SECTION 14310, ESCALATOR REHABILITATION

PART 1 - GENERAL
1.01 SUMMARY
A. This Section specifies the requirements for the rehabilitation of various Escalators located
throughout the Washington Metropolitan Area Transit Authority (WMATA) system. Work
performed under this Section will provide rehabilitated escalators complete and ready for use in
compliance with all applicable Codes and the requirements of this section.
The Authority retains the ability to make schedule changes as delineated in the Contract
Documents.
B. The general extent of removals, furnishing/installation, and additions of equipment and
components for the existing escalator rehabilitation is described in 1.02 General Description of
Escalators to Be Rehabilitated and 2.03 Construction Features herein. This specification
describes work for each aspect of the rehabilitation.
C. The following definitions apply to work of this Section:
1. Provide: to furnish and install, complete for safe operation, unless specifically indicated
otherwise.
2. Install: to erect, mount and connect complete with related accessories.
3. Supply: to purchase, procure, acquire and deliver complete with related accessories.
4. Work: labor and materials required for proper and complete installation.
5. Wiring: raceway, fittings, wire, boxes, and related items.
6. Concealed: embedded in masonry or other construction, installed in furred spaces, within
double partitions or hung ceilings, in trenches, in crawl spaces or in enclosures.
7. Exposed: not installed underground or concealed as defined above.
8. Indicated, shown or noted: as indicated, shown or noted on drawings or as specified.
9. Similar or equal: of base bid manufacturer, equal in materials, weight, size, design and
efficiency of specified product, conforming to acceptable manufacturers approved by WMATA.
10. Reviewed, satisfactory, accepted, or directed: as reviewed, satisfactory, accepted or directed,
by or to Owner.
11. Substantial Completion: The point at which the escalator is ready for use, whether the site is
finished or not. This is normally where the work has been certified as ready for the
jurisdictional inspection to take place.
12. Final Acceptance: The point at which the owner accepts the escalator project as being
complete, including all submittal requirements. This may be at a different point than
Substantial Completion.
13. Interim Maintenance: Maintenance from the point of substantial completion but prior to
revenue service.
14. Beneficial Use: When the escalator is placed into use prior to revenue service.
15. Revenue Service: When the escalator is placed into use by the riding public.
16. Notice to Proceed (NTP): within this document shall mean the date on which the escalator
contractor is notified to proceed with the project.
17. Authority having Jurisdiction (AHJ): as defined by ASME A17.1.
1.02 GENERAL DESCRIPTION OF ESCALATORS TO BE REHABILITATED
A. The general extent of the work for the escalators to be rehabilitated includes the removal,
replacement or refurbishment of existing escalator components; the cleaning of the truss; new
controller and control wiring; installation of code upgrades and other major item replacements as
indicated in these specifications. The general extent of the work is as follows, specific
requirements are included in Part 2:

1. Control Equipment - Provide new programmable logic controller (PLC) based control system
as required to suit the existing escalators; brake controllers and variable frequency drives
shall be in the same location as the main controller. Control locations for each unit shall be
installed in one of the location options as noted in Section 2.03.L.1.b.
2.

Wiring and Conduit - Furnish and install new machine room and wellway wiring and conduits.
Furnish and install new junction boxes in escalator machine rooms and pits. All existing
operating and safety switches shall be replaced, upgrade to provide all switches required by
applicable code as well as additional switches and devices noted herein. Provide lighting as
specified.
3. Electrical Supply - Reuse existing power supply 480V, 3 phase, 60 cycle, AC. Provide light &
signal 120V, 1 phase, 60 Hz disconnect. Provide new disconnect for escalator pit lights and
receptacles. Comply with requirements of the governing ASME A17.1 code and the National
Electric Code. Contractor to field verify existing electrical supply and notify the Authority
Representative of any remedial work required by other WMATA departments. Sufficient
notice shall be given to the Authority Representative to allow work to be scheduled and
completed prior to scheduled turnover of equipment.
4. Miscellaneous - Furnish and install new steps, floor plates, pit stop switches, top and bottom,
pit and machine room lighting fixtures and GFCI receptacles to meet current code. Furnish
and install new drive components including rack and axle, drive chains, motors, brakes,
reducers, drive and idler sprockets. Furnish and install new handrail and handrail drive
components. Removal of all abandoned equipment and testing for compliance to Code and
contract requirements as indicated.
5. Cleaning and Painting - The contractor shall disassemble each escalator including balustrade
panels, skirts and steps and thoroughly clean the entire unit, including the truss, pan and
entire wellway. Rusted and unpainted areas of truss shall be treated with proper corrosion
protection. Truss, tracks and pans shall be pressure washed.
6. Environmental Requirements - All furnished escalator equipment, including junction boxes,
shall be designed to operate while exposed to the natural elements of weather, including
sunlight, rain, slush, snow and ice; all conditions of relative humidity while exposed to salt,
de-icing chemicals, airborne dust, and debris, and corrosive elements; and in a dry bulb
temperature range of minus ten (-10) to plus one hundred and five (+105) degrees
Fahrenheit.
B. Other Identified Work Items: All work described herein shall be the responsibility of the escalator
contractor and provided by the escalator contractor or its approved subcontractor. This work is
part of the specifications and contract. All work identified by the Open and Inspect process (see
3.01 C.) shall be the responsibility of the escalator contractor.

1.03 DESIGN AND PERFORMANCE REQUIREMENTS

A. Compliance: Design, fabrication and performance shall comply with all the latest applicable
provisions of the Codes, Standards and recommendations of the entities listed below.
1.
Codes: Work in this Section shall comply with all governing local codes including, but
not necessarily be limited to ASME A17.1, National Electrical Code, and Board of
Standards including all "Local Laws," and cited reference standards, appeals rulings
and standards.
2.

Standards: Except as modified by governing Codes and by this Section, Work shall
comply with the latest provisions of the following:
a.

ASME A17.1 Safety Code for Elevators and Escalators. Contractor shall
comply with the requirements of the local authority having jurisdiction.

b.
c.
d.
e.
f.
g.
h.
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w.
x.

The minimum code shall be ASME A17.1 2000 unless specifically

prohibited by the AHJ.
ASME / ANSI A17.2 Inspectors= Manual for Elevators and Escalators.
ANSI A117.1 Standard on Accessible and Useable Buildings and
Facilities.
ADAAG Americans with Disabilities Act Accessibility Guidelines for
Buildings and Facilities.
International Building Code (IBC).
ASTM-A446 Steel Sheet, Zinc Coated (Galvanized) by the Hot-Dip
Process, Structural (Physical) Quality.
ASTM-B221 Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire,
Shapes and Tubes.
ANSI/AWS- Structural Welding Code, Steel. D1.1
ANSI/NFPA 70 National Electrical Code.
ANSI/NFPA 80 Fire Door and Windows.
UL 10B Fire Tests of Door Assemblies.
APA American Plywood Association.
ASTM A36 Structural Steel.
ASTM A167 Stainless and Heat-Resisting Chromium-Nickel Steel Plate,
Sheet, and Strip.
NEMA LD-3 High Pressure Decorative Laminates.
UL 486 Crimp Tools.
ASTM E152 Fire Tests of Door Assemblies.
FS-L-P-508H Plastic, Sheet Laminated, Decorative, and Nondecorative.
FS-QQ-S-698 Steel Sheet and Strip, Low Carbon.
NEII National Elevator Industry, Inc.
NFPA 130 Standard for Fixed Guideway Transit and Passenger Rail
Systems.
APTA American Public Transportation Association Heavy Duty Escalator
Design Guidelines.
ANSI Z97.1 Safety Glazing.
All other specific provisions cited herein.

B. All of the escalator equipment and upgraded components shall be designed, constructed,
installed and adjusted to secure performance in accordance with current applicable codes and
within the manufacturer's design standards with respect to smooth, quiet, convenient and efficient
operation, durability, economy of maintenance and operations, and standards of safety.
C. The system voltages stated are the rated voltages at the main line disconnect switches located in
each machine room and are subject to fluctuations with demand. The escalators shall operate
successfully with any load up to Contract load at any voltage not more than 10 percent above or
below the rated system voltage
D. The speed of the escalator shall not exceed 90 feet per minute (FPM). Deviations in speed
between no passenger load and full passenger loads shall not vary +/- 4% of the rated speed.
E. Escalators shall operate at or below a 65dBA measured five (5) feet above the escalator at any
location, with the escalator operating normally, either free running or under load. Noise
measurements shall be made with only one (1) escalator in operation, but with the entire
installation complete and in operating condition, for projects with multiple escalators. Sound levels
shall not be measured with ambient levels exceeding 49dBA. All sound tests will be conducted by
WMATA at the Authority Representatives discretion.
F. Hours of operation shall be considered as twenty-four (24) hours per day; seven (7) days per
week and for the operating, loading and environmental conditions encountered in extensively
used, rail transit systems and shall have a minimum design life of twenty (20) years.
G. Contractor shall provide non-combustible materials for all new components as defined in ASTM A

136 throughout, with the exception of, handrails, handrail rollers, chain step wheels, and electrical
equipment.
H. Contractor shall ensure that installed heat and smoke detecting devices operate and
communicate as required by governing code, and any additional WMATA requirements, with the
new controller and associated equipment. Contractor will verify interaction of escalator related fire
protection system and its interaction with the escalator and related equipment. Contractor shall
assist WMATA in all acceptance testing for these systems.
I.

Contractor shall field verify all dimensions and fabricate replacement parts to fit existing
conditions. The architectural features of each station shall be maintained and the finish of any
modification shall match the existing finish unless otherwise modified by the Authority
Representative.

J.

Alterations of any structures or of electrical or mechanical systems necessary to accommodate

the escalator installation and maintenance, such as cutting of walls, floors, and repairs as
required, or augmenting, increasing capacities of, or relocating system components, shall be
submitted to the Authority Representative for approval and such work performed by the
Contractor at no additional cost to the Authority.

K. Escalator vibration levels shall not exceed a maximum velocity reading of four-tenths (0.4) of an
inch per second root mean square (RMS). Testing shall be provided using a Fast Fourier
Transform (FFT) analyzer. Measurements shall be taken on the escalator at points designated by
the Authority.
L. These specifications are not to be construed as supplanting any code requirements.
M. In the event of a conflict between codes, regulations, these specifications or standards, the most
stringent requirement as determined by the Authority Representative shall take precedence
unless specifically addressed herein.
1.4 QUALITY ASSURANCE
A. Previous Use: Equipment, systems, and components as specified herein, shall be manufactured
by firms regularly engaged in manufacturing escalator equipment, which have been satisfactorily
used for purposes similar to those intended herein for not less than ten (10) years.
B. Contractors Experience: Work of this Section shall be performed by certified IUEC escalator
mechanics and mechanics helpers supervised by the constructor. All mechanics and supervisory
personnel shall have a minimum ten years experience involved with the installation and/or
rehabilitation/modernization of passenger escalators and shall be specially trained and have
thorough experience in the model of escalators being installed. Qualifications of the Contractors
supervisory personnel and mechanics shall be submitted to WMATA for review and approval.
C. Provide three (3) copies of and describe the Corporate Quality Manual (QM) and Quality
Management System (QMS), including proposed technical design teams QA / QC program, and
a listing of recent projects on which it has been used. If modified to be project specific, provide
how changes were made to conform to the project. Include a copy of an approved QA / QC Plan
from another recent project of similar size and scope. All copies provided to WMATA shall be
signed by the highest level of corporate management.
D. The Corporate Quality Manual provided by the Contractor will be reviewed and evaluated for
inclusion of specific quality management practices and requirements necessary for the successful
completion of all phases of this project. Theses phases include design stages, construction
specialties as well as start up, commissioning and handover to WMATA. Contractors plan must
address the implications and operations of the Quality Manual and its integration with the Quality
Assurance Operations performed by the Authority. The plan must also clearly state that
subcontractors, vendors and suppliers are responsible to the Contractor for all quality control
matters and indicate how deficiencies shall be monitored and tracked for correction to completion.

Provide a detailed explanation of how the Contractor intends to manage the QA and QC
programs of the multiple subcontractors, vendors and suppliers expected to be performing on this
project.
E. Contractors must indicate that their auditor conducting QA / QC reviews will be Lead Auditor
trained. An audit plan shall be provided which indicates the intervals when audits and
surveillances will be conducted. This will include the prime contractor, subcontractors, vendors
and suppliers. The Authority will evaluate the personnel and qualifications of the individuals
performing in the Quality Management System under the Management Resources factor during
the RFP.
F. Provide three (3) copies of the last five (5) years of Management Reviews conducted on the
Quality Management Systems implemented by the Contractor. The Contractor may wish to
include a copy of internal audits and surveillances that demonstrates commitment to their Quality
Management Policy and any other documents that demonstrate Managements commitment to
quality.
G. Contractors shall provide sufficient details to demonstrate their knowledge and understanding of
the application of the concepts in ISO 9001:1994, or 2008.
H. The Contractor shall provide three (3) copies of any training records related to quality for the
proposed project team members.
I.

In addition to the requirements indicated above, the Contractor shall comply with the following:
1. Escalator equipment shall be installed by the escalator manufacturer.
2. All subcontractors shall be submitted and approved by WMATA.
3. The Contractor shall obtain all permits and licenses and perform all required work and
inspections. Permits shall be obtained prior to the start of each escalator and a copy of each
permit shall be provided to the Authority.
4. All Contractor/subcontractor field personnel shall wear uniforms at all times clearly displaying
the companys name. Uniforms are allowed to be any color except blue.

J.
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9.

In addition to the codes and standards listed in Article 1.03, the following standards, guidelines
and regulations shall be used to establish a minimum level of quality:
American Institute of Steel Construction (AISC).
American Iron and Steel Institute (AISI).
American Society for Testing and Materials (ASTM).
American Wire Gauge (AWG).
American Welding Society (AWS).
Environmental Protection Agency (EPA).
Institute of Electrical and Electronic Engineers (IEEE).
Insulated Cable Engineers Association (ICEA).
National Institute of Standards and Technology (NIST).
10. National Electrical Manufacturers' Association (NEMA).
11. National Electrical Safety Code (NESC).
12. National Fire Protection Association (NFPA).
13. Occupational Safety and Health Act (OSHA).
14. Society of the Plastics Industry (SPI).
15. National Association of Architectural Metal Manufacturers. (NAAMM).
16. Underwriters' Laboratories, Inc. (UL).
17. United States Department of Transportation (DOT).
18. Federal Transit Administration (FTA).
19. European Standard EN115 (EN115).
20. Military Specifications (MIL).
21. American Public Transportation Association (APTA).

1.05 DELIVERY, STORAGE AND HANDLING

A. Work shall not commence on site on any unit until all parts and materials to perform that
modernization are in the Washington DC Metro Area. The WMATA stations will continue in
operation during the execution of this Contract and the Contractor shall cooperate with the
Authority Representative in scheduling the work. The Contractor shall carry on its work in such a
way as not to cause interruption of or interference with the operations of the stations except for
the escalators under renovation.
B. Delivery: Materials shall be delivered ready for use, in the approved manufacturers original and
unopened containers and packaging, bearing labels as to type of material, brand name and
manufacturer=s name. Delivered materials shall be identical to approved products and samples.
Availability and use of WMATA work trains is not guaranteed and their use shall not be a part of
contractors delivery and project completion schedule.
C. Storage: Materials shall be stored under a cover in a dry and clean location, off the ground.
Delivered materials which are damaged or otherwise not suitable for installation, shall be
removed and replaced with acceptable materials at no additional cost to the Authority. On site
staging/storage of materials is not guaranteed.
D. Floor Loading: Do not load or permit any part of the structure to be loaded with a weight that will
endanger the safety of the structure. The maximum floor loading shall not exceed 150 lbs per
sq/ft. Contractor shall be responsible for any damage caused by its operations to the curbs,
sidewalks, to the building interior and exterior surfaces, and to equipment.
1.06 SUBMITTALS
A. Prior to performing any Work of this Section submit to the Authority Representative for approval,
evidence of experience and membership as stipulated in 1.04 B. and I. herein; and evidence of
prior use and similar installations as stipulated in 1.04 A. and I herein.

B. General: Drawings and specifications shall be submitted for each escalator for all new designed
or modified parts and equipment. The submittals shall be in electronic format. A submittal log of
format and content acceptable to the Authority shall be used to track and document all submittals
required in this section. Within sixty (60) days of award submit an electronic copy of the following
in accordance with this section, the GENERAL PROVISIONS and the SPECIAL CONDITIONS:
1. Product Data: Submit the names and addresses of the manufacturers, together with catalog
information or other identifying description for all items listed in this section and all other parts
or equipment that this specification indicates that a submittal is required. The Contractor shall
submit the necessary Material Safety Data Sheets (MSDS) for all lubricants, sealers, paints,
solvents and any other potentially hazardous substances shall be submitted for approval by
WMATA.
2. Submittals: Submit shop drawings to WMATA for approval. Drawings shall show material
type and gauge, general dimensions, methods of attachment, location and size of
reinforcements and openings, and a general arrangement of components with complete
information concerning the material, articles and/or design proposed for use in sufficient detail
to show compliance with the specification including:
a.

b.

c.
d.

e.
f.
g.

h.

Equipment details, layout and elevations of external cabinets for remote

controller locations, including bill of materials showing both new and
existing equipment, remote piping diagrams, power requirements,
equipment operation description and all other Work which is required to
achieve successful completion of the Work described herein.
Layout of electrical system including motor, control panel, diagnostics
monitoring, disconnect switches, demarcation lighting, grounding and
control devices. Schematic diagrams including single-line power diagram
of the escalator system, control wiring diagram and sequence of
operation, indicating interface connections with WMATA Fire and
Intrusion Alarm (FIA), KIOSK, and Remote Monitoring System.
Schematic Wiring Diagrams of control and power wiring for review.
Schematics shall reflect as wired, point-to-point connections, and shall
indicate color code and terminal/junction/wire identification numbering.
Complete schematics of all internal components and for external devices
showing wiring down to the lowest replaceable component. Include
complete wiring diagrams with new conduit, sizes, and conductor
identification.
Written description of the mode and sequence of operation.
Drawings and technical data for machines, motors, motor drives, control
system and controller, safety devices, and switches. Include power
requirements and equipment heat release information.
Working drawings showing material, configuration, arrangement, and
dimensions for chains, steps, rack and axle, and handrail drive assembly.
Exploded view drawings shall be included to facilitate repair and
maintenance functions.
Spare Parts List: List all spare parts with recommendations for critical
items that should be stocked.

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The escalator manufacturer will provide certification, in writing and

signed by an officer of the organization, that the owner of the escalators
shall be provided with copies of any and all information, correspondence,
bulletins, newsletters, manuals, techniques, procedures, drawings,
sketches and any other documents related to maintenance, safety,
operations, design changes, modifications, retrofits, etc., which relate to
any part, component, equipment, system, subsystem or material and
services applicable to the escalators provided.
Work Area Protection Plans: The work area protection plans shall be
provided as part of the Site Specific Work Plan (SSWP) for each station
by the Contractor for review no later than six (6) weeks prior to start of
demolition. Protection plans shall clearly indicate partition systems
planned for demolition and installation phases of the project, including
planning for escalator entry and egress during handling. Plans shall
include finish details for elements exposed to the public. Partitioning
system shall include lockable access doors to prevent access to the work
area by the public. Applicable work area notification/warning signage
shall be provided by the Contractor. Signage shall be approved in size
and design by Authority prior to use. Partitioning plans shall be designed
to withstand applicable wind loads applied to the station entrance areas
as required by local building Code.
Product data sheets, working drawings and documentation indicating
installation compliance with applicable code for skirt deflection devices.
One (1) piece of sample product containing attaching hardware and all
components of system attached to a sample of skirt of type used in units
under modernization.
Any additional information and samples that are indicated in this
specification as needing approval and submission to ELES Engineering
or ELES Project Manager.

All of the above referenced shall be provided as it pertains to the original installation and for a
period of ten (10) years after final acceptance of the last escalator provided. The reference
material shall be provided within thirty (30) days of publication or internal distribution by the
escalator manufacturer. The material, even if labeled PROPRIETARY, shall be delivered to the
Authority without prejudice or delay and at no additional cost.
C. Operations & Maintenance Manual: Prior to the execution of work submit two (2) copies of the
following manuals to the Authority Representative for review. After approval and prior to the return
to service of the first completed unit, submit ten (10) bound manuals and two (2) flash drives with
electronic versions of the manual.
1.

Manuals shall be bound and indexed providing operating, trouble-shooting and

maintenance instructions, parts listing; recommended parts inventory listing, purchase
source listing for major and critical components, emergency instructions, and similar
information. Maintenance instructions shall include lubrication and periodic maintenance
requirements and schedules. Parts list and purchase source listing shall include electrical
and control equipment. Manuals shall also include approved drawings and catalog cuts,
folded if necessary. Manuals shall include information on maintenance/replacement
cycles and design life expectations.
Adjusters Manual: Provide the contractors adjusters manual, the manual shall provide
step by step procedures for calibrating and adjusting all equipment operations and
including any printed circuit boards. Manuals shall comply with the requirements of this
section, the GENERAL PROVISIONS and the SPECIAL CONDITIONS.
a. All covers shall be resistant to oil, moisture, and wear commensurate with their intended
use. Diagrams and illustrations shall not be loose or in pockets. All printed material shall
be capable of being reproduced on dry copying machines.

b. Each escalator shall be treated as a whole and not as a group of disassociated parts. The
material in the wiring diagrams shall be organized and indexed by the escalator
classifications included in this Contract. All manual sections shall be sub-divided, to the
extent required by the subject matter, and shall include, but not necessarily limited to the
following topics:
i.

General system or sub-system description and operation

ii.

Block diagrams

iii. Functional schematics

iv. Functional wiring diagram
v.

Lubrication and cleaning, including frequency, methods, and trade identifications of

recommended materials

Identifications of recommended materials

ii.

Component location and description

iii. Inspection and maintenance standards including wear limits, settings, and tolerances
iv. Installation and removal sequence
v.

Test and evaluation procedures.

vi. Spare parts lists and special tools.

c.

The detailed contents of sealed assemblies need not be displayed but their functions
must be explained and the appropriate operational specification characteristics listed as
well as procedures for test and replacement.
i. Operations & Maintenance manuals and wiring diagrams shall contain all the
information needed to operate and maintain the escalators. It shall include general
familiarization material; location, function, and operation of all controls, gauges,
indicators, and switches; emergency procedures; and trouble diagnosis methods.
ii.
iii.

The manual shall be logically organized with systems

and elements considered in descending order of importance.
The Operations & Maintenance manual and wiring
diagrams shall provide, in convenient form, all the information needed for servicing,
including lubrication, inspection, running, maintenance and adjustment, and on-line
trouble diagnosis.

d. Repair and Maintenance section shall contain a complete functional description of each
component of the escalator likely to require repair and complete procedures for the repair
and overhaul of the escalator and all components.
e.

Parts section shall enumerate and describe each component with its related parts,
including the supplier's part number, the escalator Contractor's number, and commercial
equivalents, and provision for entry of the Authority number. Cutaway and exploded
drawings shall be used to permit identification of all parts not readily identified by
description. Parts common to different components, e.g., bolts and nuts, shall bear the
same escalator Contractor's number with a cross-reference to the other components of
which they are a part. Each part or component shall be identified as being part of the next
part of the next larger assembly or sub-assembly. Four (4) copies of sample formats and

outlines of manual and catalog material shall be submitted for approval at least six months
prior to the date of acceptance testing of the first escalator. Comments will be returned to
the escalator Contractor within 30 days of submission. No changes shall be made without
the knowledge and prior approval of the Authority Representative.
f.

Manuals shall include the following data:

i. Table of Contents
ii. Escalator contractors name, address and telephone numbers with similar data for its
24-hour service organization
iii. Manufacturer's name, address and telephone number, with similar distributor and
data for its local representative or service agency
iv. Catalog, model and serial number of equipment installed. Include WMATA unit
numbers where applicable.
v. Description of equipment
vi. Statement of warranty as specified
vii. Description of modification, service and repairs performed prior to start of warranty
viii. Dates warranty begins and expires
ix. Standard starting, stopping and operating
operation

procedures for escalator sequence of

x. Emergency and special operating procedures

xi. Routine maintenance procedures
xii. Servicing and lubrication schedule
xiii.

Manufacturer's printed operating and

instructions, manufacturer's parts list, illustrations and diagrams

maintenance

xiv. One copy of each wiring diagram

xv. List of spare parts, prices and recommended stock quantities for routine maintenance
of the equipment for one year and list of spare parts that are considered critical and for
which extended time frames for acquisition would create undesirable down-time for
the equipment. Submit listing 90 days prior to completion of contract work
xvi. List of special tools required to perform inspection, adjustment, maintenance and
repair. Special tools are those developed to perform a unique function related to the
particular equipment and are not available from commercial sources. One set of all
special tools shall be provided for each escalator.
xvii. Copy of each approved shop drawing of the equipment and system. Include drawings
which show outline dimensions, weights and assembly data; do not include drawings
which show manufacturing details.
2. Operating instructions shall be printed or typewritten literature describing the function and
operation of all controls including pictorial illustrations where applicable.
3. Maintenance instructions shall be printed or typewritten schedules describing all required

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maintenance procedures for each escalator.

4. Wiring diagrams shall be full size, ladder type, complete "as-built" wiring and single line diagrams
showing the electrical connections, functions and sequence of operation of apparatus connected
with each escalator, both in the machine room and in the hoist way, shall be furnished in duplicate
for each escalator. After approval, a copy of each shall be plastic or laminated, framed, and
mounted in each escalator machine room. A reproducible .003 mil Mylar set of wiring diagrams for
each escalator shall be delivered to the Authority Representative. Coded diagrams are not
acceptable.
5. Lubrication Chart: After approval, one plastic or laminated and framed lubrication chart for each
escalator shall be furnished and mounted as directed in each escalator machine room. Chart
shall identify lubricants as well as lubrication points and required frequency of application.

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6. Record Drawings (As-Builts): The Contractor shall maintain at the construction site, one (1) set of
full size approved drawings. As work progresses, drawings shall be marked to show all deviations
which have been made from the Drawings, including buried or concealed construction and utility
features which are revealed during the course of construction. These drawings shall be available
for review by the Authority Representative at all times and shall become the property of the
Authority and be turned over to the Authority Representative at completion of the work for each
escalator. Provide in both a red-line hard copy and provide a corrected copy in electronic format
(flash drive). Both copies shall be stamped and signed as Certified As-Builts.
7. Keys: Provide a set of keys for every three escalators rehabilitated.

8. Accessories: Provide all special tools and equipment necessary for making all system
adjustments to the signal and speed controller and other equipment. NO SPECIAL TOOLS WITH
DECAYING CIRCUITS OR CLOCKS ARE PERMITTED.
9. Spare Parts: Provide the Authority with spare parts valued at 6% of the contract award. The list of
spare parts will be provided to the Authority Representative after submittals are approved.
a.

This provision requires the Contractor to furnish a list which identifies spare parts
which are required by the Contract, or any modification to the Contract, and
those additional spare parts recommended by the escalator Contractor. Submit
electronic copies of this list.

b.

The Contractor shall deliver to the Authority a list of spare parts. The list shall
contain each spare part or assembly required by the Contract, and those
recommended for stocking by the Contractor. Submit hard copies and electronic
copies on flash drives. Items on the list shall be grouped by system and
subsystem for stocking identification and the list shall contain the following
information for each item listed:
1. Part name
2. Manufacturer's name
3. Model number(s)
4. A blank column for WMATA's part number
5. Contract quantity
6. Manufacturer's recommended quantity
7. Anticipated annual usage
8. Unit price
9. Available packaging
10. Special storage and handling requirements

c.

The manufacturer's recommended quantities shall be based upon the following

reliability, usage and lead time considerations:
i.
Wear: Quantity requirements for regular replacement based on usage
and projected mean time between failures.
ii.
Consumables and Expendables: Quantity requirements for items which
are consumed, used up, destroyed, or upon failure, are otherwise made
usable for their intended purpose and are economically unrecoverable
except for inherent scrap value.
iii.
Recoverable or Repairable: Quantity requirements based on the fact that
the component/assembly is capable of being repaired or remanufactured
to a serviceable, operational condition.

12

iv.

10.

D.

Long Lead: Components which are not available from commercial

distributors or manufacturers within 30 days.

d.

Cross referencing: Where spare parts are common to more than one system or
subsystem, include a cross reference and indexing system in the spare parts list.

e.

Non-Unique parts: In all spare parts lists, items which are not unique to the
system and have been manufactured by others shall be identified by the
manufacturer's name and part number, as well as by the Contractor's part
number if any.

f.

WMATA will provide the Contractor with shipping instructions, with WMATA part
numbers for each item the Contractor is required to furnish.

g.

The Contractor shall ship the parts to the locations as directed by the Authority, at
the same time as the counterpart equipment delivery or acceptance by WMATA
of installed equipment. Shipping documents shall identify the Contract number,
manufacturer's part number, quantity, unit price and WMATA part number.

h.

Spare parts shall be properly packaged or crated so as to prevent damage during

shipment and long term storage.

i.

Spare parts shall be the same in all respects as their counterparts furnished as a
part of the assembled equipment to be delivered under the terms of this Contract.

j.

Parts furnished in accordance with this provision are WMATA spares, separate
and distinct from any Contractor obligation to replace parts, components or
assemblies under any warranty provision of this Contract.

k.

Parts lists contained in Operations and Maintenance manuals provided under the
Contract shall include assigned WMATA part numbers.

l.

Parts to be provided shall be based on the criteria described herein and final
approval of the list by the Authority Representative.

Provide copies of the PLC Program on a flash drive, as well as an annotated ladder listing of
the PLC software in hardcopy. Updates shall be provided to the Authority after any updates
are made at no cost.

Engineering Calculations, Test Reports and Certificates: Submit to the Authority

Representative test report and inspection/acceptance certificates for each escalator.
1. Engineering Calculations & Test Reports
a.
b.
c.
d.
e.
f.

Motor Sizing Calculations

Truss Deflection Calculations
Step Chain Tensile Stress Calculations, including factor of safety
Step Chain Pin Pressure Calculations
Truss Support Point Reaction Calculations
Transition curve pressures to support chain systems

2. Certificates
a.
b.
c.
d.
e.
E.

Welding certifications to AWS D1.1

Step Chain Certificate of Breaking Strength
Escalator Test Reports
Step Fatigue Tests
Certificates of calibration for all applicable tools and equipment.

Samples:

13

1. Submit one (1) sample for the following:

a.
b.
c.
d.

Handrail 6 lineal inch length of proposed handrail

Decking 6 inch square sample of proposed decking material
Skirting 6 inch square sample of proposed skirting material
Floor Plate 6 inch square sample of proposed floor plate material

2. Samples shall be clearly labeled to reflect:

a. Project Name
b. Contract Number
c. Description of Sample
1.07 GUARANTEES
A. Notwithstanding the Specifications forming a part of this Contract, any inspection or approval of
the Work by the Authority, or the existence of any patent or trade name, the Contractor
nevertheless unconditionally guarantees that the equipment furnished and installed hereunder
shall be of the best quality and shall be fully fit for the purpose for which it is intended. The
Contractor shall unconditionally guarantee all equipment against defects or failures of any kind,
including design, workmanship and materials for a period of one (1) year after the escalator has
been placed into revenue service. In the event of defects or failures in any component of the
Work of this Section, then upon receipt of notice thereof from the Authority Representative, the
Contractor shall correct such defects or failures by immediately reconstructing, repairing or
making such alterations or replacement of said component in the Work of this Section as may be
necessary or desirable, in the sole opinion of the Authority Representative, to comply with the
above guaranty. If repair/replacement has not taken place within one (1) week of identification of
said defect or failure, Contractor will pay a penalty of two (2) times the material cost of said
component, plus associated labor costs, as charged to the Authority by a supplier.
PART 2 - PRODUCTS
2.01 MANUFACTURERS
A. The original escalator equipment and manufacturer is as follows:
1. Westinghouse Modular 100 & 250 escalators manufactured by Westinghouse Elevator
Company.
2. PS-S-1200 escalators manufactured by Fujitec
3. Transvario escalators manufactured by O&K Escalators
4. E-Series TR escalators manufactured Montgomery Elevator Company
2.02 MATERIALS
A. Stainless steel shall be corrosion-resisting steel complying with Fed. Spec. Q.-S-698, Class 316,
S. S. Condition A finished as specified. For all finishes that are exposed to view, Manufacturing
Standard No.4 with vertical grain shall be used. During erection, all stainless steel surfaces shall
be protected by suitable peel off material.
B. Cold rolled steel shall be low-carbon steel rolled to stretcher leveled standard flatness, complying
with Fed. Spec. Q.-S-698.
C. Rigid Steel Conduit, conduit fittings, and flexible steel conduit shall comply with the current Fed.
Specs for the respective components.
D. Material of the floor plates shall be aluminum having an extruded, grooved, non-slip surface.
E. Material for all tamper proof screws shall be of stainless steel, spanner head.

14

F. Material of connectors or lugs shall be of copper.

G. All fasteners shall be compatible with materials being fastened. Fasteners shall be provided with
self locking nuts or retaining rings (spring washers or toothed disks) and shall be equal to or
greater than the most corrosion resistant material being fastened.
H. Truss corrosion protection: All truss structural material, both new and refurbished, shall be treated
as per 2.03.J.2.
2.03 CONSTRUCTION FEATURES
A. General
1. Unless specifically designated as otherwise, all parts or equipment identified for replacement
shall be new.
2. All welding shall be in accordance with Section 8.8 of ASME A17.1.
3. All electrical equipment, conduit, fittings, wiring and all wire shall conform to the requirements
of the National Electrical Code (NEC) and ANSI/NFPA No. 70 for outdoor locations.
4. Clearance around equipment located in each escalator machine room shall comply with the
applicable provisions of the National Electrical Code.
5. For all rehabilitated work specified, access for all maintenance actions shall be available from
the step area between the balustrade panels, in the escalator pits or from the machine room.
6. Design and construction of the equipment and parts subject to wear shall be such that similar
devices provided will be completely interchangeable. Working parts shall be accessible for
inspection, servicing and repair. Adequate means shall be provided for lubrication of all
wearing parts that require lubrication.
7. On parts of equipment subject to wear and requiring periodic replacement, provide key and
seat, nut, screws, or other removable and replaceable type mechanical fasteners. Such
replacements shall not diminish original structural integrity. Use of rivets or similar type
fasteners requiring physical deformation during field positioning will not be permitted. All
gaps and running openings that resulted due to the contractors rehabilitation work shall be
properly closed by the use of polyurethane sealant as specified or other approved means
installed in accordance with the manufacturers' instructions.
8. Components and materials, except for handrails and step wheels, shall be noncombustible
and shall meet the requirements UL-94HB. The equipment shall be quiet and smooth
running and be capable of withstanding exposure to the weather and the operating conditions
hereinafter described.
9. Surface irregularities, sharp edges, gaps, or protrusions in public and maintenance areas will
not be permitted.
10. All wiring and wire shall be Underwriters Laboratory approved, stranded Type THHW, in
accordance with the requirements of the National Electrical Code; the minimum size
permitted shall be No. 18 for control wiring and No. 12 for all power and lighting circuits. PVC
insulated wiring is not permitted. The wires shall be installed in wire raceway with approved
outlet boxes, except that a small amount of flexible conduit may be used where conduit is not
subject to moisture or embedded in concrete. Terminal boxes, pull boxes and other similar
items shall be of approved substantial construction, thoroughly reinforced, and in no case
less than No. 12 USSG for larger boxes. All electrical boxes exceeding 150 cubic inches shall
be supported independently of the conduits. All boxes shall be NEMA 4X, Vynkier, Inc. or

15

approved equal. All conduits shall be rigid galvanized, all joints shall be threaded. All flexible
conduits shall be liquid tight with approved fittings with a maximum length in accordance with
Code requirements.
11. Nameplates: Each major component of equipment shall have the manufacturers name, type,
class or catalog number on a metal plate securely attached to the item of equipment in a
conspicuous location. No nameplates shall be visible to the public.
B. Balustrades, skirts panels, and decking
1. Balustrades:
a. Balustrade panels shall be retained for reuse. Solid balustrade panels shall be
reoxidized (bronze) or cleaned and polished (stainless steel) prior to reinstallation.
Solid balustrade panels shall be pinned (every other panel) to prevent slippage.
New rubberized padding and micara pads shall be provided to prevent edges of glass
from slidding and coming into contact with adjacent panels. All balustrade panel
joints shall be aligned and adjusted to eliminate gaps, irregular joints and sharp ends.
Panels shall be inspected as outlined under Section 3.01 and defective panels shall
be identified for replacement. Replacement shall be as directed by the Authority
Representative.

16

2. Skirt Panels:
a. Skirt panels shall be reclad and reused. Method of recladding shall be in accordance
with original equipment and be submitted to Authority Representative for approval.
Additionally, skirts shall be inspected as outlined under Section 3.01 and any
defective panels beyond modification shall be identified for replacement.
Replacement shall be as directed by the Authority Representative.
b. Skirt Panel finishes shall be restored to meet the skirt index for ASME A17.1-d 2000.
c.

On solid balustrade units, skirt deflector devices shall be inspected as outlined under
Section 3.01. Devices that are to be replaced shall be manufactured by Kleeneze
Seal Tech Limited or approved equal, shall be provided and attached to the skirts on
both sides of the escalator. Deflectors shall be located and attached to meet all
governing codes and local requirements.

d. The devices shall be securely fastened to the skirt panels or decking. An 8 to 10 foot
skirt brush section shall be installed at the bottom of the escalator on each side to
facilitate the removal of steps for maintenance. The attachment of these brush
sections shall be installed in such a way to allow for multiple removals and installation
without damage to the fasteners. The location of the deflector above the steps shall
be as directed by the manufacturer and within requirements of governing code. The
device shall run continuously between the comb plate lights on each side of the
escalator steps. It shall be attached to the top of the skirt panels at the intersection of
the skirt and balustrade panels and below the continuous strip light on the balustrade.
Devices shall not hinder operation of skirt safety switches. The step nose shall pass
below the ends of the bristles of the brush with clearance per manufacturer's
installation instructions and current code requirements.
e. Top and bottom radial segments with end caps and all fittings for a complete
installation shall be provided. Fasteners for attaching the strips to the skirt panels will
be selected to be appropriate for the skirt panel construction.
3. Decking
a. Decking Panel joints shall be aligned and adjusted to eliminate gaps, irregular joints
and sharp ends. Decking shall be inspected as outlined under Section 3.01 and
defective panels shall be identified for replacement. Replacement shall be as directed
by the Authority Representative. Replacement shall be as directed by the Authority
Representative. Replacement decking shall be stainless steel #4 brush identical to
the balustrade panels and shall be supported on steel frame. Existing steel frame
shall be repaired or replaced as required.
b. Inner newel decking shall be modified to provide maintenance friendly method of
removing and replacing the decking. This should include new design for fastening as
a minimum and shall be coordinated with the code compliant design for the skirt
brushes (see skirt panels above).
C. Step Assemblies
1. The skirt panels and step to skirt gap shall comply with the requirements of ASME A17.1-d
2000 regardless of any previous version of ASME A17.1 in effect.
2. The step assemblies shall be refurbished according to the step refurbishment procedure
provided in Appendix B.
3. If steps removed from units are found to be unusable, Authority will provide a Westinghouse
B Step assembly to the Contractor for use at no cost.
D. Step (Rack & Axles) and Poly Chains

17

1. New rack & axle sections and new poly drive chains shall be provided which shall be
equivalent dimensionally, functionally and be interchangeable with the original equipment
specified.

E. Lubrication System Requirements

1. Stub Shaft:
a. Manual grease fittings shall be placed in an accessible location for periodic maintenance
and lubrication.
2. Miscellaneous Lubrication:
a. Contractor shall furnish and mount on the controller cabinet, a laminated lubrication chart
for each escalator. The chart shall show the location of each lubrication point, type of
lubricant to be used, and the frequency of lubrication.
b. Bearings
1) Sealed bearings shall be used where possible. All sealed bearings shall be enclosed
case bearings.
2) Bearings requiring manual lubrication shall be furnished with fittings to accommodate
the use of a pressure gun for lubrication.
3) Self lubricating bearings shall be approved by ELES Engineering.
4) Material other than ball or roller type bearings may be used where practical.
3. Manual Lubrication:
a. Location of manual lubrication points shall be easily accessible and available.
F. Weather Protection
1. Truss and floor plate heaters previously provided at weather exposed stations shall be
inspected and made operational. New guards shall be added to protect against accidental
contact. A separate circuit, disconnect, and thermostat is to be provided for the heaters by the
escalator installer located in the top pit.
G. Neoprene Joint Filler
1. Lubricant-adhesive:
One-part polyurethane, non-staining to adjacent surfaces, as
recommended by joint filler manufacturer.
2. Joint filler: Preformed polychloroprene or neoprene joint filler, sized for joint as required;
ASTM D2628.
3. Application: Prime and lubricate both sides of joint for adhesion of filler as recommended by
manufacturer. Fill joint continuously with joint filler bonded together to form continuous strip.
H. Sealant and Accessories
1. Primer: As recommended by sealant manufacturer; tested for non-staining and durability
characteristics on samples of actual surfaces to be sealed.
2. Solvents, cleaning agents and similar materials: As recommended by sealant manufacturer.
3. Backup material: Non-staining, compatible with sealant and primer; and resilient, closed-cell
foam sponge rubber, tube or rod stock, ASTM D1056, Class SC-E, Grade SCE 41 for general
use, Grade SCE 44 where sealant is subject to traffic.

18

4. Sealant: Polyurethane; single-component, FS TT-S-227, or two-component, FS TT-S-230;

Type I, self-leveling for joints in horizontal surfaces; Type II, non-sag for joints in overhead
and vertical surfaces. Color shall match color of surfaces being sealed.
5. Application: Apply products in accordance with manufacturer's printed instructions.
I.

Floor Plates and Floor Plate Supports

1. Floor Plates shall be replaced and shall comply with the following:
a.
Shall have 316 stainless steel frames at floor openings, designed to be
supported on truss heads.
b.
Shall be designed to cover entire area of upper and lower landings as indicated.
c.
Shall be reinforced, as necessary, to be rigid and able to withstand a live load of
two hundred and fifty (250) pounds per square foot with deflection of less than
1/16 measured at the center of the span.
d.
Shall be extruded die cast aluminum with a ribbed pattern transverse to the
escalator axis. Ribs shall be designed to provide maximum traction, and floor
plates on exposed units will be covered with applied abrasive covering material
as approved by the Authority. Surface of floor plate shall be properly treated and
prepared to allow adhesion of abrasive material and prevent premature loss of
abrasive covering.
e.
Shall have exposed portions constructed of material and finish to harmonize with
steps and combplates.
f.
Individual floor plate sections shall be lightweight and removable without special
tools or hinges to allow access to machinery and maintenance areas below.
Floor plates shall be fabricated in sections of no greater than seventy-five (75)
pounds. Area around floor plates frames shall be no greater than one-quarter
inch (1/4) and be caulked using Tremco Dymonic FC fast skinning, low modulus
polyurethane sealant.
g.
Area around floor plates shall be inspected and all tripping hazards and/or joint
deflections shall be corrected. There shall be no gaps around or between floor
plates of greater than 1/8 when the plates are secured in place.
2. Floor plate supports shall be inspected, repaired and refinished as necessary to provide
adequate support to meet the requirements of this contract.

J.

Structural Pits and Machine Room Equipment

1. Controllers shall be constructed and located as identified in Section 2.03.L.1.b. Rubber mats,
of solid construction, shall be provided for each electrical enclosure in pit spaces and shall be
3 high and 6 wider than the controller on all sides, shall have beveled edges and shall cover
the entire available workspace within the pit.
2. Truss, Truss Supports and Drip Pans: Truss, truss supports and drip pans are to be inspected
according to Section 3.01. Costs for repair or replacement of any work associated with the
truss or truss supports will be determined after the extent of any repair work has been
identified. The decision to repair and extent of the repair are at the discretion of the Authority
Representative. Entire truss, escalator bearing plates and truss supports shall be treated as
follows:
a.
Rusted areas or areas where the paint has been removed or is deteriorated will
be cleaned of rust and treated with pre primer #167 and Bar Rust 235 primer and
paint by Devoe Paint Company or approved equal.
b.
The escalator truss shall be independently grounded to the nearest structural
steel using 4/0 wire allowing enough slack for any movement of the escalator.
3. Access Doors and Pit Ladder to machine rooms: Access doors and pit ladders shall be
inspected as outlined under Section 3.01. Replacement shall be as directed by the Authority
Representative. New doors and ladders shall be installed and manufactured according to

19

governing code. If retained, all structural steel shall be cleaned and treated as required by
paragraph 2.03 J. 2.a.
4. Machine Room Floors: Machine room floors and walls shall be thoroughly cleaned and all
grease, paint and adhesives completely removed. Floors shall be painted with two coats of
approved paint as selected by the Authority Representative. Final surfaces shall be
compliant with all governing codes
5. Pit Stop Switch, Pit Lighting Fixture & Switch: Provide a new NEMA 4X stop switch for the
escalator in each pit at the point of access to the pit. The switch shall be of an approved type
and design, with a metal guard to prevent accidental operation. Plastic or fiberglass material
of box and faceplate shall not be permitted. When opened, the switch shall cause the electric
power to be removed from the driving machine and brake. Location shall be in accordance to
Code requirements. Switches shall interrupt the power supply and hold the escalator to
permit safe access to the pit for servicing. Fixture shall be as specified in 2.03 W.3
K. Operating and Safety Devices
1. All operating and safety devices required by code shall be provided according to ASME A17.1
code. All existing safety switches shall be replaced with new.
2. A disconnect switch capable of being locked in the OFF position shall be provided in the
same location as the controller for each escalator to prevent the starting of the escalator from
any other location.
3. All safety devices shall be clearly identified and accessible for maintenance within the
escalator. These devices shall be designed for easy adjustment or reset without dismantling
the escalator.
4. If an escalator stops because of a malfunction or actuation of a safety device, it shall be
impossible to operate the escalator until the safety hazard or malfunction has been corrected.
A manual start shall be necessary if the escalator stops for any reason.
5. An EMERGENCY STOP button shall be located according to ASME A17.1 and the Code. It
shall be a momentary contact-type push button. This emergency button shall be housed
under a clear, high impact-resistant plastic cover, which shall be self-closing by means of a
gravity/positive closure cover. The cover shall have clearly printed upon it, EMERGENCY
STOP, in white Helvetica medium-typeface letters. The button shall be red in color and visible
through the cover. The cover shall be provided with a switch to set off an alarm when lifted,
but it shall be necessary to press the STOP button to stop the escalator. The alarm shall be
continuous for five minutes while the cover is lifted or until manually silenced by the key on/off
switch at the operating controls. New fixture cover plate shall match dimensions and finish
balustrade panel.
6. Each escalator shall be equipped with safety devices in accordance with the current
governing Code, any other safety devices appropriate to the specific design . Existing
complate (paddle plate) device may be reused: all other combplate parts shall be new.
Combplate device brackets shall be modified according to drawing and specifications
contained in Appendix A.
a.

A manual locking mechanism shall be provided for each escalator to secure the
step chain (rack & axle) during maintenance.

7. Activation of all code designated manual reset devices and all Authority required devices
listed below, shall interrupt electric power to the individual escalator motor, automatically
apply the brakes and bring the escalator to a stop as required by ASME A17.1 code. These
devices shall be manually reset at the device as well as at the controller. The step upthrust

20

device, skirt switches and emergency stop button shall have overriding reset capability at the
key switch.
8. New step demarcation lights shall be provided at the top and bottom of each escalator.
Lights shall consist of two (2) light fixtures at each end of the escalator which shall be
installed directly below the track system. The fixtures shall be provided with green tinted LED
lamps lighting up the full width of the step separation. The lighting shall be connected to the
controller of each escalator in such manner that the lights will be illuminated only when the
escalator is in operation. Fixtures shall be suitable for corrosive and wet locations.
9. Deteriorated and Missing Roller Detector: Provide a safety device for detecting deteriorated
and/or missing step and axle rollers on the left and right sides while the escalator is running
with or without passengers or load. The roller detector shall be integrated into the safety
circuit. Devices shall be of the manually reset type at the controller.
10. Broken Step Switches: Two broken step switches shall be installed in the top turnaround and
two broken step switches shall be installed in the bottom turnaround in the area of the vertical
step position as provided for in the turnaround mount.
11. Smokes Detectors and Gate Switches:
a.
Existing smoke detectors shall be reused. Escalator shut down shall be in
accordance with ASME A17.1. The smoke alarm system shall be interfaced with
the escalator controller in such a way that upon activation of the smoke alarm,
only entering escalators shall be stopped. Once stopped, escalators shall be
capable of being reversed and started in an exiting direction only. Non-running
escalators shall be capable of being started only in the exiting mode.
b.
Closed gates at the top and or bottom of an escalator shall be interfaced with the
controller to prevent running the escalator. Activation of an override shall be
used to run the escalator in the up direction only.
12.

Replace all existing escalator key operated switches. Each keyed switch shall be clearly
and permanently labeled on engraved metal plates including starting and direction
selection. New key switch assembly bezel plates shall be provided. The change of
direction shall only be possible after the escalator is stopped by the use of the key or
emergency stop button.

L. Control System
1.
Controllers
a.
All controller enclosures shall be NEMA 4X rated, corrosion-proof, drip-proof,
vented and shall utilize continuous stainless steel hinge and three-point fastening
mechanism, Controllers shall include motor starter, control relays, fault indicator,
and all other functions of escalator controls. External lockable fused disconnect
switches between controllers and incoming junction boxes shall be provided. All
enclosures shall be fiberglass reinforced polyester as manufactured by Vynckier,
Inc. or equal. All enclosures shall be provided with strip heaters controlled by a
humidistat mounted within the enclosure. Plug-in type components shall be used
where practicable. Interlocks, wiring terminals, auxiliary contacts, indicating
controls, and safety devices shall be provided as required.
b.

Where specified, controllers shall be housed in external cabinets, furnished and

installed by the contractors, located under the truss incline area below escalator
truss or in a remote location near the escalator. Alternate controller location
configurations are defined as follows:
1.
2.

Machine rooms: Escalators are serviced by a shared machine room that

can be accessed through a hatch at the top landing of the escalators.
Pit: All designations indicating a pit for control equipment shall be located
in the top pit of the escalator.

21

3.
4.

5.
6.

Under escalator center facing configuration: The controller will be placed

in line with and under the escalator truss.
Under escalator piped to overhang: In this configuration the controller will
be placed in line with the escalator but placed at the end of the concrete
structure that supports the truss. This will require extra conduit. Under
overhang will be a stand alone cabinet (area under truss to remain
open).
In all configurations the controller and associated equipment will be
inaccessible to the public.
Doors shall be lockable with a hand-grip locking device with pins located
on top and bottom for both doors. Cabinets shall house the escalator
control components including the variable frequency drive and brake
control. An additional mainline disconnect must also be installed in the
enclosure when the control equipment is relocated from the pit. This
cabinet shall be an aluminum sheet metal cabinet of Metro Brown color
and equipped with lighting, GFCI receptacle and ventilation louvers for
heat removal. Design of structure shall be of sufficient strength and
durability for the application. Forced ventilation will be required if heat
buildup from the enclosed components cannot be removed by natural
ventilation. Contractor shall provide calculations to verify. Cabinet doors
shall be equipped with locking hinges at top to maintain doors in open
position while controller is being serviced. In instances where permanent
modification of railings and/or associated fixtures is necessary to install
controllers the Contractor shall be responsible for all modifications and
adjustments. Contractors design shall maintain existing ventilation
louvers sizes if obstructed or modified. Under truss requires sheet metal
enclosed around all dead space.
Plans and drawings for all
modifications shall be part of the submittal required in section 1.06.B.2a.

c.

Enclosures used in pit areas shall be removable to the floorplate for use in
maintenance and troubleshooting. In pits where space is lacking, smaller
controller boxes can be utilized in lieu of one large controller. Design for
enclosure boxes in pits shall be approved by the Authority Representative prior to
commencing rehabilitation.

d.

Motor drive controls shall be provided by a programmable logic controller and

shall be Allen Bradley SLC 503 PLC with off-line emulation capabilities. Solid
state or printed circuit boards will be acceptable provided diagnostic schematics
and equipment are supplied.

e.

Screw type compression terminal block rated for 20 amperes minimum shall be
used for all power circuits and 10 Amp minimum terminal blocks for control and
indicating lights. All wiring shall be stranded conductors of sufficient current
carrying rating, color coded and permanently identified at all terminations. A
maximum of three wires shall be terminated at any terminal. All wiring jumpers,
taps or multiple wire connections shall be located on a terminal; tee taps, wire
nuts or conductor splices shall not be utilized. All controls shall operate at 120
volts or lower, AC or DC. Control power shall be obtained from integral dry type
control transformers.

f.

All wiring internal or external to the controller shall be stranded copper, matching
existing AWG size or size 18 AWG minimum, moisture resistant, flameproof, and
oil resistant insulated conductors. All terminations at devices and terminals shall
utilize insulated type crimp connectors, terminal strip, phoenix or similar devices.
All terminals shall be identified with wire numbers which correspond to wiring
diagrams. Wiring shall be laced and tied at terminal blocks. All conductors shall
be identified with embossed tubing sleeves at each terminal. All terminations
shall be made within boxes at terminal strips.

22

2.

g.

Power outage reset shall be accomplished using the key switch and shall not
require resetting at the controller.

h.

Five (5) copies of the annotated ladder listing with flowchart of the PLC software
shall be provided in electronic format and in hardcopy.

i.

Controller to include circuits for braking and safety device operation.

Fault Finding Annunciator:

a.
Two (2) fault finding annunciator panels shall be provided for each escalator to
visually indicate the activation of specified safety devices. Both panels shall be
constantly active. One panel shall be located in the controller enclosure and one
at the lower balustrade at a location indicated by the Authority Representative.
The controller annunciator panel shall be an Allen Bradley Panelview 550. For
the balustrade panel a Noritake Graphics Module, EZ Automation Model EZS4M-FS or equal fault code LCD display device shall be installed outside the
truss at the newel end on the right side of each escalator to display the code for
the last fault which occurred on the unit. The fault finding panel sections shall be
identified with respect to each escalator served by the panel.
b.

The fault finding annunciator shall provide the capability to store; (1) 99
activations of any and all safety devices, (2) 99 events of a minimum of 125
different error or event codes, (3) 99 entries of the escalator travel distances in
inches or millimeters after application of the brake(s), and (4) 99 entries of motor
current draw in five minute increments. All data points shall be date and time
stamped.

c.

Stack memory shall be used so that, when full, the oldest data point is
overwritten as new data is accumulated.

d.

Events to be stored include, but are not limited to, internally detected error codes,
operational mode selection, start up, power down, and run direction. The fault
displays shall use definitive word descriptions at the controller with an error code
number provided at the balustrade panel. Annunciator shall only display the root
cause of the shutdown when it occurs.

e.

Software protocols and standard personal computer connection shall be provided

to simultaneously transmit fault finding annunciator data (i.e.; event reports,
safety device activation, exception reporting, and equipment status) to the
Authoritys AEMS central computer, via an RS232 connection using an Allen
Bradley DF1 protocol.

f.

The system shall automatically initiate the transmittal of data when failures occur,
when safety devices are tripped, or when data is requested from the Authoritys
AEMS central computer, and shall continue to transmit until all data is properly
received by the requesting AEMS computer. The Authority will specify all
communications interface requirements for remote retrieval of data. The
Authority will perform final integration with the AEMS system.

g.

The Contractor shall also provide software, connection, and cabling to allow
download and store data from any fault finding annunciator panel to a laptop PC
being utilized at the escalator location.

h.

The Contractor shall provide test plans for approval that shall satisfactorily
demonstrate all functions.

i.

Elapsed time indicators, calibrated in hours shall be provided for each escalator,

23

and shall clock the running time of the escalator.

j.

The CPU module must provide DH-485 and RS-232 communication ports. In
addition, the contractor shall install an Allen Bradley network interface module,
(model 1761-NET-AIC) beside the PLC in the controller and provide 24-vdc
power to the module. RS-232 port shall be left open to be used by the AEMS
Remote Monitoring System.

k.

The Allen Bradley PLC will be used for remote monitoring capabilities into
WMATA established engineering monitoring network. All required coordination
for wiring and programming on the PLC and the DH-485 network, shall be made
with WMATA. Contractor shall pull all remote monitoring cables to the interface in
the escalator controller from the pull box (WMATA provided) in the upper or lower
pit area. Network cable shall be Belden 89842.

l.

The programmable controller shall have one serial port which supports
accessibility to ladder logic and data to the remote monitoring network.
1.

The programmable controller shall have one dedicated serial port which
supports RS-485 signals. It shall be used for driving the fault displays in the
controller and lower balustrades as applicable.

2.

The controller PLC shall use an integrated programming, error checking,

communications setup ladder-type software package that shall be supplied
by the Contractor.

3.

Shall have the ability to communicate with all other models of

programmable controller manufactured by said manufacturer.

4.

Shall have the ability to monitor the status of any processor remotely via
the network.

5.

Provide battery backup of the RAM memory for a minimum of 2 years.

PLC memory and programs shall be retained in non-volatile memory such
as an Allen Bradley 1747-M13 module.

6.

Diagnostics
a.) The processor shall have built-in diagnostics and self-test, such
that each time power is cycled, the processor does a complete
CPU and RAM memory test. Additionally the power-up test will
momentarily light up all diagnostic LED=s to be sure they are
working. A power up test will not be performed if the internal flag
(bit) for Fireman=s Service Phase I is latched. The processor shall
be capable of reporting major and minor fault codes and processor
status information back to the polling master, provided the fault is
not a catastrophic hardware failure where the processor is unable
to power up.
b.)

The processor shall have a built-in watchdog timer to ensure that

all processor program scans occur within the time limit set by the
watchdog timer. The watchdog timer cycle shall be adjustable
from 20 msec to 2.5 seconds in 10 msec increments.

c.) The processor shall have individual LED indicators that are clearly visible and labeled for easy
identification. At a minimum the following indicators must be provided:
i.) CPU is in RUN mode

24

ii.) CPU is FAULTED

iii.) CPU battery is LOW
iv.) I/O points are FORCED and are not under program control
COMMUNICATION channels are active.
7.

8.

Input/Output Modules
a.)

The Input/Output Modules shall be slot type and compatible with the
PLC processor I/O structure. Each module shall be provided with a
removable wiring terminal strip so that modules may be changed
without removing associated wiring.

b.)

Discrete Input Modules: 24 VDC, 16 point input module suitable for

use with input devices. Provide Allen-Bradley Model 1746- IB16.

c.)

Discrete Output Modules: 24 VDC, 16 point output module for use

with 24 VDC output relays. Provide Allen-Bradley Model 1746OB16.

d.)

Analog Input Modules: Converts 8 differential analog signals to

proportional twelve-bit binary values. The module shall accept 4 B 20
Ma signals. Provide Allen-Bradley Module 1746-NI8

e.)

Analog Output Modules: Converts 12-bit binary values to four analog

output signals. The module shall output a 4 B 20 ma DC s signal.
Provide Allen-Bradley 1746-N18.

I/O Chassis and Power Supply

a.)

The I/O Chassis shall be a minimum 10-slot chassis. The chassis

shall accept PLC slot type modules to provide backplane
connections. After the power supply, the first slot shall accept the
Allen-Bradley 1747 5/03 CPU module.

b.)

Power supplies shall provide power to the PLC processors, I/O rack
and I/O modules. The power supply shall be suitable for operation of
120 VAC, single phase power. Power supply capacity shall be a
minimum of 150% of the connected load. Provide Allen-Bradley as
required by the application.

c.)

I/O structure (layout) should be based on the most recent designs to

provide system wide escalator I/O uniformity on all rehabilitated units
and new installations.

d.)

As minimum status, faults and analog data as listed in the table

below for remote monitoring interface shall be available from the
serial port. Some of this data may be available in the tables of data
for the two fault displays:

Signal Description

PLC Input

AC Overload

Brake Wear Limit

Brake Picked Switch

Comments

25

Broken Step

Broken Handrail

Comb Plate Impact

Handrail Entry Guard

Handrail Over/Under Speed

Main Drive Chain

Non-Reversal Switch

10

Skirt Impact

11

Step Level

12

Step Upthrust

13

Gate Switch

14

Missing Step

15

Motor Over-Temperature

16

24 VDC power

17

Balustrade Stop Switch

18

80 % Brake Wear

19

Latch Fault

20

Non-Latch Fault

21

Fire & Smoke

22

Inspection Mode

23

Pit Stop Switch

24

Running Up

25

Running Down

26

Escalator PLC Low Battery

27

Escalator PLC Communication

28

Maintenance Mode

29

Handrail 1 Speed

30

Analog Points

Handrail 2 Speed

31

Analog Points

Drive Motor Current

32

Analog Points

Brake Stop Distance

33

Analog Points

26

Spare

34

Spare

35

Spare

36

M.

Variable Frequency Drive

1. The escalator shall be started and continue to run with drive motor power provided by an
appropriately sized variable voltage, variable frequency AC motor drive with braking resistors
as required for the duty. Motor contactors shall be installed to meet Code requirements when
running off a solid-state drive. Accommodation shall be made to set a second maintenanceoperation speed in the solid-state drive. There shall be no bypassing of the solid-state motor
drive for normal operation or maintenance operation.
2. When on inspection, or normal operation, a test mode shall be provided whereby the control
system variable frequency drive and drive components shall be capable of being set to
various running speeds including overspeeding the escalator by 40%.

N.

Drive Motor(s) and Drive Components

All new drive components shall be provided as described in the following paragraphs. New drive
components shall include reducer shaft and key, split hub and key, stub shafts, stub bearings,
speed sensor, thermal relay, broken drive belt switch arms, broken drive belt switch shaft, broken
drive belt switch roller, broken drive chain switches, drive belts, belt sheaves and taper lock
bushings, vibration shock mounts, brake adapter plates, brake covers, motor adapter plates,
reducer valve, pipe elbow and drain hose.
1. New TEFC drive motors shall be provided.
2. All motors furnished shall be designed, manufactured, and tested in accordance with the
latest applicable standards of ANSI, IEEE, ASTM, and OSHA (Safety and Health Standards,
29CFR1910). All motors shall be rated for continuous duty.
3. Insulation of all windings shall be impregnated and baked to prevent absorption of moisture
and oil. The insulation resistance between motor frame and windings shall not be less than
one megohm. The motor windings shall stand a dielectric test of twice the normal voltage
plus 1000 RMS volts of 60-Hertz, alternating current for one minute. Insulation shall be Class
F.
4. Drive motors installed shall be Baldor Type ECP3770T-4 for 7.5HP and Baldor Type
ECP3774T-4 for 10HP, or approved equal. Motor characteristics shall include: heavy gauge
steel and cast iron frames, ball bearings, inverter spike resistant windings, low-loss electrical
grade lamination steel, three-year warranty, dynamic balancing for vibration no greater than
half the NEMA vibration standard, and have a rated efficiency at full load of greater than 92%
for the 7.5HP and 91% for the 10HP motor.
5. Motor leads in the conduit box shall have the same insulation class as the windings. Motor
lead wire shall be rated 125 C and shall be sized for 105 C at the motor nameplate amperes
at 1.0 Sf per EASA recommendations. Leads are to be numbered for clockwise rotation when
facing opposite the shaft end.
6. Motors shall be provided with a compression type grounding lug, the same size as motor
leads, mounted in the conduit box by drilling and tapping into the motor frame or by a double
ended silicon bronze cap.
O. Inspection and Maintenance Control
1. Provide a new hand held inspection controls not accessible to the general public. It shall
transfer the control of the escalator to inspection operation at each landing in a portable
control station. The number of control units provided shall be one control unit per every three

27

units rehabilitated.
2

Switches shall be manually operated, with 2 positions, labeled INSPECTION and

NORMAL. When in inspection mode, it shall operate the escalator solely under the control
of the constant pressure operating device under maintenance speed. The device shall be
designed so that if more than one inspection transfer switch is in operation and is in the
inspection position, then all constant pressure operating devices at all locations shall be
inoperative. The completion or maintenance of an electric circuit shall not be used to initiate
inspection control.
The constant pressure operating devices shall allow movement of the escalator only by
constant application of manual pressure and be distinctly recognizable from indications on the
device as to the direction of travel. The device shall also be protected against accidental
contact and be located to that the escalator steps are in sight. The device shall have a stop
switch in conformance with A17.1 adjacent to the constant pressure operating device and
have a cord length not greater than 10 feet in length.

4. When operating in inspection mode, all safety devices with the exception of the missing step
device shall be operative.
P. Brake & Brake Control
1. Each escalator brake shall be replaced with a new glide stop brake of the existing design,
Warner part number ER-825ND brake assembly. The brake flywheel and brakeboards shall
be replaced with new. All other brake controls shall be reused. Return old flywheel to
WMATA as retained parts. Brake control box shall be inspected as outlined under Section
3.01 and defective boxes shall be identified for replacement. Replacement shall be as
directed by the Authority. An improved brake system may be substituted with the approval of
the Authority Representative. Brake boxes installed in pits shall be easily removable with
enough cable to be capable of being raised and placed outside the pit area itself.
2. Brake burnishing shall be provided at each escalator start-up, after contract speed is attained,
so that zero (0), one (1), two (2) or three (3) application of the brakes for one (1) second, with
one (1) second between each application of the brakes, is automatically accomplished. The
selection of zero, one, two or three applications shall be made on the controller panel and
shall be by means of a rotary switch which is readily accessible for selection use during
maintenance, repair or inspection actions. Burnishing shall be initially set at one (1).
Q. Reducer(s)
1. New reducers shall be provided which shall be equivalent dimensionally, functionally and be
interchangeable with the original equipment specified for a Westinghouse Mod 100 Escalator.
All reducers shall have a 35:48:1 gear ratio.
2. Existing reducers shall be removed from the site and delivered to the Carmen Turner
Maintenance Facility or as directed by Authority Representative. All reducers must be
drained before leaving the site.
R. Drive and Idler Sprockets
1. New cast iron drive and idler sprockets shall be provided. They shall be accurately machined
and installed to distribute the load evenly on the sprocket teeth and chain rollers and shall
operate smoothly. Sprocket teeth shall be hardened to 35-45 Rockwell specifications.
2. Idler Sprocket Stub Shaft & Channel

28

a.

The idler sprocket stub shaft & channel shall be inspected as outlined under
Section 3.01. If defective, the top and bottom guides as well as the idler shaft
shall be replaced.

S. Tracks
1. Step, axle and horizontal guide roller tracks shall be inspected as outlined under Section 3.01
and defective track sections shall be identified for replacement. Replacement shall be as
directed by the Authority Representative. All track sections shall be adjusted as required to
maintain and correct as necessary, the horizontal and vertical track alignment relative to the
truss centerline. Top and bottom turnarounds shall be replaced. Replacement turnarounds
shall be equivalent dimensionally, functionally and be interchangeable with the original
equipment specified. Hold down tracks shall be provided at the combplate area at both top
and bottom of tracks.
2. Design and fabrication of new track sections to replace damaged track shall retain steps and
running gear safely under load requirements at the normal operating speed.
3. All existing and new tracks shall be supported on trusses to provide accurate alignment and
smooth transition to return stations. The rolling surface of the new track shall match the
existing track dimensions and shall have a smooth and quiet transition. Replacement track
shall be of same type material and be of same hardness as original track.
4. The track system shall be smooth for continuous support of the chain wheels from sprocket to
sprocket. The transition between incline and upper landing level shall be as existing. An
adjustable step chain roller guide shall be installed above the rollers where they pass over a
drive to limit vertical displacement of the step chain rollers on any escalators that do not
already have this feature. This item shall be inspected for addition as outlined under Section
3.01.
5. The new sections of guiding system for the step chains (rack & axle) and step wheels shall be
steel profiles with smooth and even running surfaces, and with the joints cut diagonally to the
running direction. The profiles shall not be welded together at the joints.
T. Handrails
1. All new handrail, handrail guides, guide strips, drive components, drive belts, etc. shall be
provided.
2. New handrails shall be provided and shall be constructed of laminated, steel, wire, mesh or
steel cable reinforced with a Hypalon slider or equal, flexible elastomer material vulcanized
into an integral, non-separating, seamless, smooth handrail meeting the O.E.M. requirements
for the MOD 100 escalators compatible with the handrail drive system to be provided by the
Authority.
3. Handrail color shall be black. Handrails shall have a flame spread rating of seventy-six (76) to
two hundred (200), when tested in accordance with ASTM E 84.
4. All handrail drive wheels shall be provided with suitable bearings of grease sealed type or
provided with ample means for lubrication as approved by the Authority Representative.
5. The handrails, handrail wheels and guides shall be so arranged that the handrail cannot be
thrown out of alignment under normal operating conditions. The Contractor shall take the
necessary steps to ensure the flow to ground of accumulated static electricity, by means of
metallic rollers or other appropriate means installed at appropriate locations to prevent
potential shock at all points along the handrails. New handrail guard boots shall be required
at every handrail entry point.

29

6. Handrail speeds shall be synchronized with step speed so that there is no more than a plus
or minus 4-inch displacement of the handrail with respect to the step in a full run of the
escalator in either direction.
7. All
handrail guides and/or rollers shall be replaced, constructed of material which shall not corrode or pit and
shall minimize frictional wear to the under surface of handrail. On the exposed portion,
guiding shall be by adjustable rollers having sealed bearings, and set in such a way so as not
to cause wear on the handrail.
U. Newel sheaves and rollers
1. Newel sheaves and rollers shall be replaced. Newel sheaves and rollers shall have sealed
bearings that have the provision for retention of lubricant to ensure satisfactory lubrication
and operation.
V. Handrail Drive
1. For solid balustrade units, new posi drive handrail drives, Schindler part number 2-40388-89,
shall replace existing H07 handrail drive units at the ratio of one (1) posi drive unit for each 40
feet of escalator rise. Guides and rollers shall be as listed above.
W. Lighting
1. On all solid balustrade panel escalators, the Contractor shall provide new escalator
balustrade lighting where not previously provided or replace all existing built-in escalator
balustrade lighting fixtures; complete with all conduit, wiring, lenses, gaskets and seals.
Fixtures shall be suitable for corrosive and wet locations and the finished appearance shall
conform to fit, finish and design of current fixtures. LED lights are preferred. If fluorescent
lights are provided they shall be enclosed, 120-volt warm white, low temperature, rated at 240
mA, as manufactured by General Electric, North American Philips, Sylvania or equal with a
minimum life of 15,000 hours. The ballast shall be electronic, instant start, high frequency
type rated 0 to 300EF and shall be installed under/within the housing, under the lamp, for
easy removal and installation, and to maintain the continuity of the lighting strip. All fixtures
shall be hardwired to the branch circuits and protected by GFCI in the panel. On those units
where lighting does not exist, install on every panel on each side for the entire length of
escalator incline or at a minimum of every 48 on center between fixtures.
2. High density and intensity LED lighting shall be provided within each skirt panel at the comb
entry area. Lighting systems shall project onto the comb mesh line and shall provide
illumination levels in excess of five (5) ft candles for the entire width of the step.
3. The Contractor shall furnish and install new electric power receptacles and maintenance work
lighting fixtures in the upper and lower pits and at points every fifteen (15) feet along the truss
incline. Lighting fixtures shall be quick start type PL (low temp) compact fluorescent lamps as
required for complete illumination of working spaces and specified areas within the interior of
the escalator and its immediate surroundings. Upper and lower pits shall have internal
lighting of 15-foot candles minimum. Each receptacle shall be of the GFCI duplex type,
waterproof, grounded, and rated for one hundred and twenty (120) volts at twenty (20)
amperes. The receptacles in the pits shall be surface mounted on the walls, not less than
thirty (30) inches from the floor. Lights shall be fluorescent fixtures of watertight construction,
suitable for outdoor use and exposure to the elements. A main light switch shall be located at
the entry to wellway and/or pit.

30

4. Provide new GFCI receptacles, new pit lighting fixtures and switches shall be provided in
each escalator in the pit.
5

Provide new bulbs for all permanent light fixtures in machine rooms. Lighting shall meet all
governing code requirements. Contractor to install additional light fixtures as needed to meet
Code lighting requirements in the machine room.

6. Contractor shall refurbish existing direction light assemblies complete with all conduit, wiring,
and accessories. One red and one green light shall be located on the right hand side of each
escalator landing. A green light shall indicate that the escalator is moving away from the
landing being approached. A red light shall indicate that the escalator is moving toward the
landing being approached. Red light lense shall be equipped with the international NO
ENTRY symbol silhouetted over the red lense. New lenses and lamps are required at a
minimum.
2.04 OPERATION
A. Kiosk Control Panel: Contractor shall verify proper operation of the kiosk control panel to ensure
that new control system is made compatible with the kiosk control system and gate switches.
Kiosk status indicators shall include an UP, DOWN, and Out Of Service light; UP or DOWN, as
appropriate, shall be on when the unit is running, and Out OF Service shall be on steady for a
normal (keyswitch) shutdown and shall flash for other shutdowns. When power is removed from
the escalator either with the mainline or from power loss, the UP, DOWN and Out of Service lights
shall be off. Notify WMATA if wiring between control panel and escalator is not intact or if kiosk
control panel is inoperable.
2.05 ELECTRICAL REQUIREMENTS
A. Electric equipment for all escalators shall be designed, selected, and fabricated in accordance
with NEC, NEMA, IEEE, and ANSI standards as applicable, and as specified herein. All
equipment including motors, controllers, switches, indicators, circuit breakers, panel boards,
lighting, heating, wiring, conduit, boxes and other appurtenances for proper installation and
operation of the escalators shall be furnished and installed by the Contractor.
B. Provide new wiring and conduit from the mainline disconnect switch throughout the escalator
control system with complete wiring and conduit systems in the wellway, machine room and pits,
including traveling cables adequate for the proper operation of the equipment. Each wire shall be
identified on both ends of the wire with wrap around or shrink type wire markers. The wire marker
number shall be a unique number, incorporates the instrument / equipment tag number if
applicable, shall be easily cross referenced with schematic drawings, and shall have the same
number on both sides of the wire. Wires shall be identified as indicated above at ALL controller
locations, all terminations, including junction boxes. Handwritten labeling will not be permitted.
1. Conduit, Boxes and Fittings
a. All wiring for the escalator equipment and the control devices shall be per the NEC.
b. All wiring for escalator equipment and control devices is in GRS conduit or liquid-tight
flexible conduit, 3 feet maximum may be used where conduit is not embedded in
concrete.
c. Rigid conduit and fittings shall be UL-approved galvanized steel conforming to the
requirements of UL 6 and ANSI C80.1. The minimum size shall be 3/4-inch for power
circuits and one-inch for control circuits. Power and control circuits shall be in separate
conduits.
d. Liquid-tight flexible conduit shall conform to the requirements of UL 360 and consist of a
flexible hot dip galvanized steel core spiral wound with continuous copper ground built in
the core for sizes up to 1-1/4 inch and a neoprene jacket overall. Sizes 1-1/2 inches and

31

e.

f.
g.

h.
i.
j.
k.
l.
m.

n.
o.
o.
p.

above shall be installed using a separate ground wire. Fittings for flexible conduit shall
be watertight and shall conform to the requirements of UL 514B.
Outlet boxes shall be watertight, stainless steel for exterior units and galvanized
malleable iron, cast iron or ductile iron for interior units conforming to the requirements of
UL 514A. Wiring device cover plates shall have weatherproof construction. Junction,
switch, and pull boxes shall be non-metallic NEMA 4X conforming to the requirements of
UL 50 and UL 514A and having screw covers with liquid-tight gaskets.
Provide NEMA 4X waterproof fittings, watertight hubs and appurtenances as required by
the installation to preclude the entry of water or moisture into the system.
All conduits terminating in steel cabinets, junction boxes, wireways, switch boxes, outlet
boxes and similar locations shall have approved insulation bushings. If the bushings are
constructed completely of insulation material, a steel locknut shall be installed under the
bushing. At ends of conduits not terminating in steel cabinets or boxes, the conductors
shall be protected by terminal fittings having an insulated opening for the conductors.
Conduit fittings and connections using set screws or indentations as a means of
attachment are not permitted.
Connect motors and other components subject to movement or vibration, to the conduit
with liquid-tight flexible conduit.
All existing machine room conduit and wiring shall be replaced with new materials to suit
the new equipment. Conductors in the machine rooms shall be installed in rigid conduit.
All existing wiring and conduit shall be replaced with new.
Conduits shall be brought and connected to suitable approved connection boxes at all
outlets, apparatus and panels.
The conduits shall be of such size that the wires or cables can be readily installed and
replaced, if necessary. No conduit shall be less than 3/4 inch trade size. The total overall
cross sectional area of the wires contained in any conduit shall not exceed 40 percent of
the internal area of the conduit.
Conduits shall be neatly and systematically run. All exposed conduit and boxes shall be
supported by approved and substantial straps, hangers or clamps to the structural steel,
reinforced concrete, or other approved supports.
In all machine rooms the equipment shall be laid out and installed so as to allow as
adequate and convenient access for maintenance as space conditions will permit.
All screws used for terminal connections of all wiring (machine room and pit) shall be
provided with "star washers" of proper size and type.
All existing conduit and wiring shall be removed and wall/floor slabs patched with fire
rated material.

2. Conductors
a. Unless otherwise specified, conductors shall be stranded or solid coated annealed
copper in accordance with Code for Type THHW. Where 16 and 18 AWG are permitted
by Code, either single conductor cable in accordance with Code for Type TF, or multiple
conductor cable may be used provided the insulation of single conductor cable and outer
jacket of multiple conductor cable is flame retardant and moisture resistant. PVC
insulation will not be permitted. Multiple conductor cable shall have color-coding or other
suitable identification for each conductor. Conductors for control boards shall be in
accordance with Code. No joints or splices shall be permitted in wiring except at outlets.
Tap connectors may not be used.
b. All wiring shall test free from short circuits or grounds. Insulation resistance between
individual external conductors and between conductors and ground shall be not less than
one megohm.
c. Where size of conductors is not given, capacity shall be such that maximum current shall
not exceed limits prescribed by Code.
d. Equipment grounding shall be furnished and installed. Ground conduits, supports,
controller enclosures, motors and all other non-current conducting metal enclosures for
electrical equipment in accordance with Code. The ground wires shall be copper, green,
insulated and sized as required.
e. Terminal connections for all conductors used for external wiring between various items of
escalator equipment shall be solder-less pressure wire connectors in accordance with

32

Code. The Contractor may at his option make these terminal connections on No. 10 or
smaller conductors with approved terminal eyelets set on the conductor with an approved
pressure type terminal block. Terminal blocks using pierce-through serrated washers are
not acceptable.
f. Cables shall include ten percent spare wires but not less than 2 spare conductors. All
spares to be properly tagged or otherwise identified with clear and indelible markings.
g. All insulated wiring shall be tag coded at their terminals in the machine room and shall
agree with the approved wiring diagrams. All spares shall be marked.
C. The Contractor shall provide equipment grounding conductors from the junction boxes for all
feeders and branch circuits as shown and required. Electrical equipment shall be provided with a
minimum of two ground paths. One path shall be a green, insulated equipment-grounding
conductor. The second path shall be a connection, to grounded metallic items using metallic
fasteners, metallic conduit and/or bonding jumper. Provide a #6 AWG insulated grounding
conductor attached to each truss and running back to the main feeder junction or tap box and
spliced to the equipment grounding conductor run with the feeder wires. On escalator, bond
exposed metallic items, AC equipment enclosures and lighting fixtures to grounded escalator
metallic structure with metallic fasteners as shown.
D. The Contractor shall take the necessary steps to ensure the flow to ground of accumulated static
electricity, by means of metallic rollers or other appropriate means installed at appropriate
locations to prevent potential shock at all times at all points along the handrails.
E. The Contractor shall be responsible for grounding and bonding all parts of the escalator metallic
structure, equipment and raceway in accordance with the applicable requirements of the NEC
and the codes and regulations of the jurisdictional authorities.
F. Provide circuit protection for signal system incorporated in circuit breaker, disconnect switch or
power controller.
G. In the machine room and escalator pits the equipment shall be laid out and installed so as to
allow adequate and convenient access for maintenance.
H. Each major component of equipment shall have the manufacturers name, type, class or catalog
number on a metal plate securely attached to the item of equipment in a conspicuous location.
I.

All cabinets containing motor drives, filter boxes, transformers and power reactors shall be
supported on rails and isolated from the base building structure with elastomeric pads having a
minimum static deflection of 3/8 (Mason Type N, or equivalent). All connections to and from the
cabinetry shall be flexible in order not to compromise the isolation system. Use non-rigid conduit
for the final electrical connection, with all other conduit supports and clamps provided on a
neoprene sponge insert. No connections shall be made through the top of the cabinets; if
connections cannot be made through the bottom of the cabinet, a drip loop must be provided for
side connections.

J.

Supply, install and connect all fused main line disconnect switches, of the lockable type, for each
escalator in the machine rooms in accordance with ASME A17.1 and local requirements.

K. All signal wiring shall be brought directly terminal in or near the escalator controller with discrete
wiring. No circuit boards, other than for the bottom fault display or incorporated into transducers,
shall be installed in the escalator outside the controller area.

33

2.06 MECHANICAL REQUIREMENTS

A. All bearings, pivots, guides, gearing and similar elements subject to friction or rolling wear in the
entire escalator installation, shall be accurately and smoothly finished and shall be arranged and
equipped for adequate and convenient lubrication. Means shall be provided for flushing and
draining the larger bearings and gear cases. All oiling holes shall have dustproof self-closing
caps.
B. All plain bearings shall be liberally sized in accordance with the best escalator usages, which
have proved entirely satisfactory on heavy-duty installation. Submit bearing sizes to the authority
for Approval.
C. Ball and roller bearings shall be of liberal size and of a type and make which have been
extensively and successfully used for similar heavy duty on other escalator installations. They
shall be fully enclosed. Loading, lubrication, support and all other conditions of use shall be in
accordance with the recommendations of the bearing manufacturer, based on previous extensive
and satisfactory escalator usage. Submit bearing sizes to the Authority for approval.
D. All bolts used to connect moving parts, bolts carrying hoisting stresses, and all other bolts,
subject to vibration or shock, shall be fitted with adequate means to prevent loosening of the nuts
and bolts. Bolts transmitting shearing stresses between machine parts shall have tight body fit in
drilled holes. All bolts subject to vibration shall be provided with split ring lock washers.
E. All bearing and sliding surfaces of shafts, pins, bearings, bushings, guides, etc., shall be smoothly
and accurately finished. They shall be assembled and installed in accurate alignment and with
working clearance most suitable for the load, speed, lubrication and other conditions of use.
F. Belts, pulleys, chains, gears, couplings, projecting setscrews, keys, cables and other rotating
parts shall be fully enclosed and properly guarded.
2.07 SHOP FABRICATION
A. The various parts of the escalator systems shall be fabricated and assembled insofar as practical,
in the shop to minimize field assembly. Parts which cannot be shop-assembled but require close
field fit shall be trial-assembled in the shop and given field erection marks where necessary to
eliminate fitting work at the construction site.

PART 3 - EXECUTION
3.01 INSTALLATION
A. Procedures for taking a unit out of service shall be performed in accordance with Appendix C
EOC Key Functions.
B. Escalator Enclosure:
1.
Contractors work area protection plan shall be submitted as indicated in Section 1.06.
Upon removal from service and prior to revenue operations, the escalator shall be
completely barricaded with lockable doors at both ends and fully enclosed by the
Contractor to preclude their use without permission of the Contractor until final
acceptance and release for general use by the jurisdictional inspector and the Authority
Representative. The enclosure shall be fabricated in a manner to allow easy access by
authorized persons for maintenance, testing, and adjustment, and shall be removed by
the Contractor when directed by the Authority Representative. Barricades shall be
painted Sherwin Williams SW6959 Blue Chip. Work area inside the barricades shall be

34

protected from damage during Contractors period of use. Safety barricades shall be
constructed in accordance with the NEII Field Safety Handbook, WMATA Construction
Safety and Environmental Manual and all applicable OSHA guidelines.
Proper
maintenance and upkeep of the barricades to ensure the safety of the contractors
workforce, WMATA rail patrons and all WMATA employees is the responsibility of the
Contractor.
2.

Passenger information signs shall be provided by the Authority for the project. The
Contractor shall be responsible for securely attaching the signs to the barricade,
maintaining an accurate completion date on the signs and for replacement of any
damaged or missing signs.

C. Open and Inspect:

1.
The following escalator components shall be inspected at the start of the rehabilitations
and as they become visible for inspection by the Authority Representative in order to
determine if replacement and/or repair is necessary. If replacement is approved, the cost
shall be in accordance with the work item cost provided in the proposal for replacement
of each of the following:
a.
Glass balustrade panels
b.
Metal balustrade panels
c.
Step, axle and horizontal roller tracks.
d.
Drive sled.
e.
Solid balustrade panels and skins
f.
Skirt panels
g.
Deck covers and moldings
h.
Drip pans
i.
Motor bedplate/mount
j.
Baggage stops
k.
Skirt support brackets, top and bottom
l.
Brake control box

m.
n.
o.
p.
2.

Skirt deflector devices

Idler Sprocket Stub Shaft
Idler Sprocket Stub Shaft Channel
Adjustable Step Chain Roller Guide

The following escalator components shall be inspected at the start of the rehabilitations
and as they become visible for inspection by the Authority Representative in order to
determine if replacement and/or repair is necessary. If replacement is approved, the cost
shall be determined after the extent of any repair work has been identified. The decision
to repair and extent of the repair are at the discretion of the Authority Representative:
a.
b.

Truss/truss supports
Access doors and pit ladders to machine rooms

D. Install all replacement equipment, systems, and components in strict accordance with
manufacturer's instructions and approved shop drawings and submittals.
E. It is the Contractors responsibility to ensure that existing equipment can be safely removed and
new equipment installed in existing spaces through existing access. Contractors work plan and
job hazard analysis shall be submitted for every station, identifying rigging methods and potential
hazards for accomplishing the work.

35

F. The WMATA stations will continue in operation during the execution of this Contract and the
Contractor shall cooperate with the Authority Representative in scheduling the work. The
Contractor shall carry on its work in such a way as not to cause interruption of or interference with
the operations of the stations except for the escalators under renovation. Contractor shall
maintain kiosk logbooks during rehabilitation and perform all work in accordance with ELES
Operations Center (EOC) procedures (see Appendix C). All work shall be performed in
accordance with WMATA Standard Operating Procedures #19 (Maintenance and Testing on
Revenue Facilities) (see Appendix D).
G. The Contractor shall confine its operations to the escalator work area. No other areas, interior or
exterior, are to be used for the rehabilitation activities of this Contract without the consent and
prior scheduling of the Authority Representative. Upon completion of the work of this contract,
the areas used for rehabilitation purposes shall be restored to a condition equivalent to the
original and acceptable to the Authority Representative.
H. Temporary shutdown of an adjacent operating escalator shall be requested by Contractor and be
approved and coordinated by the Authority Representative. Such work is to be done outside of
normal peak hours of the station.
I.

All approved selective unit work identified under Open & Inspect items as outlined under Section
3.01 B.1 will be performed concurrently with the replacement component work, Code upgrades
and adjusting.

J.

Contractor shall clean and degrease the truss, pans and entire wellway utilizing an
environmentally approved cleaning system to remove all dirt, grease, loose particles, rags, wood,
etc., as required. A combination of wipe down and pressure wash is required as a minimum.
Contractors procedure shall be provided to the Authority Representative for approval prior to the
commencement of any work.

3.02 ACCEPTANCE INSPECTION AND TESTS

A. Upon completion of rehabilitation work for the escalators, perform all acceptance inspections and
tests required by the ASME A17.1 code, prior to beginning rehabilitation work on the next
escalator; the Authority shall perform a substantial completion inspection in accordance with the
CIP Commissioning Procedure (see Appendix E). All tests results will be included as part of the
CIP Commissioning Procedure documents. Provide all instruments, materials and labor required
for the tests. Final acceptance tests shall be made by the Authority and the Authority Having
Jurisdiction (AHJ). The Contractor shall request a scheduled date for proposed acceptance
inspection, in writing, to the Authority Representative one (1) week prior to each requested
inspection date. Submit copies of all test results to the Authority Representative. The O & M
manuals, schematics, final as-built drawings and sequence of operation shall be submitted to the
Authority Representative for approval prior to the execution of the work on the next escalator. The
approval process will not delay the start of work on the next escalator.
B. All malfunctions and deficiencies revealed by the tests shall be forthwith corrected by the
Contractor at no additional cost to the Authority.
C. All safety devices shall be tested for proper operation and deceleration according to ASME A17.1
requirements. Tools independent of the on-board PLC and diagnostic tool shall be used to
measure escalator deceleration upon safety device actuation.
D. Run Test: Escalators shall be tested for a period of twenty four (24) hours continuous runs with
sixteen (16) of those hours in the escalators normally running direction and with no shutdowns
permitted except to change the direction of the units. For units that are designated to run in both

36

directions it shall be run twelve (12) hours in both directions. Should a shutdown occur the
problem shall be corrected and a new run test shall commence for that point forward.
E. Speed Tests: The actual speed of the escalators shall be determined in both directions of travel
with full contract load and no load in the escalators. Speed tests shall be made before the full
load run test and after the full load run test. The actual measured speed of the escalators with all
loads in either direction shall be within 4% of specified rated speed. Full speed runs shall be quiet
and free from vibration and sway.
F. Static Load Tests: The escalators shall be statically load tested under full load.
G. Skirt Index Testing: The tests shall be performed in accordance with ASME A17.1-2000 code
requirements for new escalators. The Table in Section 8 of ASME A17.1 for existing escalators
shall not apply in this instance.
H. Insulation Resistance Tests: The escalator's complete wiring system shall be free from short
circuits and grounds and the insulation resistance of the system shall be determined by the use of
a Megohmmeter, at the discretion of the inspector conducting the test.
I.

All escalators systems, if connected to the emergency power system (generator), will also be
tested with the emergency power system.

J.

Performance Guarantee: Should any of these tests develop any defects or evidence of poor
workmanship, any variance or noncompliance with the requirements of the specified codes and or
ordinances or any variance or noncompliance with the requirements of these specifications, the
following work and or repairs shall be complete at no expense to the Authority.
1.
2.
3.

Replace equipment that does not meet code or specified requirements.

Perform work and furnish labor, materials and equipment necessary to meet specified
operation and performance.
Perform and assume cost for retesting required by Governing Code Authority and
Authority to verify specified operation and performance.

K. Special Tools
1.
2.

Diagnostic Equipment: one per station location.

Skirt Index Tools: two (2) shall be provided to WMATA.

L. Warranties and warranty maintenance: Contractor shall be responsible for all warranty work,
including labor and materials, for a period of one year.

3.03 CLEANING AND ADJUSTMENTS

A. Throughout the construction the work areas and revenue areas shall be kept clean and safe.
B. After completion of work of this section, and before the issuance of Certificate of Final
Completion, work shall be thoroughly cleaned, and properly adjusted, so that it is in proper
operating condition. The entire work shall be left in a clean condition, satisfactory to the Authority
Representative.
3.04 INSTRUCTION OF AUTHORITY'S PERSONNEL
A.

The Contractor shall provide a training program incorporating all aspects of the installation,
operation and maintenance of the mechanical, electrical and control equipment. The

37

training program shall be completed prior to scheduling final inspection. The Contractor
shall provide competent equipment manufacturers authorized representative, having
specialized technical knowledge and training to conduct the lectures. The Contractors
Training Program, including but not limited to a Training Plan, Instructors Guide and
Student Training Manual shall be submitted to the Authority Representative for approval.
Proposed instructors with resumes shall be submitted to the Authority Representative for
approval.
B.

A two part training course consisting of three (3) days (7 hours per day) shall be provided
and shall include all necessary graphics, equipment, video, etc. One-day session shall be
centered on the operation and maintenance of the equipment and system and a two-day
session shall deal with controls and trouble-shooting.

C.

A minimum of ten (10) groups of ten (10) maintenance mechanics or apprentices will
attend the training. Classroom facilities will be provided by the Authority.

D.

The course shall cover the theory and the practical aspects of start-up, operation,
shutdown, dismantling, and re-installation of the system furnished and installed under this
Contract, but with the main emphasis directed toward maintenance and trouble-shooting
procedures. The students shall be thoroughly trained in finding and replacing faulty
components by means of test-and-check procedures using appropriate test equipment.
The course shall be suitable for the Authoritys maintenance personnel not having prior
experience or background in control maintenance. Each student shall be given a training
manual, which shall consist of manufacturers instruction manuals, bulletins and/or cuts
covering the approved equipment, approved equipment drawings and wiring diagrams,
maintenance and troubleshooting procedures, component replacement procedures, testing
and alignment procedures; as well as all other pertinent technical data and information.
The approved Operational Maintenance Manual shall be used as a reference in addition to
the training manuals provided. Each employee shall be provided with an O&M manual.

E.

All drawings and instructional material in the training manuals shall be of good quality.
Printed material shall be used where available, but clean, clearly legible white prints (or
other approved reproductions) of printed material will be acceptable. Material that is faded,
smeared, or otherwise difficult to read will be rejected.

F.

In addition to the training manuals furnished to each employee attending the training
course, the Contractor shall furnish the Authority with ten (10) additional complete training
manuals. All manuals will become the property of the Authority.

3.05 OWNERSHIP OF REMOVED EQUIPMENT

A.

At the commencement of work on each escalator, contractor will contact the Authority in
writing to determine what equipment, if any, is to be retained by the Authority. The Authority
Representative will respond within five (5) working days.

B.

The specified equipment shall be delivered to the Authority at the Carmen Turner Facility at
3500 Pennsy Drive in Landover, Maryland as directed by the Authority Representative. All
parts, components or equipment not specified for retaining shall be disposed of properly by
the Contractor.
END OF SECTION

38

APPENDICES
Appendix A
Comb Plate Assembly Specification
Appendix B
Step Refurbishment Procedure
Appendix C
EOC Key Functions/Processes
Appendix D
Standard Operating Procedure #19 (Maintenance and Testing on Revenue Facilities)
Appendix E
CIP Commissioning Procedure

39

APPENDIX A
COMB PLATE IMPACT SWITCH ASSEMBLY SPECIFICATION
The following procedure shall be used with the existing comb plate impact switch in order to enhance its
operation:
1. Inspect the bronze paddle plate and other existing hardware to verify acceptability for re-use in
this application.
2. Inspect the paddle plate and truss plate and if necessary, assemble a rectangular shim plate(s)
under the paddle plate so that the bronze paddle plate sits well over the weld bead on the truss
plate. The thickness of the shim plate may vary from unit to unit depending upon the weld bead.
3. Mount the bronze paddle plate assemblies (right hand & left hand) on to the truss plate with 2 cap
screws ( x 13/16 long). Ensure cap screws are aligned correctly with the truss plate.
4. Care must be taken that when installed, the bronze paddle plates are perfectly level with each
other (right hand & left hand).
5. Install new comb switch stud to secure the comb plate assembly to the truss (see the attached
drawing & pictures, comb switch stud).
6. The nuts used to compress the spring on the comb switch stud shall be a aerospace or
automobile nut (see picture provided).
7. The threaded rod and locknut application is the same for both horizontal and vertical actuation
devices.
8. Ensure that the cap screws ( x 1long) used to assemble the comb plate over the adaptor
plate are aligned properly.
9. Care must be taken that the threaded rod that has the spring compressed in it for vertical
actuation be concentric with the access hole on the comb plate.
10. Replace the old comb switch bracket with the new bracket (fabricate as per the attached drawing
& picture, comb switch plate BL) to mount the comb switches.

Fully Assembled View

Note: Spring nut in this view is to be replaced with nut described in Step 6 of procedure.
Comb Switch Stud

Comb Switch Plate BL

Comb Switch Plate BL

APPENDIX B
STEP REFURBISHMENT PROCEDURE
1.0

Scope of Work
The Contractor shall provide all labor, materials, and equipment required to refurbish step
assemblies. The refurbished step assembly shall meet all ASME A17.1 code requirements and
all OEM specifications.
2.0

Requirements

2.1.1

Conditions of Service
The Contractor shall refurbish all step assemblies in accordance with the following guidelines:
a.

Remove rollers and demarcations from steps and discard.

b.

Clean and degrease each step assembly thoroughly using an environmentally approved
cleaning system to remove all dirt, grease and loose particles.

c.

Disassemble steps removing arms and risers from tread board and discarding all
fasteners.

d.

Risers are to be grit-blasted using a media suitable for powder coating process and
inspected for wear and damage. Damaged risers are to be replaced with new. Risers
shall be powder coated black using a process that guarantees a minimum 500 hours of
salt spray protection.

e.

Arms (A-Frames) are to be grit-blasted and inspected for structural cracks using a
fluorescent penetrant inspection process per ASTM E1417. All defective arms are to be
discarded and replaced with new.

f.

Trail roller axles are to be inspected for wear and replaced as necessary. Accepted arms
are to be painted with a rust inhibitive coating.

g.

Treads are to be grit-blasted and inspected for broken/worn ribs. Broken and worn ribs
are to be rebuilt using a process that bonds new metal to the base metal. The repaired
ribs shall be rebuilt to a height and width greater than a new unused tread. The new
material should be indiscernible from the original casting in appearance and properties.
Welded ribs are to be machined to a height and width consistent with adjacent ribs and
conforming to ASME A17.1.

h.

Treads are to be painted/coated using an approved epoxy coating. After proper curing
the top surfaced of the ribs is to ground/polished to remove the coating and expose the
bare aluminum.

i.

Mounting hardware shall be added to each step for installation of step guide pad,
Schindler part number SCS409172 or approved equal. Mounting hardware shall be such
that the guide pads extend out from the step assembly 0.080 inches. The step guides
shall be designed and installed to ensure that the gap between the step side plate and
the skirt panel does not exceed one-sixteenth (0.080 inch) of an inch at either side of the
skirt panel.

j.

Step is to be re-assembled using all new fasteners, demarcation strips and rollers. All
fasteners to have a rust inhibitive coating. All parts must conform to OEM specifications.
All demarcations will be replaced with bright yellow demarcations and comply with the
latest ADAAG requirements.

k.

Step assemblies shall be transported on skids. Each skid shall be banded and covered
with shrink-wrap.

2.02

Welder certifications in accordance with ASME A17.1 shall be submitted for approval.

2.03

Contractor shall inspect all refurbished step assemblies upon delivery. All step inspection reports
shall be maintained by the Contactor and be readily available for Authority review if requested.

APPENDIX C
EOC KEY FUNCTIONS/PROCESSES

Work Order Management

Responding To Callback/Trouble Calls
Caller (Station Manager, ELES In- MOC:
EOC:
House or Contract Personnel):
1. Opens work orders in
1. Reviews Equipment, Location,
1. Discovers or responds to
Maximo in Waiting Approval Description, Labor Group, Work
elevator/escalator outage or
status
Type, Problem Code for
problem
2. Issues work order number
accuracy/consistency
2. Initiates a Station Logbook
to caller
2. Checks "Maintenance Alert"
entry
3. Work order notification is
box and saves work order to
3. Calls MOC to have a work
sent electronically to EOC via check for pre-existing work orders
order opened, and receive a work email
- if cancelling work order is
order number
4. Calls EOC as necessary to necessary, notifies MOC and
verify receipt of high priority
Station Manager
Note: Remote Monitoring
work orders such as
3. Updates equipment status
(SCADA) work orders will be
incidents, accidents or key
(Up or Down) as necessary
opened automatically in Waiting
station outages
4. Enters a Target Finish Date
Scheduling status - with no input
5. Changes work order status to
from MOC
Approved when/if dispatched or
assigned
6. Changes work order status to
In Progress when/if work is
starting
7. Changes work order status for
SCADA work orders to
Approved or Cancelled as
necessary
8. For Incidents/Accidents, notify
appropriate inspectors,
supervisors and management
Starting Assigned/Scheduled Work Actions
ELES In-House or Contract
MOC:
EOC:
Personnel:
1. If called, opens work orders 1. Reviews and updates
1. Has been scheduled to perform in Maximo in Waiting
equipment status (Up or
a service action (repair,
Approval status
Down) as necessary
maintenance, inspection, etc)
2. Issues work order number
2. Changes work order status to
2. Initiates a Station Logbook
to caller
In Progress when/if work is
entry
3. Work order notification is
starting
3. Calls EOC when arriving at job
sent electronically to EOC via
site to report start of work action
email
for scheduled work orders
4. Calls MOC to obtain Preventive
Maintenance, Inspection or
Repair work order numbers, calls
EOC to report work start

Updating/Completing Work Orders

All ELES Personnel (Mechanics,
EOC:
Supervisors, Inspectors, Contract, 1. Reviews and updates equipment status (Up or Down) as
Parts Support):
necessary
1. Assigned or scheduled service
2. Leaves work order status as In Progress if work is ongoing, or
action is performed (callback,
equipment is unavailable for use
repair, maintenance, inspection,
3. Changes work order status to Complete if all work is complete
parts delivery/pickup, etc)
and the equipment is in service - for Incidents/Accidents
2. Completes Station Logbook
management approval must be obtained in advance
entry
4. Enters Actuals data (Task, Component, Position, Reason For
3. Calls EOC to update/complete
Repair, Work Accomplished Codes)
work order, with the following
5. Will generate child work orders for follow-up work actions, such
data: description, start/stop times, as Safety Work Orders and Incomplete PMs
component code, position code (if
needed), work accomplished
code, reason for repair code
Staff Coordination
All ELES Personnel (Mechanics, Supervisors, Inspectors, Contract, Parts Support) must call the EOC:
1. Call Supervisors at the beginning of work shifts - only call EOC if no Supervisor available
2. Call EOC when arriving or departing locations/assignments during shift
3. Call Supervisor at the end of work shifts - only call EOC if no Supervisor available
4. Supervisors will call EOC with updated attendance

Workflow Coordination
All requests/schedules for planned activities should be submitted to the EOC:
1. Planned Elevator outages (for Bus Bridges)
2. Preventive Maintenance, Rehab/CIP, Major/scheduled repairs, and Inspection schedules
3. Support requests/commitments
4. Overtime requests/schedules
5. Panel re-skin pickups and deliveries

Materials Support Coordination

ELES Callback Mechanics Only:
1.Calls EOC to initiate
parts/materials reservations in
Maximo and to coordinate parts
deliveries for out of service units
and/or emergencies only

ELES Maintenance/Repair
Mechanics:
1. Calls supervisor to initiate
parts/materials reservation in
Maximo and to coordinate
parts deliveries
2. Supervisors will call EOC
to coordinate parts deliveries

EOC:
1. Coordinates parts deliveries;
initiates a parts/materials
reservations in Maximo for out of
service units and/or emergencies
only

APPENDIX D
STANDARD OPERATING PROCEDURE #19
Maintenance and Testing on Revenue Facilities
PURPOSE
The purpose of this Standard Operating Procedure (SOP) is to ensure consistency and provide
guidance for all personnel desiring the use of the revenue railroad for maintenance or testing of
vehicles or facilities.
SCOPE
This SOP is applicable to contractors, consultants, and all other personnel (including WMATA
employees) desiring access to the revenue railroad or Rail Transportation (RTRA) facilities for
maintenance or testing.
RESPONSIBILITIES
19.2

The General Superintendent of RTRA is responsible for approval of the operational plan for all
tests to be performed on the revenue railroad or on RTRA facilities.

19.3

The Superintendent of the Operations Control Center (OCC) is responsible for approval,
issuance, and implementation of General Orders. They are used to define track sections for
maintenance and testing and will remain in effect until fulfilled superseded or canceled by the
Superintendent of OCC.

19.4

Authority offices, contractors, and consultants are responsible for scheduling all activities in
accordance with this SOP.

19.5

Superintendents assigned to RTRA are responsible for providing support services when
requested, and subsequently approved in accordance with this SOP.

19.6

Test Directors are responsible for test approval by the appropriate office (RAIL, TSDV, etc.) to
assure safe operation during tests.

19.7

Personnel requiring access rights are responsible for: advising OCC of their work areas, and after
approval by OCC, monitoring the appropriate radio frequencies during access.

19.7.1 When a maintenance organization requires to work in an area controlled by rights of another
maintenance organization they must request permission from the rights holder in advance in
writing. Approved requests will be provided in writing to OCC and the requestor. All requests
shall be forwarded to MOC for record keeping and coordination. Written approved work requests
must also be provided to the Supervisor or Crew Leader holding the rights.
The rights holding supervisor is responsible for all work crews in the area governed by the rights.
All crews are under the direct supervision of the supervisor of the crew holding the rights. Also,
this supervisor will be responsible for appropriately coordinating all movement within the work
area with OCC. No movements shall take place without prior notification to the supervisor in
charge and coordination with OCC.
In cases where the requestor requires rights on an adjacent or opposite track which causes a
lock-out, the rights may be granted if the requestor is capable of clearing in ten minutes or less,
upon notification.

This notice does not relieve the rights holder of their responsibilities or supersede the
requirements of any other Metrorail Safety Rule or Procedure.
EXCLUSIVE RIGHTS
19.8

All requests to obtain exclusive use of a section of yard track must be submitted to and approved
by the Assistant Superintendent of Operations in charge of the specified yard.

19.9

All requests to obtain exclusive use of a section of mainline track must be submitted to and
approved by the Superintendent of OCC and appear on the General Order.

ACCESS RIGHTS
19.10

All requests to obtain access rights for authorized WMATA personnel must be coordinated with
and be approved by OCC prior to entering the right-of-way. OCC must also be notified when
personnel have completed their tasks and are clear of the right-of-way. All other access rights
must appear on the General Order.

GENERAL ORDER PROCEDURES

19.11

All requests for rights must be submitted, via the General Orders & Track Rights System
(GOTRS), to the Superintendent of OCC by 1700 on the Wednesday preceding the scheduled
week. When a holiday falls on a Thursday, all requests must be submitted by 1000 Wednesday.

19.12

Only the Superintendent of OCC may approve the issuance of General Orders for requests after
track allocations have been scheduled.

19.13

When red tags are issued, an earlier clearing time may be required and any deviation from
scheduled times must be approved by the Superintendent of OCC.

19.14

All requests must include the following information:

a. Department requesting rights
b. Date and hours of the request
c.

Line, Track and Chaining

d. Contact rail status

e. Equipment to be utilized
f.

Individual making the request

g. Purpose of the request

GENERAL ORDER FORMAT AND CONTENT
19.15

General orders will be identified by bold type reading:

GENERAL ORDER

19.16

The heading will include the date of the order, the number of the general order and to whom the

order is addressed. General Order numbers will be continuous on a yearly basis.

19.17

The General Order will identify for each approved area:

a. The work to be performed and type of rights requested
b. The contractor or Authority Department involved
c.

The date and hours affected

d. The identification and location of the work area involved

e. The contact rail status when necessary
f.

Instructions for flagging when necessary

SUSPENSION OF A GENERAL ORDER

19.18

OCC has the authority to suspend or cancel a portion, or all of a General Order when conditions
require it.

19.19

When a General Order is canceled, OCC will immediately notify all concerned parties and
document all actions taken.

MODIFICATION OF A GENERAL ORDER

19.20

After publication of a General Order, modifications will not be allowed except for emergencies or
for cancellations of rights. All cancellations will be documented by OCC identifying the rationale
for the cancellation.

19.21

Emergency modifications of General Orders will be allowed only when conditions exist which will
cause a portion of the mainline to be taken out of service during revenue hours.

CONDUCTING TESTS (other than routine maintenance tests)

19.22

Personnel requiring the revenue railroad or RTRA facilities for tests shall:
a. When requiring exclusive rights for the mainline tracks, request those rights in accordance
with Section E of this SOP and attach a copy of the request to the test procedure.
b. Submit to RTRA, no later than ten (10) working days prior to the test, a test request
identifying:
1. The purpose
2. The expected results
3. The Test Director (by name)
4. All personnel participating and/or observing (by name)
5. A detail operational plan including:

a. Operating scenario
b. RTRA personnel required
c.

Equipment and facilities to be used

19.23

The Test Director shall be responsible for obtaining a Covenant not to Sue from all non-WMATA
personnel involved in a test.

19.24

After approval of the operational plan by the General Superintendent of RTRA, the appropriate
RTRA Superintendent shall provide the necessary support as identified in the test procedure.
Also, a single point of contact shall be provided for the Test Director. This individual will be
responsible for the safety of the RTRA personnel and equipment while testing is being performed.
Any modification to the operational scenario will be coordinated through the individual designated
as the single point of contact.

APPENDIX E
CIP COMMISSIONING PROCEDURE
1. PURPOSE
The purpose of this administrative procedure is to establish consistent guidelines within TIES, so
affected staff can effectively manage the elevator/escalator commissioning process for new or
modernized elevators/escalators.
2. SCOPE
This procedure is applicable to all TIES offices, Contractor, Vendor and Consultant Program/Project
employees but specifically intended for use by the Office of Elevators and Escalators, Capital
Improvement Program Management, Inspections Group, Maintenance Group and Engineering.
3. RESPONSIBILITIES
A. The General Superintendent of TIES/ELES and the TIES/ELES CIP Project Manager are
responsible for the overall implementation and enforcement of this procedure.
B. The TIES/ELES CIP Group is responsible for the overall administration of the
modernization and/or replacement process as well as the quality assurance (testing and
inspections) of vertical transportation equipment.
C. The CIP Project Manager, CIP Assistant Project Manager and Construction Engineer are
responsible for maintaining and updating this procedure. The CIP Project Manager is
responsible for assigning staff to manage and monitor the modernization/replacement
process and perform the testing and inspections of the vertical transportation equipment.
D. Supervisors of Contract Inspections/Inspectors are responsible for the day-to-day
monitoring of construction activities. Tasks include:
a) Recording contractors daily activities
b) Performing O & I
c) Verifying completion of items found during O & I
d) Monitoring construction for adherence to specifications
e) Monitoring construction for adherence to applicable codes
f) Notifying construction engineers of unforeseen field conditions
g) Estimating per cent complete of project
h) Conducting SCI [in Arlington County, Virginia, the SCI is equivalent to an acceptance
inspection]
i) Creating punch lists
j) Verifying completion of punch list items
E. The assistant project manager and construction engineers are responsible for overseeing
tests and inspections. Tasks include:
a) Tracking progress of construction toward completion
b) Scheduling SCI with contractor
c) Assigning ELES inspectors to perform SCI
d) Assisting/participating in a small number of inspections

e) Coordinating with other departments to perform system tests of equipment that affects
elevators/escalators e.g. TSSM/COMM to perform test of smoke detection system
f) Creating and tracking punch list items from the O&I and SCI
g) Scheduling the AHJ in Maryland
h) Tracking punch list items created by AHJ inspectors
i) Tracking acceptance inspection documents from AHJ and SCI documents from
inspectors
j) Coordinating with Maintenance Manager and CIP Project Manager to return vertical
transportation equipment to service
4. DEFINITIONS
AHJ
ASME A17.1
CIP
COMM
DCRA
DLLR
ELES
O&I
SCI
TIES

Authority Having Jurisdiction

Safety Code for Elevators and Escalators
Capital Improvement Program
Communications
Department of Consumer and Regulatory Affairs (Washington, DC)
Department of Labor, Licensing and Regulation (Maryland)
Office of Elevator and Escalator Services
Open Step Inspection/Open and Inspect
Substantial Completion Inspection
Transit Infrastructure and Engineering Services

5. POLICIES
A. A report of substantial completion of the vertical transportation equipment will be issued by
the Authority upon completion of the modernization/replacement of the equipment. An
acceptance report of the equipment will be issued by the AHJ except for Arlington County,
VA where the Authority is the AHJ. These reports indicate that the elevator/escalator meet
the minimum standards for revenue service operations and could include a list of
discrepancies. The discrepancies shall be corrected by the Contractor or responsible
Authority department within 30 days.
B. The Contractor shall have their representatives perform all tests and inspections required
by the contract. The Contractor shall provide all tools and personnel necessary to perform
the required tests and inspections.
C. The Contractor is responsible for enforcing its quality plan. Therefore, the Contractor shall
provide all necessary resources to prepare the elevators/escalators and ensure they are
ready for the Authoritys inspection prior to requesting an SCI.
6. PROCEDURE
A. Day-to-day review of the Contractors progress will be monitored by a WMATA Supervisor
of Contract Inspections. One Supervisor of Contract Inspections will be assigned to each
project and will be designated as the Inspector of Record for the specific project.
B. The Contractor will complete and ensure that all work done is in compliance with approved
technical specifications, applicable codes and quality standards. The Contractor must
notify the ELES CIP Group one week prior to the equipment inspection date.

C. WMATA Supervisor of Contract Inspections will complete an SCI. The SCI will be
composed of several tests and deliverables including but not limited to the following:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)

Safety Switch Activation

Run Tests
Smoke Test/fire Service
Comb Impact Switch Activation Force Measurement
Brake Torque and Slide
Step-to-Skirt Index
Wiring Diagrams (as-built)
PLC program
Locking Bars
Handheld Maintenance Station

The Supervisor of Contract Inspections will complete the commissioning checklists during
the substantial completion inspection.
D. The Contractor must correct all major discrepancies before being allowed to start the next
modernization/replacement. Exceptions will be handled on a case by case basis. The
Contractor needs to request a second inspection to close the discrepancies.
E. All units will undergo a 72-hour burn-in period before the Contractor moves to the next
piece of equipment.
7. ATTACHMENTS
A.
B.
C.
D.
E.

Elevator/Escalator Inspection Checklist

Major Component Checklist
Operating & Safety Devices Checklist
Comb Impact Installation Inspection
Step-to-Skirt Graph

Attachment A - Elevator/Escalator Inspection Checklist (Sample)

Escalator Inspection Checklist

Date Date:
2011

Station:
Unit No.:
ASME A17.1 Code Year:___
Top Comb Impact Results:
Direction
Left
Vertical
Horizontal
Bottom Comb Impact Results:
Direction
Left
Vertical
Horizontal
Dynamometer Serial No.: Calibration Expiration Date:

Center
N/A

Right

Center
N/A

Right

Safety Switches Tested Mechanically________ Passed _______ Failed

Smoke Test ________Passed_________Failed
Underspeed/Overspeed Conditions Demonstrated: XX overspeed tripped; xx underspeed tripped
Brake Torque ; Torque Wrench S/N: xxxxxx Calibration Date: xx/xx/xx
Brake Slide Down: Actual: xx PLC: xx Up: Actual: xx PLC:
Up Direction Handrail Speed ______ left H/R ______ right H/R
Down direction Handrail Speed ______ left H/R ______ right H/R
Step Speed______ up direction______ down direction
350 lbs Load Test on Top and Bottom Combs___Passed ___Failed
Floor Plate Gaps _______Top ________Bottom
Light Levels (FC): Top Landing Combplate: xx/Floorplate: xx; Bottom Landing Combplate: xx/Floorplate: xx
Light Levels (FC): Incline: xx; Controller: xx
Balustrade Panels Gaps: Acceptable
Disconnect: Fused and Lockable: Yes Electrical Feed Label:____________________
Jumpers Removed from Controller/Jumper Log Completed _____________________
Gear oil level in reducer:
Step-Skirt Index: _____Passed ______Failed
Run Test: Up Direction Hours Completed ____ Date Checked_____
Run Test: Down Direction Hours Completed ____ Date Checked_____
Stuck Keyswitch Test: ____Passed; _____Failed
Powerloss Fault Recall Test: _____Passed; _____Failed
Visual Inspection Comments:

Steps (treads, demarcations, step tabs):

Rollers (step and axle, half moon clips):

Handrails (pinch points, color, track, Nylatron, Nylathin):

Conduits and Fittings (anti-short bushings/inserts):

Boxes (labels, openings, covers):

Wires (labels, gauge, color):

Lights (balustrade, understep, comb, direction):

Deck (gaps and baggage stops):

Signs (deck, key switch, machine space):

Comb Sections:

Remote Monitoring (kiosk lights):

Additional Space for Comments:
Inspectors Name and QEI Certification Number:

Attachment B - Major Component Checklist (Sample)

Attachment C - Operating & Safety Devices Checklist (Sample)

Attachment D - Comb Impact Installation Inspection (Sample)

WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY

OFFICE OF ELEVATOR/ESCALATOR SERVICES
Comb Impact Installation Inspection
Date:
Station:
Unit#
Top Comb Impact Results:
Direction

Left

Center
N/A

Right

Left

Center
N/A

Right

Vertical
Horizontal
Bottom Comb Impact Results:
Direction
Vertical
Horizontal
Dynamometer Serial No.:

Comments:

Signature:

Calibration Expiration Date:

Attachment E - Step-to-Skirt Graph (Sample)