A22_SOLICITATION.pdf

SEE ADDENDUM

(No Collect Calls)

W912EE-16-T-0037 08-Sep-2016

b. TELEPHONE NUMBER

601-631-5826

8. OFFER DUE DATE/LOCAL TIME

11:00 AM 16 Sep 2016

5. SOLICITATION NUMBER 6. SOLICITATION ISSUE DATE

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA – FAR (48 CFR) 53.212

(TYPE OR PRINT)

(SIGNATURE OF CONTRACTING OFFICER)

ADDENDA ARE

26. TOTAL AWARD AMOUNT (For Gov t. Use Only )

23.

CODE 10. THIS ACQUISITION IS

SUCH ADDRESS IN OFFER

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT

BELOW IS CHECKED

TELEPHONE NO.

W912EE9. ISSUED BY

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME

VELMA GRANT

2. CONTRACT NO. 3. AWARD/EFFECTIVE DATE 4. ORDER NUMBER

(TYPE OR PRINT)

30b. NAME AND TITLE OF SIGNER 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a.UNITED STATES OF AMERICA

0 27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1. 52.212-4. FAR 52.212-3. 52.212-5 ARE ATTACHED.

25. ACCOUNTING AND APPROPRIATION DATA

1. REQUISITION NUMBER

20.

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED.

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

W807PM61754535

ARE NOT ATTACHED

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA ARE ARE NOT ATTACHED

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

. YOUR OFFER ON SOLICITATION

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN

% FOR:SET ASIDE:UNRESTRICTED OR X

SMALL BUSINESSX

WOMEN-OWNED SMALL

BUSINESS (WOSB)

17a.CONTRACTOR/ CODE FACILITY

OFFEROR CODE

VICKSBURG CONTRACTING OFFICE

4155 CLAY ST

VICKSBURG MS 39183-3435

18a. PAYMENT WILL BE MADE BY CODE

RATED ORDER UNDER

DPAS (15 CFR 700)

13a. THIS CONTRACT IS A

13b. RATING

CODE15. DELIVER TO CODE B4R0000 16. ADMINISTERED BY

12. DISCOUNT TERMS11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

SEE SCHEDULE

14. METHOD OF SOLICITATION

RFQ IFB RFPX

OD OPS DIV

4155 CLAY ST

VICKSBURG MS 39183-3435

TEL: FAX:

601-631-7261FAX:

TEL: 601-631- SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

8(A)

HUBZONE SMALL

BUSINESS

ECONOMICALLY DISADVANTAGED

WOMEN-OWNED SMALL BUSINESS

(EDWOSB)

SIZE STANDARD:

1,500 EMP

NAICS:

333618

OFFER DATED

29. AWARD OF CONTRACT: REF.

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND

EMAIL:

TEL:

31c. DATE SIGNED

SEE SCHEDULE

SCHEDULE OF SUPPLIES/ SERVICESITEM NO. QUANTITY UNIT UNIT PRICE AMOUNT

24.22.21.19.

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

(CONTINUED)

PAGE 2 OF88

ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED: ______________________________________________________

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE 32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f . TELEPHONE NUMBER OF AUTHORIZED GOVERNMENT REPRESENTATIVE

37. CHECK NUMBER

FINALPARTIALCOMPLETE

36. PAYMENT35. AMOUNT VERIFIED

CORRECT FOR

34. VOUCHER NUMBER

FINAL

33. SHIP NUMBER

PARTIAL

38. S/R ACCOUNT NUMBER 39. S/R VOUCHER NUMBER 40. PAID BY

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT

41b. SIGNATURE AND TITLE OF CERTIFYING OFFICER 41c. DATE

42a. RECEIVED BY (Print)

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

STANDARD FORM 1449 (REV. 2/2012) BACK

Prescribed by GSA – FAR (48 CFR) 53.212

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

SEE SCHEDULE

20.

SCHEDULE OF SUPPLIES/ SERVICES

21.

QUANTITY UNIT

22. 23.

UNIT PRICE

24.

AMOUNT

19.

ITEM NO.

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Job

SUPPLY & INSTALL NECESSARY PARTS & LABOR

FFP

FOR ENGINE REPLACEMENT AT FOOL RIVER PUMPING PLANT,

U.S. ARMY CORPS OF ENGINEERS

Furnish all labor, materials, supplies and equipment necessary to for Fool River Engine Replacement in accordance with the specifications.

FOB: Destination

MILSTRIP: W807PM61754535

PURCHASE REQUEST NUMBER: W807PM61754535

NET AMT

Section C - Descriptions and Specifications

SCOPE OF WORK

DIESEL FUELED ENGINE PUMP DRIVE

TABLE OF CONTENTS

PART 1 GENERAL

1.1 SECURITY REQUIREMENTS FOR UNCLASSIFIED CONTRACTS

1.1.1 SITE VISIT and COORDINATION

1.2 CONTRACT DURATION AND PAYMENT

1.3 REFERENCES

1.4 SYSTEM DESCRIPTION

1.4.1 General Requirements

1.4.2 Arrangement

1.5 SUBMITTALS

1.6 WELDER QUALIFICATIONS

1.7 REGULATORY REQUIREMENTS

1.7.1 General

1.7.2 Layout and Shop Drawings

1.8 DELIVERY, STORAGE, AND HANDLING

1.9 PROJECT/SITE CONDITIONS

1.10 MAINTENANCE

1.10.1 Extra Materials

1.10.2 Special Tools

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

2.1.2 Nameplates

2.1.3 Personnel Safety Devices

2.2 MATERIALS

2.2.1 Filter Elements

2.2.2 Pipe (150 psi System and Under)

2.2.3 Temperature Gauges for Oil or Water Service

2.2.4 Pipe Hangers

2.2.5 Pressure Gauges

2.3 DIESEL ENGINE

2.3.1 Crankcase Pressure Relief Valve

2.4 FUEL SYSTEM

2.4.1 Fuel Pump

2.4.2 Filter

2.4.3 Strainer

2.4.4 Safety Bypass Valve

2.5 LUBRICATION

2.5.1 Pump Filters

2.5.2 Lube-Oil Sensors

2.5.3 Lubricating Oil Strainer

2.6 COOLING SYSTEM

2.6.1 Coolant Pumps

2.6.2 Radiator

2.6.3 Thermostatic Control Valve

2.6.4 Temperature Sensors

2.6.5 Expansion Tank

2.7 SPECIAL LIMITATIONS

2.7.1 Vibration Isolation and Seismic Restraints

2.8 AIR INTAKE EQUIPMENT

2.9 EXHAUST SYSTEM

2.9.1 Flexible Sections and Expansion Joints

2.9.2 Exhaust Muffler

2.9.3 Exhaust Piping

2.10 EMISSIONS

2.11 STARTING SYSTEM

2.11.1 Compressed Air Starting System

2.11.1.1 Air Filter

2.11.1.2 Air Driven Motors

2.11.2 Starting Aids

2.11.3 Jacket-Coolant Heaters

2.12 SAFETY SYSTEM

2.12.1 Audible Signal

2.12.2 Visual Signal

2.12.3 Alarms and Action Logic

2.12.3.1 Shutdown

2.12.3.2 Problem

2.12.4 Alarm Panel

2.12.5 Time-Delay on Alarms

2.13 GOVERNOR

2.13.1 Speed Regulating Governor

2.13.2 Emergency Overspeed Governor and Load Limit

2.13.3 Governor Controls Location

2.14 ENGINE INSTRUMENT BOARD

2.15 PANELS

2.15.1 Enclosures

2.15.2 Analog

2.15.3 Parameter Display

2.16 BASE

2.17 PAINTING

2.18 FACTORY INSPECTION AND TESTS

2.19 CLUTCH

PART 3

EXECUTI

ON

3.1 INSTALLATION

3.1.1 Setting and Aligning

3.1.2 Alignment Tolerances

3.2 INSTALLATION

3.2.1 Supports

3.2.1.1 Ceiling and Roof

3.2.1.2 Wall

3.2.2 Flanged Joints

3.2.3 Cleaning

3.2.4 Pipe Sleeves

3.3 ELECTRICAL INSTALLATION

3.4 ONSITE INSPECTION AND TESTS

3.4.1 Contractor Supplied

3.4.2 Instruments

3.4.3 Sequence

3.4.3.1 Electric Protective Device Tests

3.4.3.2 Safety Run Test

3.4.3.3 Final Inspection

3.5 MANUFACTURER'S FIELD SERVICE

3.5.1 Onsite Training

3.5.2 Field Engineer

3.6 ACCEPTANCE

3.7 WARRANTY

W912EE-16-T-0037

DIESEL FUELED ENGINE PUMP

DRIVE

PART 1 GENERAL

1.1 SECURITY REQUIREMENTS FOR UNCLASSIFIED CONTRACTS

All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

I-Watch: The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training."

All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than 3 business days after the initial contract award." *When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility Verification, with the designated Government representative. This Form will be provided to the Contracting Officer and shall become part of the official contract file.

1.1.1 SITE VISIT AND COORDINATION

Bidders are highly recommended to schedule a site visit with the COR to get measurements and record site conditions for the work. The Technical point of contact for this contract shall be Mr. Larry Raborn at larry.e.raborn@usace.army.mil, 601-631-7464. All work shall be coordinated through the Fools River Pumping Plant Manager, Mr. Doug Ward at doug.d.ward@usace.army.mil, 318-386-5054.

1.2 CONTRACT DURATION AND PAYMENT

All work associated with this contract shall be completed within 120 days from contract award. Payment for the removal and disposal of the existing engine, installation of the new diesel engine and accessories will be made at the contract lump sum price after completion of the work.

1.3 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C39.1 (1981; R 1992) Requirements for Electrical

Analog Indicating Instruments

ASME INTERNATIONAL (ASME)

ASME B16.11 (2009) Forged Fittings, Socket-Welding and Threaded

ASME B16.3 (2010) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.5 (2009) Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard

ASME B31.1 (2010) Power Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing

Qualifications

ASME BPVC SEC VIII D1 (2007; Addenda 2008; Addenda 2009) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2010) Standard Specification for Seamless

Carbon Steel Pipe for High-Temperature Service

ASTM A181/A181M (2006) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A234/A234M (2011) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A53/A53M (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM C533 (2009) Standard Specification for Calcium Silicate

Block and Pipe Thermal Insulation

ASTM D 975 (2011) Standard Specification for Diesel Fuel

Oils

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2012) National Electrical Safety Code

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND

FITTINGS INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-69 (2003) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

MSS SP-80 (2008) Bronze Gate, Globe, Angle and Check

Valves

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for

Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2006) Enclosures

NEMA MG 1 (2009) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2012) Flammable and Combustible Liquids Code

NFPA 37 (2010; TIA 10-1) Standard for the

Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 70 (2011; TIA 11-1; Errata 2011) National

Electrical Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J1995 (19905; R 1995) Engine Power Test Code - Spark

Ignition and Compression Ignition - Gross Power Rating

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 60 Standards of Performance for New

Stationary Sources

1.4 SYSTEM DESCRIPTION

1.4.1 General Requirements

Remove and dispose of the existing damaged diesel engine and cooling system located at the Fool River Pumping Station. Provide and install a complete and totally functional diesel engine with all necessary ancillary equipment including, but not limited to, air filtration, starting system, clutch, instrumentation, lubrication, fuel system, cooling system including building mounted intake louvers and exhaust duct, and engine exhaust system.

The engine rating shall be in accordance with SAE J1995 and shall supply a minimum Industrial intermittent (IND-C) rating of 650 hp at 1800 rpm. The diesel engine shall be a complete unit with all components, accessories, and system interconnections coordinated, so that the complete assembly shall have the capabilities required, for continuous operation at the required power. The engine shall have a manufacturer’s service and repair center within 100 miles of the Fools River pumping station.

1.4.2 Arrangement

The engine shall be mounted in the location of the existing damaged engine and shall be installed to match the existing geometry within the pumping station and be connected to the existing speed reducer. Connect the engine shaft to the existing speed reducer input shaft with existing intermediate shaft and couplings. The engine shall be supplied with air starters which will be supplied with air from the existing air tank. The new diesel engine must be tied into the existing emergency combustion air shut off system, existing gear reducer, existing fuel system, existing supply air for starting, new clutch for powering the existing gear reducer, new air intake louvers, new air exhaust duct, and the engine exhaust must exit the building through the existing engine exhaust penetration. The contractor shall ensure the compatibility of these components including, but not limited to, the proper fit of engine and reducer shafts, the interaction of new and existing major and minor components, and control of safety and alarm signals. New cooling air intake louvers shall be installed through the existing building skin on the east facing wall of the building.

Intake louvers shall have a maximum face velocity of 600 fpm air velocity. Cooling air exhaust duct and louvers shall be installed through the building skin in the south facing wall of the building. The building skin shall be modified as necessary to match the cooling requirements of the new engine. Building structural components may not be modified for the installation of the cooling louvers. Supply fuel for the engine from the existing day tank located near the engine mounting location and in accordance with NFPA

37. Fuel oil will be supplied to day tank from the existing outside storage tank. Use a cooling system to maintain engine and lubricating oil temperatures at the temperatures recommended by the manufacturer. The engine shall be supplied with a completely independent lubrication system with an engine-driven primary pump. The engine shall be supplied with a standard engine manufacturer’s skid mounted cooling system. All modifications to the existing building skin by the contractor shall be made water tight in accordance with the louver manufacturer’s recommendations.

1.5 SUBMITTALS

The contractor shall provide submittals with the required information to the contracting officer a minimum of two weeks prior to commencing work. Submittal approval is required for the following. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted:

1.5.1 Shop Drawings

Layout and Shop Drawings; G Installation;

G As-Built Drawings; G

1.5.2 Product Data

Diesel Engine; G Cooling System; G

1.5.2.1 Equipment and performance data certifying that the engine and cooling system function properly in the ambient temperatures specified and provides the following design and performance data:

a. The maximum allowable inlet temperature of the coolant fluid.

b. The minimum allowable inlet temperature of the coolant fluid.

c. The maximum allowable temperature rise in the coolant fluid through the engine.

d. The magnitude of monitored values defining alarm or action set points, and the tolerance (plus and/or minus) at which the protective device activates the alarm or action.

e. The minimum allowable inlet fuel temperature.

f. The maximum impact/dynamic load that will be transferred from the engine to the structure.

1.5.2.2 Manufacturer's standard catalog data including a description and depiction of the engine and all ancillary equipment in sufficient detail to demonstrate complete specification compliance. If standard catalog data does not contain sufficient detail to verify compliance, then submit supplementary support documentation to verify compliance. All data submitted shall be on the engine manufacturer's letterhead and signed by a representative or official of the manufacturer authorized to make technical representations of his company's products.

Project/Site Conditions

The record of the Contractor's survey of the existing installation site conditions and verification of site work details.

Onsite Training

A letter giving the proposed date for conducting the onsite training course and the agenda of instruction.

Manufacturer's Published Instructions

Posted instructions, including wiring and control diagrams showing the key mechanical and electrical control elements and a complete layout of the entire system. The instruction set shall be weatherproof, laminated in plastic, framed, and posted at a location as directed.

Field Engineer

Certification that the field engineer is qualified to perform the specified functions.

Diesel Engine Pump Drive; G

Written documentation that the products being supplied are appropriate for this engine pump drive, including past performance of the drive on certain types of service, i.e., marine generators, pump drives, locomotives, metal shredders, etc., with a minimum operation of 2,000 hours per year of service with a minimum of 2 years of qualifying service. The certification of the unit's speed, horsepower, and duty rating that forms the basis of the qualifying experience is required for acceptance and shall be within 30 percent of this drive's rating.

Welder Qualifications

A letter listing the welder-qualifying procedures for each welder, complete with all supporting data such as test procedures used, what was tested to, and a list of the names of all welders and their identification symbols.

Installation; G

A copy of the manufacturer's installation and alignment procedures, including a detailed description of the manufacturer's recommended break-in procedure.

1.5.3 Test Reports

Engine; G

A fully documented shop test report.

The field test report, documenting all data for lubrication oil temperature and flow, cooling water temperature and flow, and compliance with specified performance criteria tested during the field tests.

1.5.4 Certificates

Regulatory Requirements; G

Certificates of compliance for equipment and installation including official, signed statements from manufacturers and installation Contractors.

The statements shall certify the item and quantity supplied and either the date of shipment or installation.

1.5.5 Operation and Maintenance Diesel

Engine; G

An Operation and Maintenance Manual detailing start-up and operating procedures, lubrication instructions, installation and alignment procedures, routine maintenance requirements and procedures, complete detailed procedures for disassembly and reassembly of the engine, parts list for all parts detailed, assembly plans of the engine showing all parts, suppliers for all parts, settings and adjustment for protective devices, and a list of all tools, handling devices, and spare parts furnished.

1.6 WELDER QUALIFICATIONS

Welding shall be in accordance with qualifying procedures using performance qualified welders and welding operators. Qualify procedures and welders in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by a previously qualified employer may be accepted as permitted by ASME B31.1. Notify the Contracting Officer 24 hours in advance of tests, and the tests shall be performed at the work site, if practical. The welder or welding operator shall apply the assigned symbol near each weld made as a permanent personal record.

1.7 REGULATORY REQUIREMENTS

1.7.1 General

Design, fabrication, and installation of the equipment shall conform to the applicable national, state, and local codes. Manufacturer shall certify the engines in accordance with 40 CFR 60 Subpart IIII Standards of Performance for Stationary Compression Ignition Internal Combustion Engines, for emergency stationary internal combustion engines.

Submit documentation for conformance according to paragraph SUBMITTALS.

1.7.2 Layout and Shop Drawings

Submit layout and shop drawings including the following:

1.7.2.1 Base-mounted equipment, complete with base and all

attachments including anchor bolt template and recommended clearances for maintenance and operation.

1.7.2.2 Complete starting system.

1.7.2.3 Complete fuel system.

1.7.2.4 Complete cooling system.

1.7.2.5 Complete intake and exhaust systems.

1.7.2.6 Layout of relays, breakers, switches, and instrumentation provided and applicable single line and wiring diagrams with a written description of the sequence of operation.

1.7.2.7 Lubrication system complete including piping, pump(s), strainers, filters, heat exchangers for lube oil and turbocharger cooling, controls, and wiring.

1.7.2.8 Location, type, and description of vibration isolation devices for all applications.

1.7.2.9 The safety system, together with a detailed description of its operation. Wiring schematics, safety devices with a listing of their normal ranges, alarm and shutdown valves (to include operation parameters such as pressures, temperatures, voltages, currents, and speeds) shall be included.

1.7.2.10 Layout of the engine control panel and alarm panel.

1.7.2.11 Mounting and support for each panel and major piece of electrical equipment.

1.7.2.12 Engine lifting points and rigging instructions.

1.7.2.13 Alignment information for the engine, gear box and pump specifying sequences, tolerances, and temperature change effects.

1.7.2.14 Intake louvers and radiator exhaust duct layout and arrangement drawings, showing building penetrations and mounting details.

1.8 DELIVERY, STORAGE, AND HANDLING

Protect material and equipment from weather, humidity, temperature variation, dirt, dust, and other contaminants during delivery and storage. Lifting, moving, and storage of the engine shall be in accordance with manufacturer's requirements.

1.9 PROJECT/SITE CONDITIONS

Maximum Air

120 degrees F

Minimum Air Temperature

15 degrees F

Installation Elevation 50 ft. above sea level

1.10 MAINTENANCE

1.10.1 Extra Materials

Furnish the following minimum spare parts when applicable to the type of engine proposed.

UNITS DESCRIPTION

1 Air start motor (if applicable)

1 Air start check valve (if applicable)

4 Refills, with storage box, for all lubricating oil filters for the engine

4 Refills, with storage box, for all fuel oil filters for the engine

1.10.2 Special Tools

Provide one complete set of special tools required for maintenance. Special tools are those that only the manufacturer provides for special purposes or to reach otherwise inaccessible parts. The tools shall be supplied complete with a suitable tool box.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

Provide materials and equipment, comprising the engine drive system, which are the standard products of manufacturers regularly engaged in the production of diesel engine pump drives and that essentially duplicate products which have been used satisfactorily for at least two years prior to bid opening. An offer proposing an experimental engine, one having a lesser or greater number of cylinders than the offerors’ standard production engines, or one without a demonstrated satisfactory service record as a full diesel engine operating not less than 1,200 hours a year at not less than 75 percent rated load, will be rejected. All products shall be new.

2.1.2 Nameplates

Provide each major component with the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the equipment. As a minimum, nameplates shall be provided for the following items:

a. Engines

b. Radiators

c. Exhaust mufflers

d. Clutch

2.1.3 Personnel Safety Devices

Insulate, fully enclose, guard, or fit with other types of safety devices all exposed moving parts, parts that produce high operating temperatures, parts which may be electrically energized, and parts that may be a hazard to operating personnel. Install the safety devices so that proper operation of the equipment is not impaired.

2.2 MATERIALS

2.2.1 Filter Elements

Provide fuel-oil, lubricating-oil, and combustion-air filter elements which are the manufacturer's standard type and able to filter out particles down to a 25 to 40 micron size, unless otherwise noted.

2.2.2 Pipe (150 psi System and Under)

Pipe for sleeves, fuel/lube-oil, compressed air, coolant, exhaust, and miscellaneous uses shall comply with ASTM A53/A53M, or ASTM A106/A106M steel pipe. Pipe smaller than 2 inch shall be Schedule 80. Pipe 2 inch and larger shall be Schedule 40.

a. Flanges and flanged fittings: ASTM A181/A181M, Class 150, or ASME B16.5.

b. Pipe welding fittings: ASTM A234/A234M, Grade WPB or WPC, Class 150 or ASME B16.11, 3,000 lbs.

c. Threaded fittings: ASME B16.3, Class 150.

d. Valves: MSS SP-80, Class 150.

e. Gaskets: manufacturer's standard.

2.2.3 Temperature Gauges for Oil or Water Service

Manufacturer's standard flush-mounted, 2 inch minimum diameter dial size with standard operating point at 50 percent of the full gauge range. Gauge construction and materials shall be appropriate for the intended service.

2.2.4 Pipe Hangers

MSS SP-58 and MSS SP-69

2.2.5 Pressure Gauges

Manufacturer's standard flush mounted, 2 inch minimum dial diameter with standard operating point at 50 percent of the full gauge range. Gauge construction and materials shall be appropriate for the intended service.

2.3 DIESEL ENGINE

a. The engine shall be a full diesel, 4 cycle, compression-ignition type, for stationary applications and shall operate on No. 2-D diesel fuel conforming to ASTM D 975. The engine shall be naturally aspirated, turbocharged, or turbocharged-aftercooled.

b. The engine shall supply a minimum Industrial intermittent (IND-C) rating of 650 hp at 1800 rpm. The engine shall be of the vertical in-line, or vee type with a solid cast block or individually cast cylinders. The engine shall be current model of a type in regular production and shall be complete with all devices specified or normally furnished with the engine.

2.3.1 Crankcase Pressure Relief Valve

A pressure relief valve shall be provided in the crankcase. The crankcase shall be vented in accordance with the manufacturer's recommendations, except the engine exhaust shall not be used as the venting system. Crankcase breathers, if provided on engines installed in either a building or enclosure, shall be piped to vent to the outside.

2.4 FUEL SYSTEM

The fuel system for each engine shall conform to requirements of NFPA 30 and NFPA

37. The fuel system shall include the following items.

2.4.1 Fuel Pump

The engine shall be provided with an engine-driven, positive displacement engine fuel pump. The pump shall have the capacity to transfer fuel from the day tank at a rate in excess of maximum fuel consumption stated in paragraph FUEL CONSUMPTION, as well as supplying adequate pressure for the fuel injectors.

2.4.2 Filter

A minimum of one duplex filter with a trans-flow change-over valve shall be supplied with the engine. The filter shall have inlet and outlet connections plainly marked. An indicating differential pressure gauge shall be provided across the filter. The filter shall be located on the inlet side of the fuel pump. The filter shall be capable of filtering out particles down to 25 micron size.

2.4.3 Strainer

A full flow strainer of the replaceable cartridge type shall be provided between the engine and the fuel tank, upstream of the duplex filter. An indicating differential pressure gauge shall be provided for upstream and downstream of the strainer. The strainer cartridge shall be capable of filtering out particles down to 125 micron size.

2.4.4 Safety Bypass Valve

A safety bypass valve shall be provided next to the pump isolation valve to prevent the buildup of excessive pressures if the discharge line or fuel pump filters become clogged.

This bypass shall protect the fuel piping from over-pressurizing and will relieve it at 60 psi.

The bypass valve relief line shall return the fuel to the engine day tank.

2.5 LUBRICATION

The engine shall have a separate lube-oil system conforming to NFPA 30 and NFPA 37.

The system shall be pressurized by an engine-driven pump. The lube-oil pump shall draw oil from the oil pan through a mesh intake and force it through a lubricating oil cooler and a single full-flow strainer into the engine. The pump shall be protected by a relief valve to bypass the oil into sump. A portion of the oil from the sump shall be bypassed through a lubricating oil filter and back into the engine oil pan. The lubricating oil temperature shall be regulated by means of an automatic temperature regulator which will control the amount of bypass oil around the cooler. The system shall be readily accessible for service such as draining or refilling. Each system shall permit the addition of oil and have oil-level indication with the set operating.

2.5.1 Pump Filters

One full-flow, duplex, 80 micron filter shall be provided for each pump. The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have inlet and outlet connections plainly marked. An indicating differential pressure gauge shall be provided across the filter.

2.5.2 Lube-Oil Sensors

The engine shall be equipped with lube-oil temperature and pressure sensors.

Temperature sensors shall provide signals for pre-high and high lube-oil indication and alarms. Pressure sensors shall be located downstream of the filters and provide signals for pre-low and low lube-oil indication and alarms.

2.5.3 Lubricating Oil Strainer

A full-flow, oil strainer shall be furnished in-line, ahead of the engine. The strainer shall be as recommended by the engine manufacturer. A bottom drain plug shall allow easy removal of the sludge.

2.6 COOLING SYSTEM

a. The engine shall have its own cooling system. The system shall be of the closed type and operate automatically while the engine is running.

b. The cooling system shall have an engine-driven water pump, fin tube radiator, expansion tank, and an automatic temperature regulating valve. The maximum temperature rise of the coolant across the engine shall not exceed the engine manufacturer's recommendation.

c. The engine cooling system shall be of the closed type arranged to prevent rust and minimize formation of scale deposits within the engine. The system shall circulate jacket-coolant through the engine at the temperature and flow rate recommended by the engine manufacturer. The coolant shall be an ethylene-glycol water mixture with a concentration sufficient for freeze protection at the minimum outdoor temperature specified. The maximum temperature rise of the coolant shall be no more than that recommended by the engine manufacturer.

2.6.1 Coolant Pumps

Engine-driven jacket water pumps shall be of the centrifugal type. The engine shall have an engine-driven primary pump. The pump shall be a bronze fitted, single stage type with removable seal rings and stuffing box and properly sized for the intended purpose.

2.6.2 Radiator

The radiator shall be sized to limit the maximum allowable temperature rise on the coolant across the engine to that recommended by the engine manufacturer, for the maximum outdoor design temperature and site elevation. Radiator fabrication materials shall be corrosion resistant and for service in the ambient application conditions. The radiator may be factory coated with corrosive resistant film provided that corrective measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via over-sizing or other compensating methods. Internal surfaces shall be compatible with the contractor supplied liquid fluid coolant. The radiator shall be the pressure type incorporating a pressure valve, vacuum valve, and a radiator cap. Radiator caps shall provide for pressure relief prior to removal. Each radiator and the entire cooling system shall be capable of withstanding a minimum pressure of 7 psig. Each radiator shall be protected with a strong grille or screen guard. Radiators shall have at least two tapped holes. One tapped hole in the radiator shall be equipped with a drain cock; the rest shall be plugged.

2.6.3 Thermostatic Control Valve

A modulating type, thermostatic control valve shall be provided in the coolant system to maintain the engine coolant temperature in the range recommended by the engine manufacturer.

2.6.4 Temperature Sensors

The engine shall be equipped with coolant temperature sensors. Temperature sensors shall provide signals for pre-high and high coolant temperature indication and alarms.

2.6.5 Expansion Tank

An expansion tank shall be furnished for the engine. The tank shall be properly fitted for vent, overflow, expansion, and make-up lines. The tank shall be suitable for an operating temperature of 250 degrees F and a working pressure of 125 psig. The tank shall be constructed of welded steel, hot-dipped galvanized inside and outside after fabrication, tested, and stamped in accordance with ASME BPVC SEC VIII D1 and registered with the National Board of Boiler and Pressure Vessel Inspectors. The tank shall be mounted so that the bottom of the tank is above the top of the engine. The tank shall be supported as recommended by the engine manufacturer.

2.7 SPECIAL LIMITATIONS

2.7.1 Vibration Isolation.

The maximum engine vibration in the horizontal, vertical, and axial directions shall be limited to 6 mils peak-peak RMS, with an overall velocity limit of 0.95 inch/sec RMS.

The engine shall be provided with a vibration-isolation system in accordance with the manufacturer's standard practice. Vibration-isolation systems shall be designed as an integral part of the base and mounting system.

2.8 AIR INTAKE EQUIPMENT

Filters and silencers shall be provided in locations that are convenient for servicing as shown on the project plans. The silencer shall be of the high-frequency filter type, located in the air intake system as recommended by the engine manufacturer. A combined filter silencer unit meeting requirements for the separate filter and silencer items may be provided.

Expansion elements in air-intake lines shall be rubber.

2.9 EXHAUST SYSTEM

The system shall be separate and complete for the engine. Exhaust piping shall be supported to minimize vibration. Provisions shall be made for pipe thermal expansion.

Where a V-type engine having more than one exhaust outlet is provided, a V-type connector, with necessary flexible sections and hardware, shall connect the engine exhaust outlets. The exhaust connectors shall incorporate engine-mating and silencer-mating flanges, eliminating the need for adapters. The exhaust shall be routed so the pipe utilizes the existing building exhaust penetration.

2.9.1 Flexible Sections and Expansion Joints

A flexible section shall be provided at the engine and an expansion joint at each muffler.

Flexible sections and expansion joints shall have flanged connections. Flexible sections shall be multiple-ply stainless steel expansion bellows type with standard 1.5 and 3 inch allowable axial expansion. Elements in the flexible sections shall be capable of absorbing vibration from the engine and compensating for thermal expansion and contraction.

2.9.2 Exhaust Muffler

A chamber type exhaust muffler shall be provided. The muffler shall be fabricated of welded steel and designed for inside mounting. Eyebolts, lugs, flanges, or other items shall be provided as necessary for support of the muffler in the location and position of the existing engines muffler. The pressure drop through the muffler shall not exceed the recommendations of the engine manufacturer. The muffler shall have a drain valve, nipple, and cap at the low-point of the muffler. The muffler shall be supplied complete with any necessary soot boxes or inspection ports required for adequate operation and maintenance. The entire exhaust system shall be sized appropriately so that the operation of the engine is not affected by the exhaust system.

2.9.3 Exhaust Piping

Horizontal sections of the exhaust piping shall be sloped downward away from the engine to a condensate trap and drain valve. Changes in direction shall be made utilizing long radius fittings. Exhaust piping, mufflers, and silencers shall be insulated with ASTM C533 calcium silicate insulation, minimum of 3 inch thickness or an appropriate thickness to limit the surface temperature to values below 175 degrees F. Insulation shall be secured with not less than 0.375 inch width Type 304 stainless steel bands spaced no farther apart than 8 inches on center. An aluminum jacket encasing the insulation shall be provided. The aluminum jacket shall have a minimum thickness of 0.016 inch with a factory-applied polyethylene and kraft paper moisture barrier. The jacket shall be secured with not less than1/2 inch wide stainless steel bands, spaced no farther apart than 8 inch on centers. Longitudinal and circumferential seams of the jacket shall be lapped not less than 3 inch. Jackets on horizontal lines shall be installed so that the longitudinal seams are on the bottom side of the pipe. The seams of the jacket for the vertical lines shall be placed on the off-weather side of the pipe. On vertical lines, the circumferential seams of the jacket shall overlap so that the lower edge of each jacket overlaps the upper edge of the jacket below. Vertical exhaust piping shall be provided with a hinged, gravity-operated, self-closing rain cover. When the exhaust pipe exits the building, the pipe should be isolated from the wall by means of thimbles in accordance with

NFPA 37.

2.10 EMISSIONS

The finished installation shall comply with Federal and local regulations and restrictions regarding the limits of emissions such as carbon monoxide (CO), hydrocarbon (HC), and nitrous (NOx).

2.11 STARTING SYSTEM

The diesel engine shall be provided with a starting system. The system shall be pneumatic and of sufficient capacity to start the engine at the minimum temperature specified. The system shall have a start-stop switch which provides functions including testing, reset, manual run/start, manual stop, and adjustable cranking and cooling down operation. The starting system shall be the manufacturer's standard equipment.

2.11.1 Compressed Air Starting System

The engine shall utilize the existing compressed air system located within the pumping station. The system shall be furnished complete with oilers, regulators, and solenoid control valves. The starting system shall be air motor type with a working pressure of 150 psig. The contractor shall provide a flexible connection between the existing pumping station air piping and the engine starting system.

2.11.1.1 Air Filter

An air filter shall be installed upstream of the air connection to the engine. The filter shall be capable of removing particles 3/8 inch and larger.

2.11.1.2 Air Driven Motors

The air motor starting system cranking motors shall be complete with a solenoid valve, strainer, and lubricator.

2.11.2 Starting Aids

2.11.2.1 Jacket-Coolant Heaters

A thermostatically controlled electric heater shall be mounted in the engine coolant jacketing to automatically maintain the coolant within ±10 deg. F of the control temperature. The heater shall operate independently of engine operation so that starting times are minimized, condensation is controlled, and the system ensures dependable, cold weather starts. Power supply for the heaters will be 208 volts AC.

2.12 SAFETY SYSTEM

Devices, wiring, remote annunciator panels, alarm panels, etc., shall be provided and installed as a complete system to automatically activate the appropriate signals and initiate appropriate safety actions. The safety system shall be provided with a self-test method to verify its operability. Alarm signals shall have manual acknowledgment and reset devices. The alarm signal systems shall reactivate for new signals after acknowledgment is given to any signal. The systems shall be dealt with as an alarm on that system element. The remote annunciator panels and alarm panel shall be as specified in paragraph PANELS.

2.12.1 Audible Signal

The audible alarm signal shall sound at a frequency of 70 Hz at a volume of 100 dB at 10 ft. The sound shall be continuously activated upon alarm and silenced upon acknowledgment. Signal locations shall be as shown on the plans.

2.12.2 Visual Signal

The visual signal shall be a panel light. The light shall normally be off but activated to blinking upon alarm. The light shall change to continuously lit upon acknowledgment. If automatic shutdown occurs, the display shall remain in an activated status to indicate the cause of failure and shall not be reset until the cause of alarm has been cleared and/or restored to the normal condition. Shutdown alarms shall be amber.

2.12.3 Alarms and Action Logic

2.12.3.1 Shutdown

Shutdown signals shall simultaneously activate the audible signal, activate the visual signal, and stop the engine.

2.12.3.2 Problem

Problem signals shall activate the visual signal.

2.12.4 Alarm Panel

The panel shall be fabricated and located as specified in paragraph PANELS, and shall contain the following functions:

FUNCTION OR INDICATION/CONTROL ACTION (AUXILIARY ACTION)

a. Red emergency stop (push button or switch)/shutdown engine.

b. Day tank overfill indication (95 percent volume)/problem (shutdown pump supplying fuel to day tank).

c. Engine overspeed indication (overspeed indication point as recommended by the engine supplier)/shutdown engine.

d. High lube-oil temperature indication (temperature as submitted)/shutdown engine.

e. Low lube-oil pressure indication (pressure as submitted)/shutdown engine.

f. High coolant fluid outlet temperature indication (temperature as submitted)/shutdown engine.

g. Pre-low lube-oil pressure indication (110 percent of low lube-oil pressure)/problem (none).

h. Pre-high coolant fluid temperature indication (10 degrees F lower than high coolant-fluid outlet temp. alarm)/problem (none).

i. Pre-high lube oil temperature indication (10 degrees F) lower before problem (none).

j. Day tank empty indication (20 percent volume remaining)/shutdown engine.

k. Failure to start within the specified time indication/problem (none).

l. Compressed air low-pressure indication (80 percent of working pressure)/problem (none).

2.12.5 Time-Delay on Alarms

For startup of the engine, time-delay devices shall be installed bypassing the low lubricating oil pressure alarm during cranking and the low coolant-fluid outlet temperature alarm. The lube-oil time-delay device shall return its alarm to normal status after the engine starts. The coolant time-delay device shall return its alarm to normal status 5 minutes after the engine starts.

2.13 GOVERNOR

Each engine shall be provided with a governor to control the rotational speed of the engine in response to changing load requirements. The governor shall be configured for safe manual adjustment of the speed during operation of the engine, without special tools.

2.13.1 Speed Regulating Governor

The engine governor shall maintain close speed regulation under all load conditions. The speed variation shall not exceed 6 percent of normal speed when full load is suddenly applied or removed. The design of the governor shall be such that the engine speed may be changed by governor adjustment during engine operation to any speed between 80 and 100 percent of the normal speed (corresponding to normal operating pump speeds) within 2 percent. The speed fluctuation at any load shall not exceed 2 percent. A raise/lower speed control shall be mounted on the engine instrument board. The engine fuel rack servomotor shall be suitable for operation from a 120-V AC source.

2.13.2 Emergency Overspeed Governor and Load Limit

An emergency governor with overspeed trip shall be provided on each engine to shut down the unit should the speed exceed a predetermined RPM. The overspeed trip shall also provide an alarm signal for remote indication. The emergency governor shall be independent of the regulating governor. When the overspeed stop has been tripped, the shutdown mechanisms shall be such that the engine fuel and air supply is prevented in the shortest time practicable from entering the engine cylinders. The trip mechanism may be part of the governor. The engine shall have an overload fuel limit set at 110 percent of the full load specified in paragraph DIESEL ENGINE.

2.13.3 Governor Controls Location

The governor control shall be located at a point convenient to the location of the engine instrument board.

2.14 ENGINE INSTRUMENT BOARD

The engine instrument board shall be as specified in paragraph PANELS, and shall contain the following items:

a. Coolant-fluid inlet temperature display

b. Lubricating-oil pressure indicator

c. Lubricating-oil inlet temperature display

d. Red emergency stop (push-button or switch)

e. Run-time meter

f. Fuel meter display

g. Fuel-header-pressure display

h. Tachometer display

i. Engine start-stop switch

j. Start-attempt indicator light

k. Lubricating-oil pre-lubricating pump start-stop switch

l. Alarm panel

m. Ethernet port capable of reading and writing to engine control for external PLC communication

2.15 PANELS

Each panel shall be of the type and kind necessary to provide specified functions.

Panels shall be mounted on the engine base by vibration/shock absorbing type mountings. Instruments shall be mounted flush or semi-flush. Convenient access to the back of panels shall be provided to facilitate maintenance. Instruments shall be calibrated using recognized industry calibration standards. Each panel shall be provided with a panel identification plate which clearly identifies the panel function as indicated.

Each instrument and device on the panel shall be provided with a plate which clearly identifies the device and its function as indicated. All instruments and devices shall be vibration resistant.

2.15.1 Enclosures

Enclosures shall be designed for the application and environment, conforming to NEMA ICS 6. Locking mechanisms shall be keyed alike.

2.15.2 Analog

Analog electrical indicating instruments shall be in accordance with ANSI C39.1 with semi-flush mounting. Panel-mounted instruments shall be the manufacturer's standard with an accuracy of not less than 2 percent. The instrument's operating temperature range shall be -4 to +150 degrees F.

2.15.3 Parameter Display

Continuous indication of the tachometer, lubricating-oil pressure, and safety system parameters shall be provided. A momentary switch shall be specified for other panels.

2.16 BASE

The base shall be constructed of structural steel. The base shall be designed to rigidly support the engine, ensure permanent alignment of all rotating parts, be arranged to provide easy access to allow changing of lube-oil, and ensure that alignment is maintained during shipping and normal operation. The base shall not permit skidding in any direction during installation and shall withstand and mitigate the effects of synchronous vibration of the engine and pump. The base shall be provided with suitable holes for mounting to the existing engine pedestal and anchor bolts.

2.17 PAINTING

The engine and the accessory equipment including, but not limited to, panels, valves, piping, intake, and exhaust system components shall be cleaned, primed, and painted in accordance with the manufacturer's standard color and practice.

2.18 FACTORY INSPECTION AND TESTS

Prior to shipment, the engine shall be inspected and tested at the factory in the presence of the Contracting Officer or the authorized government representatives. The inspection shall cover all components including, but not limited to, governors, instrumentation panels, engine starting system, intake and exhaust, lubrication system, cooling system, and fuel system. Inspection shall be completed and all necessary repairs made prior to testing.

Unless otherwise directed by the Contracting Officer or the authorized government representative, the following factory tests shall be performed:

a. Simulated emergency or overspeed trip test.

b. Sustained operation test of 4 hours at rated full load.

c. Sustained operation test of 2 hours at 70 percent of rated full load.

d. Fuel consumption tests of not less than 1 hour each at 70 and 100 percent rated full load,…