building construction area other than part of a stormwater line. Since the new building will be constructed on piles, relocation of this line is not anticipated.

16.3 Construction of Duct Banks

SFC #4 will require new duct banks. A new duct bank will be constructed from the 230 kV Control Building to newly installed open-air bus, then from the opposite end of this bus to the SFC #4 transformer/reactor. Another new duct bank will be constructed between the 25 Hz output transformer and 25 Hz SFC circuit breaker. The third new duct bank will be constructed between the 25 Hz SFC circuit breaker and existing 25 Hz traction power substation.

All foundations in the 60 Hz Filter Yard are to remain. Therefore, new duct banks will not be required between the 230 kV Control Building and the existing SFCs #1, #2, and #3. Existing duct banks will be used.

For the remaining SFC units, the preferred method of construction in the 25 Hz filter yard area will be to keep the existing duct banks and route new cables between the 25 Hz output transformers and the 25 Hz SFC output circuit breakers. Reuse the existing duct banks and cables between the 25 Hz output circuit breakers and the 25 Hz traction power substation. Remove the existing SF6 circuit breakers, instrument transformers, and switches and install new equipment. Note that the preferred type of circuit breaker requested by SEPTA includes current transformers.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 86 of 87 Any duct bank that contains 60 Hz auxiliary power and control cable is planned to remain.

16.4 Construction of Oil Containment Pits

If 60 Hz SFC transformers are required by the selected SFC vendor, a new oil containment pit will be constructed for SFC #4. The existing oil containment systems for SFCs #1 and #3 may need to be upgraded or replaced. SFC #2 presently has no oil containment pit; a new one will be constructed. The construction and modification of the oil containment pits will follow all applicable standards in accordance with IEEE 980, Guide for Containment and Control of Oil Spills in Substations.

16.5 Repair of Existing Foundations and Building

The repairs of existing foundations and SFC building components will be performed right after each SFC unit has been demolished, with repairs occurring prior to beginning any installation of electrical or mechanical equipment in that particular SFC building. Repairs in the Control Room building should be scheduled during the construction of the SFC #4 building.

16.6 Installation of New SFCs The SFC power blocks must fit through existing doorways and within the existing and new SFC rooms. Installation of each new SFC must occur independently of others that remain in operation.

16.7 Testing and Commissioning of New SFCs SFC equipment routine tests are to be performed in the vendors' factories as well as field tests to be completed at the site. Time must be allocated by SEPTA to witness factory testing, and the construction schedule must allow time for testing and fully commissioning SFC units on an individual basis. Each SFC unit must be completely commissioned prior to beginning construction on the next unit.

16.8 Operation in Parallel with Existing Converters For active power load sharing, the SFCs will follow a synchronous machine model. The existing cycloconverter uses a similar model and, therefore, load sharing can be done by use of the same parameters. For reactive power, the SFCs use a reactive power versus voltage curve that can be adapted to the parameters of the cycloconverter. Load sharing between existing and new units during construction may not be optimal, but it must be functional and allow the station to meet the varied load demand that occurs on a second-by-second interval.

It is not expected that the existing load sharing computer will need to be integrated with the new SFC control system. As existing units are removed from service, they will simply be set to "off" in the existing load sharing computer system.

16.9 Rigging and Transportation Constraints

It is anticipated that the dimensions of new equipment will be similar to the existing equipment and that no special rigging and transportation constraints are anticipated. Proper rigging and transportation instructions must be provided by the equipment vendors.

It is preferred not to modify the existing access roads on the east and west sides of the SFC building. This will allow for access to the 25 Hz and 60 Hz transformer areas without reaching over equipment.

For transporting equipment into the existing SFC rooms, access is anticipated through the existing doorways, and no new access ways will be created. If SFC power electronic equipment is transported in prefabricated assemblies, these will need to be disassembled if transportation into the SFC rooms is not possible through existing doorways. Modifying the existing building is not within the scope of this project, e.g., cutting holes in the building in the transformer bays to allow SFC equipment to pass into the building on prefabricated assemblies.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria 60% Design Submittal STV Inc., Project No. 4017500 Page 87 of 87 16.10 Protection of Equipment During Excavation, Demolition, and Construction Adequate temporary protection will be required during excavation, selective demolition, and construction in order to prevent failure of any existing or new equipment. Construction phasing drawings will identify boundaries of construction and will take into account permitting requirements should SFCs be required to be de-energized and tagged out.

Additionally, SFC equipment will require either a temporary or permanent form of protection from dust during demolition and construction. This project will install walls separating the main SFC rooms from their adjacent power distribution/control areas. These walls will create corridors, allowing protection from dust and equipment damage during the construction and demolition phases. It will also provide a passageway for personnel during normal equipment operation.

Wayne Junction SFC Rehabilitation Eval-4017500-E-002, Rev. C Design Criteria Attachment 1 STV Inc., Project No. 4017500 Page 1 of 14

Scope of Work - Summary

No. Area Equipment Discipline Assessment Determined Actions 1. 230 kV Control

Building 13.2 kV switchgear Electrical • One spare 13.2 kV circuit breaker available

for new SFC #4.

• Existing overcurrent relays

• Use existing 13.2 kV circuit breaker.

• Use existing overcurrent relays.

• Install new conduits from 13.2 kV switchgear out top of switchgear, across room, out wall.

2. 230 kV Control Building

480 V switchgear Electrical • Two spare 480 V circuit breakers are available for the new SFC #4 auxiliary power.

• Use existing circuit breakers and run two new feeder circuits for SFC #4 to converter building switchgear room.


13.2 kV-480 V transformers

Electrical • Perform a load study. Determine whether transformers can meet the existing as-built load plus the additional load of the new building and SFC equipment.

• Keep station auxiliary transformers. Test existing auxiliary transformers to determine their health. Perform a loss angle and dissipation factor test. Provide a report and recommendations to SEPTA.


13.2 kV conduits Electrical, Structure

• Need new conduits coming from 13.2 kV switchgear, thru the wall, and down the side of the building

• Add conduits and modify control building wall.


Fire suppression and alarm control panels

Electrical • System is obsolete • Replace the existing Pyrotronic suppression/fire alarm control panels with new updated addressable fire alarm system and a suppression activation panel in the 230 kV control building

6. 60 Hz Filter Yard Control cables between 230 kV Control Building and SFC building

Traction Power • Control and instrumentation cables are associated with the filter instrument transformers.

• Remove abandoned cables that are no longer necessary related to the filters.

• Cut back instrument transformer and grounding switch control cables in filter yard and remove abandoned cables. Use spare conduits to run new control cables to SFC building to new interface panels near the SFC vendor control equipment.

7. 60 Hz Filter Yard 13.2 kV power cables and open-air bus feeding SFC input transformers

Traction Power, Structural

• Cables for SFCs #1, #2, and #3 are routed from 230 kV control building in duct banks,

• Keep duct banks between 230 kV control building and open-air bus (under access road next to auxiliary transformers). Keep cables between 230 kV control building and 13.2 kV open-air bus.Keep


No. Area Equipment Discipline Assessment Determined Actions then up to open-air bus, then in duct banks to 60 Hz transformers

• Duct bank riser supplying SFC #2 transformer may be damaged at stub-up near transformer due to sinking ground.

• New duct bank required for SFC #4.

open-air bu. Repair existing duct banks at 60 Hz transformers as required. Route new cables in existing duct banks from 13.2 kV open-air bus to 60 Hz transformers, if required, based on SFC vendor equipment locations.

• In both cases, add all new power and control cables for SFC #4 in a new duct bank.

• On existing open-air bus, keep the existing grounding switch, CTs, PTs, and surge arresters. Replace instrument transforms if the SFC vendor requires a different accuracy or ratio.

• Modify fencing so that each open-air bus is surrounded by the minimum required fencing. Areas where filters were removed do not require fencing.

8. 60 Hz Filter Yard 480 V power cables feeder converter building switchgear

Electrical • Existing cables are routed from 230 kV control building via duct banks to converter building switchgear to supply power to SFCs #1, #2, and #3.

• New 480 V power circuits are required for the new SFC #4.

• Add two new 480 V power circuits from 480 V switchgear in 230 kV control building to converter building switchgear.

• Route these two new 480 V circuits in a new combined power/control duct bank used for the SFC #4, 13.2 kV power feeders.

9. 60 Hz Filter Yard 60 Hz filters and associated equipment

Traction Power • None can be used for new converters

• Filter foundations are in good shape

• Remove filters and their associated grounding switches and instrument transformers. Keep filter foundations.

10. 60 Hz Filter Yard Grounding Electrical • The new SFC #4 area will require a new grounding grid

• Add grounding grid where required (where personnel will operate switches, breakers, or touch metal objects such as transformers and fences)

11. 60 Hz Transformer Area

60 Hz transformers Traction Power • None can be used for new converters • Remove 60 Hz transformers and bus duct into the SFC building.


No. Area Equipment Discipline Assessment Determined Actions 12. 60 Hz Transformer

Area Foundations Structural • Good shape • Reuse existing foundation and modify, if possible.

• Build new foundations where required for new equipment.


Oil retention pits Traction Power, Structural

• There are concrete pits for SFCs #1 and #3.

• SFC #2 has no oil retention pit

• Add new oil retention pits for SFC #2 and SFC #4 if vendor has oil filled equipment.

• Repair or rebuild oil retention pits for SFC #1 and SFC #3 if vendor has oil filled equipment.


Wing walls Structural • SFC #2 wing wall foundation has signs of soil erosion

• The existing fill at the base of the wing wall will need to be excavated and recompacted


Deluge system Plumbing • Deluge system appears to be in good condition.

• Deluge system will need to be disassembled when removing transformers.

• Replace deluge system parts as necessary to meet design criteria.

• Provide new deluge initiation devices and suppression panel to control all deluge systems. Install panel within east deluge room.


Building walls Structural, Architectural

• Openings in the exterior wall for the existing bus duct.

• Modify existing openings for new transformers or reactors.

• Larger openings in height should not require structural work

• Larger openings in width will require structural work to replace header and lintel

17. 60 Hz Transformer Grounding Electrical • The new SFC #4 area will require a new grounding grid

• Add and/or repair grounding grid around new transformers and/or reactors as required.

18. 60 Hz Deluge Valve Room

Halon system Fire Protection • System is obsolete • The entire system is to be replaced per the SOW.

• New dedicated FM-200 system initiation and notification devices and suppression panel to be provided.


No. Area Equipment Discipline Assessment Determined Actions 19. SFC Control Room Fire suppression

and alarm control panels

Electrical • System is obsolete • Replace the existing Pyrotronic suppression/fire alarm control panels with new updated addressable fire alarm system.

• New fire alarm system to monitor all new fire suppression panels in scope of work.

20. SFC Control Room SFC control equipment

Traction Power • All equipment is obsolete and not required for new converters

• It is preferred to keep control panels in place until all new converters are installed. Then, remove obsolete equipment and cabling once new converters are commissioned. This will minimize impact and risk to operating equipment.

21. SFC Control Room SCADA/RTU Communications • Existing SCADA/RTU system is obsolete • Replace SCADA/RTU system

22. SFC Control Room Fire suppression system

Fire Protection • Control room has paneled drop ceiling, which will not contain FM-200 agent

• Replace control room ceiling.

• Replace fire suppression system with up-to-date clean agent system.

• New dedicated FM-200 system initiation and notification devices and suppression panel to be provided.

23. SFC Control Room HVAC unit Mechanical • Existing Trane roof top unit (RTU) serving the control building is in good condition

• Existing cook exhaust fans and unidentified intake ventilator are in fair condition

• Existing ductwork and ductwork insulation are in fair condition.

• A fire damper protects the supply into the control room. No fire damper protects the return opening.

• Replace exhaust fans and intake venitlator on control building.

• Replace RTUs due to age of equipment.

• No additional fire dampers required per code; no walls are fire rated.

• Design systems to accommodate the fire protection system that is to be installed.

• New DDC system will be provided.

24. Converter Switchgear Room

Converter switchgear

Electrical • There are three transfer switches and associated main breakers that feed the converter distribution panels

• Remove transfer switches and existing switchgear one SFC at a time. Replace with switchboards located in SFC Corridors that contain main


No. Area Equipment Discipline Assessment Determined Actions breakers to converter vendor power distribution transfer switches and panels.


208Y/120 V lighting panels

Electrical • Appear adequate for existing facility

• Will need at least one new lighting panel for new SFC #4 building

• Have SFC Contractor provide one new 208Y/120 V ac distribution panel for each SFC unit. After new LED lighting is installed in SFC hallways and rooms, connect the lighting circuits to new SFC Contractor-supplied lighting panels.

• Keep existing panels LP-1 and LP-2 in switchgear room to feed the rest of the SFC Building lighting and receptacle circuits. Feed these from exisitng 480-208Y/120 V dry-type transformers located in Switchgear Room. Feed the transformers from the new 480 V switchboards located in SFC Corridors.


Battery chargers Electrical • Existing chargers supply power to two redundant battery systems

• Battery chargers have recently been replaced.

• Upgrade battery chargers to supply 125 V dc to 25 Hz circuit breaker controls. New battery chargers are required to match the technical requirements of the new sealed batteries to be installed by this project.

27. Wash Room Sink and toilet Plumbing • Appears to be in adequate condition • No work

28. Janitors Closet Faucets and mop basin

Plumbing • Appears to be in adequate condition • No work

29. Battery Room Batteries Electrical • There are two redundant 200 AH battery systems that presently supply dc power to protection and control systems.

• Both battery systems have recently been replaced with wet cell batteries.

• Upgrade battery system to supply 125 V dc to 25 Hz circuit breaker controls. Both battery systems will be replaced with new sealed batteries, using SEPTA's latest specifications.

30. Battery Room Shower/eye wash system

Plumbing • Need to replace with tempered water system

• Replace shower and eye wash system. Install new hot water heater to provide tempered water.

31. SFC Building Fire alarm system Electrical • Appears adaquate, but may need to be replaced for new fire suppression system.

• Replace fire alarm devices throughout building with addressable devices, except in spaces with a


No. Area Equipment Discipline Assessment Determined Actions dedicated fire suppression system controlled by a dedicated panel.

32. SFC Building Door alarms and security

Electrical • Appears adequate based on SEPTA's needs • SEPTA has requested the installation of a new intrusion alarm system.

33. SFC Building Roof - personnel protection

Structural • No guard rail system • Add designated tie-off points

34. SFC Building Roof - roofing materials

Architectural • Roofing material is in poor shape

• Existing built up roofing system is exhibiting surface cracking beneath the ballast. It is likely the roofing system is original.

• Sealant at coping is deteriorated which can permit water infiltration

• Damaged coping

• OSHA compliant fall protection not provided at Roof top Units

• Replace roofing materials with a new roof.

• Replace coping

• Provide OSHA compliant fall protection at HVAC units

35. SFC Building Roof - roofing materials

Environmental • Roofing material contains asbestos and must be abated as an asbestos-containing material

• Abate roofing materials as an asbestos-containing material.

36. SFC Building Upper walls Architectural • Efflorescence and staining on walls is present throughout indicating potential infiltration of water into the cavity

• CMU has limited spalling and cracks which should be repaired.

• Mortar joints appeared to be wet on the north facade.

• Slight shifting of the parapet wall on both ends of the north façade

• Peeling paint

• Roof replacement should alleviate water infiltration from above. Clean façade to remove efflorescence

• Repair CMU cracks to eliminate water infiltration.

• Structural investigation recommended to review shifting of parapet walls. Repair as necessary

• Scrape, prime and paint areas of peeling paint

• Remove and replace damaged sealant


No. Area Equipment Discipline Assessment Determined Actions • Damaged sealant

37. SFC Building Lower walls Architectural • Multiple locations with open and cracked mortar joints

• Several holes are present in a CMU block

• Existing past repairs are present which are already deteriorating and will need additional repair

• Water is infiltrating from the roof level and progressing towards the base CMU within the wall cavity. Without weep holes the bases are cracking and heaving.

• The north wall is bulging near the top course, moss is growing from the cracked horizontal mortar joint.

• Damaged louver blades and flashing

• Spalled wall penetrations

• Open wall penetrations

• Repair walls per assessment.

• Provide weep holes to allow for water to exit wall cavity.

• Structural investigation recommended to review bulging of wall. Repair as necessary

• Repair damaged louver blades and flashing, if they are being kept.

• Repair spalled penetrations

• Seal wall penetrations

38. SFC Building Interior Architectural • General wear of all painted surfaces, but overall in good shape

• Peeling paint on the east wall of SFC #3 & SFC #1 indicates potential water damage may have, or be occurring.

• Crack was seen on the east wall of SFC #3 & SFC #1

• Cracking or mortar joints at the janitor closet

• Portions of the linear ceiling in the hallway are detached, need to be re-attached

• Repaint interior walls

• Repair cracked interior walls.

• Repair interior ceiling in hallway.

• Replace HVAC register

• Replace paper towel dispenser

• Remove and cap water fountain (not potable) - a water cooler is present in the control room

• Paint battery room ceiling


No. Area Equipment Discipline Assessment Determined Actions • Missing HVAC ceiling Register

• Damaged Paper towel dispenser in toilet room

• Water fountain not in working condition

39. SFC Building Interior space of SFC Room

Architectural, Structural

• Several vendors require a wall between the SFC equipment and the main corridor to keep equipment clean and personnel safe

• Add a new wall and set of doors in each SFC room.

• SFC #4 will also require a similar wall.

40. SFC Building Converter heat exchangers

Structural • There are presently no SFC heat exchangers installed on the roof

• Install vendor-provided SFC heat exchangers on roof. These are sized by SFC vendors. Structural engineering to provide supporting structures to support heat exchangers.

41. SFC Building Floors Structural • Some flooring has dropped due to settlement. This does not affect the stability of the structure.

• This is a tripping hazard.

• Address the tripping hazard in the middle section of the interior floor slab in the switchgear room and in the corridor between the battery room and the workshop storage room.

42. SFC Building Lighting Electrical • Existing building lighting appears adequate (check lighting levels).

• New building for SFC #4

• Leave existing lighting locations alone, unless they need to be moved to coordinate with new SFC equipment.

• All lighting that is not already replaced with LED-type lighting will be replaced with LED lighting per SEPTA's request.

• Add new LED-type lighting for SFC #4 building.

43. SFC Building SFC power block Traction Power • Existing cycloconverter is obsolete • Replace existing cycloconverter equipment with 4 x 15 MVA SFCs.

• Remove existing bus work and fencing from SFC #1 and #3 basements.

• Add power distribution equipment.

• Add control equipment.


No. Area Equipment Discipline Assessment Determined Actions • Add pump skids.

44. SFC Building Control wiring Traction Power • Existing cycloconverters are hard-wired to control room

• Disconnect existing wiring.

• Add fiber optic wiring for new converters.

• Add interface panels in new SFC hallways to permit connecting existing 25 Hz traction power substation relay wiring, 25 Hz and 60 Hz yard equipment wiring, and 230 kV control building wiring to new SFC control equipment. These interface panels provide new terminal block connection points, replacing the existing termination points in the control room.

45. SFC Building Power wiring Traction Power • Existing cycloconverters have a single set of power feeders for switching system

• Cut 480 V power feeders in trenches in switchgear room.

• Splice new power 480 V feeders in pullboxes and/or SFC basements to new SFC power distribution equipment in each SFC Corridor. Remove existing 480 V switchboards after new SFC switchboards are installed.

• Use new SFC Contractor-supplied 480 V switchboards to feed SFC air-conditioning and heating systems as well as SFC auxiliary power loads.

46. SFC Building HVAC system Mechanical • Existing Trane RTU serving SFC #1, #2, #3 are in poor condition

• Existing roof mounted make-up air units (MAUs) serving SFC #1 and #3 are in fair condition

• Existing ductwork is in fair condition.

• Existing ductwork insulation is in poor condition.

• Replace existing roof top air-conditioning units (RTUs) and remove two make-up air units.

• Remove existing outside air louvers and patch wall opening to match existing.

• Install four new RTUs for SFC Rooms and one new RTU for SFC Control Building.

• Install four split-system heat pumps to serve the SFC corridors.


No. Area Equipment Discipline Assessment Determined Actions • Existing outdoor air intake louvers are in fair

condition. • Install four electric unit heaters to serve the SFC

Corridors and one electric unit heater in Battery Room.

• Install two new exhaust fans: one for Battery Room and one for Toilet Room/Janitor Closet.

• Modify ventilation ducts as required for new converter system bus work.

47. SFC Building SFC #4 structure Architectural, Structural

• This room does not presently exist • Build addition from standard CMU & Brick construction

48. SFC Building SFC #4 Structure Architectural, Plumbing

• The new SFC #4 building does not require a new water closet and lavatory if occupancy is 15 persons or less

• Acceptance of designed occupant load shall be verified with AHJ to ensure an additional facility is not required.

49. SFC Site Grading and drainage

Civil • Perform assessment of grading and drainage related to new SFC #4 building

• Modify site grading and drainage as required

• Remove existing fencing and add new fencing as required

• Connect new sump pits to existing storm sewer system.

• Connect new SFC #4 Building roof drain system to existing storm sewer system.

50. Workshop Piping and backflow valves

Plumbing • A pipe recently broke in this room, but was repaired.

• Backflow valves were recently replaced.

• No work required in Workshop.

51. SFC Building Exterior envelope Architectural, Fire suppression

• FM 200 fire suppression system requires airtight building envelope

• Replace weather stripping with air tight seal and install automatic closers at all exterior doors.

52. SFC Building Soil Environmental • The soils are defined as both “Regulated Fill” and “Clean Fill”.

• The contractor shall develop their own site-specific HASP for protection of their workers.


25 Hz transformers and bus duct

Traction Power • None can be used for new converters • Remove 25 Hz transformers and bus duct into SFC building.


No. Area Equipment Discipline Assessment Determined Actions 54. 25 Hz Transformer

Area Oil retention pits Traction Power,

Structural • There are concrete pits for SFCs #1 and #3.

• SFC #2 has no oil retention pit

• SFC #4 is being added

• Add new oil retention pit for SFC #2, if required by SFC vendor.

• Repair/replace oil retention pits for SFCs #1 and #3, if required by SFC vendor.

• Build new oil retention pit for SFC #4, if required by SFC vendor.


Wing walls Structural • SFC #2 wing wall foundation has signs of soil erosion

• The existing fill at the base of the wing wall will need to be excavated and recompacted


Deluge system Plumbing • Deluge system appears to be in good condition.

• Deluge system will need to be disassembled when removing transformers.

• Replace deluge system parts as necessary to meet design criteria.


Building walls Structural, Architectural

• Openings in the exterior wall for the existing bus duct.

• Modify existing openings for new transformers or reactors.

• Larger openings in depth will not require structural work

• Larger openings in width will require structural work to replace header and lintel


Foundations Structural • Good shape • Reuse existing foundation and modify, if required.

• Build new foundations, where required.

59. 25 Hz Transformer Grounding Electrical • The new SFC #4 area will require a new grounding grid

• Add grounding grid for SFC #4 switchyards and connect to existing grounding grid system.

• Add ground mats for new outdoor switches.

60. 25 Hz Transformer Combination of oil retention, wing walls, deluge, foundations

Traction Power, Structural, Plumbing

• If a vendor's transformer does not fit in the existing area, then additional work beyond the present scope is required.

• New foundations

• New wing walls

• Piles to support a bridge for transformer foundation


No. Area Equipment Discipline Assessment Determined Actions • New deluge

• New oil retention

61. 25 Hz Filter Yard 25 Hz filters and associated equipment

Traction Power • Filters cannot be used with new equipment • Remove filters and their associated grounding switches and instrument transformers. Keep filter foundations.

62. 25 Hz Filter Yard 25 Hz circuit breakers, switches, and instrument transformers

Traction Power, Civil, Structural

• SEPTA does not want to keep the existing SF6 live-tank breakers.

• Existing switches and instrument transformers are functional, but would need to be moved if the SF6 breakers are replaced.

• Replace existing SF6 live-tank breakers with new ABB magnetically operated circuit breakers. Manufacturer to provide input for foundation design.

• Replace disconnect and grounding switches.

• Replace instrument transformers. Ratings to be confirmed by new SFC vendor.

• Replace surge arresters.

• Modify foundations, as required.

• For SFC #4, install new ABB magnetically operated circuit breaker, new disconnect switch, new grounding switches, new surge arresters, and new instrument transformers.

• Grading and drainage for SFC #4 equipment.

63. 25 Hz Filter Yard Control cables between SFC building and equipment

Traction Power • Control and instrumentation cables are associated with the filter instrument transformers and circuit breaker control

• Remove cables that are abandoned

• Add new control cables for new SFC #4 ABB magnetically operated circuit breakers and instrument transformers

• Remove instrument transformer and grounding switch control cables in filter yard. Use spare conduits to run new control cables to SFC building to new interface panels near the SFC vendor control equipment.


No. Area Equipment Discipline Assessment Determined Actions 64. 25 Hz Filter Yard Power cables

feeding SFC output transformers

Traction Power • Cables are routed from 25 Hz output transformers to open-air bus, then to output breakers, then through duct banks to 25 Hz traction power substation.

• Keep all 12 kV, 24 kV, and rail return power cables, unless new 25 Hz transformers require different cable lengths.

• Keep open-air bus and existing cable riser locations.

• Keep existing rail return bus located next to each open-air bus (previously used for connecting filter).

• Install new duct banks from new 25 Hz SFC #4 output transformer to 25 Hz circuit breaker, then a new duct bank to 25 Hz traction power substation with new cables.

• Install new rail return bus located next to new open-air bus for SFC #4 (to be similar to other units and to provide a point to terminate a filter should ever there become the need).

65. 25 Hz Filter Yard Grounding Electrical • The new SFC #4 area will require a new ground grid

• The replace circuit breakers and associated equipment will need new ground grid

• Add ground grid where required (where personnel will operate switches, breakers, or touch metal objects such as transformers and fences)

• Add ground mats at disconnect and grounding switches.

66. 25 Hz Traction Power Substation

SFC #4 Equipment Traction Power • The new SFC #4 will be routed to a new transfer bus in the 25 Hz traction power yard.

• Add power cable connections to transfer bus.

• Add disconnect switch

• Add structure to support cables.

• Add surge arresters.

67. 25 Hz Traction Power Substation

Protective relaying Traction Power • A new protective relaying zone will be created for the SFC #4 feeder.

• Add new current transformers (CTs) to 25 Hz traction power substation bus and around new ABB magnetically operated breaker (CTs come with new breaker).


No. Area Equipment Discipline Assessment Determined Actions • Add new protective relay in 25 Hz traction power

substation control house.

Reference: Emails from D. Ferrante (SEPTA) to B. Swartley (STV), 1/22/16, 1/28/16, 7/11/16, 7/13/16, 7/19/16.