B08 - AMD 0005 SPECS ONLY_MODIFIED SEC 41 65 10_PG1_7-18.pdf

1 W912EK26BA007

AMND 0005

31 JULY 2026

The following modifications are made to SECTION 41 65 10.

SECTION 41 65 10

a. PAGES 1, 7-18. Delete Section 41 65 10 Pages 1, 7-18 in their entirety, and substitute therefore revised Section 41 65 10 Pages 1, 7-18, Amendment

0005, dated 31 JULY 2026.

ATTACHMENTS: Section 41 65 10 Pages 1, 7-18

Muscatine PL84-99 SOLICITATION NO.: W912EK26BA007

SOLICITATION 06/2026 B5MUSC13202401

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 65 10

DIESEL FUELED ENGINE PUMP DRIVES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 WELDER QUALIFICATIONS

1.4 DELIVERY, STORAGE, AND HANDLING

1.5 PROJECT/SITE CONDITIONS

1.6 LAYOUT AND SHOP DRAWINGS

1.7 FIELD ENGINEER

1.8 INSTALLATION AND ALIGNMENT PROCEDURES

PART 2 PRODUCTS

2.1 PERSONNEL SAFETY DEVICES

2.2 MATERIALS AMND 0005

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

2.2.6 Engine AMND 0005

2.2.7 Shaft

2.2.8 Automatic Greaser

2.2.8.1 Grease Piping

2.2.9 Engine Radiator

2.2.10 Engine Clutch

2.2.11 Gear Drive

2.2.12 Compressed Air Piping

2.2.12.1 Steel Piping

2.2.13 Engine Installation Plan

2.2.14 Pre-Functional Checklist

2.2.15 Functional Checklists

2.3 DUCT SYSTEMS

2.3.1 Metal Ductwork

2.3.2 Corrosion Resisting (Stainless) Steel Sheets

2.3.3 Duct Liner

2.4 EXHAUST SYSTEM

2.4.1 Flexible Sections and Expansion Joints

2.4.2 Exhaust Muffler

2.4.3 Exhaust Piping

2.5 EMISSIONS

PART 3 EXECUTION

3.1 PROPOSED INSTALLATION PROCEDURES

3.2 PIPING INSTALLATION

SECTION 41 65 10 Page 1 AMND 0005

31 JULY 2026

PART 2 PRODUCTS

For submittal items, submit product datasheets unless otherwise stated.

2.1 PERSONNEL SAFETY DEVICES

Insulate, fully enclose, guard, or fit with other types of safety devices for 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 as recommended by manufacturer.

Install the safety devices so that proper operation of the equipment is not impaired. This includes a painted fabricated steel guard for the engine drive shaft and universal joints. Design the guard to be secured in place to the structure to guard personnel from accidental contact with rotating components and not for drive failure.

2.2 MATERIALS AMND 0005

All materials to have similar look, functionality, and operation as diesel powered pump system No. 3 located at the pump station. All components Components to be new and unused. Engine may be new or re-manufactured.

Components to match other colors and finishes of pump System No. 3 components or as provided by manufacturer. All equipment to have a nameplate or tag stating model number, serial number, and design characteristics in an easily accessible location.

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. Filter elements to be located in an accessible location that does not obstruct walking paths or other equipment. See Section 33 52 10 FUEL SYSTEMS SERVICE PIPING for more information.

2.2.2 Pipe (150 psi System and Under)

Pipe for sleeves, lube-oil, coolant, exhaust, and miscellaneous uses in accordance with ASTM A53/A53M, or ASTM A106/A106M steel pipe. Provide Schedule 80 pipe for pipe smaller than 2 inches . Provide Schedule 40 pipe for pipe that is 2 inches and larger.

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

b. Pipe welding fittings: Provide in accordance with ASTM A234/A234M , Grade WPB or WPC, Class 150 or ASME B16.11 , 3,000 pounds .

c. Threaded fittings: Provide in accordance with ASME B16.3 , Class 150.

d. Valves: Provide in accordance with MSS SP-80 , Class 150.

e. Gaskets: Provide manufacturer's standard.

SECTION 41 65 10 Page 7 AMND 0005

2.2.3 Temperature Gauges for Oil or Water Service

Manufacturer's standard flush-mounted, 4 inch minimum diameter dial size with standard operating point at 50 percent of the full gauge range.

Provide proper gauge construction and materials for the intended service.

Design gauges for vibration when engine mounted. Gages in accordance with

ASME B40.200 .

2.2.4 Pipe Hangers

Provide in accordance with MSS SP-58 . Refer to Section 33 52 10 FUEL

SYSTEMS SERVICE PIPING.

2.2.5 Pressure Gauges

Provide manufacturer's standard flush mounted, 4 inch minimum dial diameter with standard operating point at 50 percent of the full gauge range. Provide proper gauge construction and materials for the intended service. Design gauges for vibration when engine mounted. Gauges in accordance with ASME B40.100 .

2.2.6 Engine AMND 0005

Provide one Diesel Industrial Engine. Engine to be rated to 1,500 H.P.

and to meet Tier 2 Emissions levels. Engine to not require Diesel Exhaust Fluid (DEF). Coordinate with Manufacturer to ensure proper installation.

Provide with manufacturer recommended base and mounting. Properly align with shaft, gear drive, radiator, and other components. Match characteristics and looks of existing pump System No. 3 Engine. Engine to use same oil filters, lubrication, and maintenance as existing Pump System No. 3. Provide with manufacturer recommended radiator, high speed shaft, and clutch. Engine to be programmed to run at 1,206 rpm. All engine installation and programming to be completed to provide fully functioning system. Provide according to all manufacturer recommendations and specifications. Engine may be new or re-manufactured. Re-manufactured engines must meet or exceed Original Equipment Manufacturer (OEM) specifications. Re-manufactured engines require complete disassembly, replacement or precision machining and repair of worn components to new condition, thorough cleaning, and certification by original manufacturer.

All accessories and engine components are to be manufactured by the same company as the engine manufacturer or to be items recommended by the manufacturer to be used with the engine. Provide with the following characteristics or components:

a. Aftercooler core, corrosion resistant.

b. Air cleaners and service indicators.

c. Inline clutch installed with rear support. Provide with manual hand clutch.

d. Includes adjustable speed drop capability.

e. Requires 24V DC 10-amp continuous, 20-amp intermittent, clean electrical power.

f. Pneumatic speed control, 10-100PSI.

g. Outlet controlled thermostat and housing.

h. Manufacturer recommended Radiator group.

i. Dual Jacket water heater 480V 12KW. UL recognized. 240-480-volt, single phase, 12 kW total, LH and RH mounted. For use in 32 F minimumair temperature with 440 fpm max air flow. Fixed thermostat.

Set for cut in at 140 F.

SECTION 41 65 10 Page 8 AMND 0005

j. Radiator plumbing

k. Dual outlets

l. Exhaust manifolds dry.

m. SS Flex.

n. NBG kit.

o. 14 inch 90-degree elbow with SS rain cap ship loose.

p. Dual turbo chargers.

q. Exhaust outlet min 8 inch I.D.

r. 14 inch residential grade silencer ship loose.

s. Fitting or flange to connect to exhaust piping.

t. Flywheel, SAE No. 00.

u. Flywheel housing, SAE No. 00

v. SAE standard rotation.

w. Fuel transfer pump. Ensure fuel pumps are sized to provide required fuel.

x. Flexible fuel lines.

y. Electronically controlled unit injectors.

z. Fuel filters, water separator, and fuel priming pump. Shutoff valves to be located on both sides of fuel components.

aa. Instrument panel included. Panel to include service meter, lube oil pressure gauge, tachometer, system voltage, fuel pressure gauge, jacket water temperature gauge, intake manifold temperature gauge, lube oil temperature gauge, turbocharger inlet temperature gauge (RH/LH), air cleaner restriction gauge (RH/LH), oil and fuel differential gauges, aftercooler temperature gauge, boost pressure gauge, start-stop switch, cool down logic and auto-crank cycle, E-stop, alarm horn, SEMS module with diagnostic display and exhaust pyrometer with thermocouples).

ab. Crankcase breather.

ac. Oil cooler.

ad. Shallow oil pan.

ae. Oil pan drain valve, 2 inch NPT female connection.

af. Simplex oil filter-LH.

ag. Pre lube pump 24 volts.

ah. 13 inch rails.

ai. Included air starting motor and silencer. AMND 0003

aj. Electric air start control.

ak. Shutoff Group Air.

al. Accessory drive.

am. Lower LH front (available PTO usage).

an. Front housing, two sided.

ao. Engine to satisfy all requirements of NFPA 37 .

ap. Vibration damper and guard.

aq. Manufacturer recommended battery charger.

ar. Battery box, cables and batteries.

as. Lifting eyes.

at. DTO 2D drawings.

au. Manufacturer industrial start-up.

av. EPA Replacement Engine.

aw. Remote mounted speed control hand knob. (Harness installed. Hand knob shipped loose. Provides full engine rpm control. Includes electronic rotary throttle control. 12-32-volt operation, twist knob, locking design, two turns low to high speed, counter clockwise to increase engine speed).

ax. Charging alternator 24V 60 Amp-CJ. (RH Mounted. Includes Upper RH Accessory drive and alternator drive. Belt driven. Heavy duty with integral regulator, belts, belt guard, and mounting).

ay. Manufacturer: Company specializing in packaged engine systems with minimum 10 years documented experience.

SECTION 41 65 10 Page 9 AMND 0005

az. Supplier: Authorized distributor of engine generator manufacturer with service facilities within 100 miles of project site.

ba. Fuel shutoff valves at engine.

Provide a consumables parts list and supply of all maintenance items needed for 1 year after the contract has been completed including fuel filters, oil filters, and other engine components. Provide a 5 year warranty on all equipment, parts, labor, and services. Provide Engine Manual digitally and hard copy as part of O&M Manual submittal under Section 01 78 00 CLOSEOUT SUBMITTALS. Provide digital and printed laminated instructions for engine startup.

2.2.7 Shaft

Shaft to be in proper alignment with engine and gear drive, have safety guard so that shaft cannot be touched during operation, be provided with nickel plating and have a horsepower rating greater than or equal to 1,500 HP rating for diesel engine with additional rating factors applied as recommended by manufacturer for the application. Provide with universal joints on each end and proper connections to gear drive and engine. Ensure shaft offset angle and elevation does not exceed manufacturer recommendations. Provide guard for shaft with universal joints on each end. Verify shaft is sufficient and does not exceed critical speeds. Shaft to meet all manufacturer recommendations.

2.2.8 Automatic Greaser

Automatic greaser to match on-site Pump System No. 3 greaser in functionality and style. Grease line to have five lines running to pump well, connect to existing grease ports, and lines to be fabricated from copper. All accessories and greaser components are to be manufactured by the same company or be items recommended by the manufacturer to be used with the greaser. Provide with the following characteristics or accessories:

a. Dual piston pump with working pressure rating of 3,500 psi (240 bar).

b. Life rating of pump more than two million cycles at 3,500 psi.

c. Steel reservoir supplied with visual indicator and low level warning switch standard.

d. Air bleed in reservoirs to eliminate air pockets at 3,000 psi.

e. Reversing valve set at 1,500 psi.

f. Adjustable relief valve - readily accessible on the outside.

g. Grease Injectors:

(1) Operating Pressure: 1,200-3,500 psi

(2) Material: Carbon steel, 300 series stainless steel

(3) Surface Protection: Zinc

(4) Maximum Operating Temperature: 350 degrees F

h. Controller

(1) Controller to be mounted to rest of unit.

(2) All greaser controls to be programmed according to Pump requirements.

2.2.8.1 Grease Piping

Provide 3/8 inch seamless drawn copper tubing. Tubing to be light-drawn copper tubing conforming to ASTM B75/B75M. Heating elements to be able to withstand an internal hydrostatic pressure of 3,500 psig for not less than 15 seconds without leaking or any evidence of damage.

SECTION 41 65 10 Page 10 AMND 0005

2.2.9 Engine Radiator

Provide manufacturer recommended radiator assembly. Provide ductwork from engine to radiator and out to louver. Ductwork to be provided with an access door. Engine radiator to have similar look, functionality, and operation as diesel powered pump system No. 3.

2.2.10 Engine Clutch

Coordinate with engine manufacturer to ensure proper functionality of engine clutch with engine. Engine clutch to have a manual hand clutch.

Clutch to have a horsepower rating of at least 1,500 HP. Clutch to be painted to match engine color, and have similar look, functionality, and operation as diesel powered pump system No. 3.

2.2.11 Gear Drive

Gear drive to have similar look, functionality, and operation as diesel powered pump system No. 3. Gear drive to be painted to match right angle gear drive for pump system No. 3, and to have a ratio of 3:1. Verify that the rotations of the gear drive will turn the pump the correct direction at the correct speed. Coordinate with manufacturers to ensure proper functioning of gear drive with other components. Properly align gear drive with shaft, engine, and other components. Verify gear drive and adaptor plate dimensions to ensure proper functionality and stability.

Grating around gear drive to be reused. If grating is damaged or does not fit due to changes, provide new grating. Refer to Section 43 21 39 WATER, VERTICAL TURBINE & APPURTENANCES PUMPS for further details.

2.2.12 Compressed Air Piping

Provide compressed air piping in kind to existing compressed air piping.

Low pressure compressed air piping and accessories to be rated for 125 psig at 150 degrees F.

2.2.12.1 Steel Piping

a. Pipe: Pipe to conform to ASTM A53/A53M, be seamless carbon steel, Schedule 40, and black.

b. Fittings: Fittings 2-inches and larger to conform to ASME B16.9, and be carbon steel, butt welded, and schedule 40 flanged fittings, 1/16 oil resistant synthetic rubber gaskets conforming to ASTM D1330, bolts conforming to ASTM A193/A193M Grade B7, and nuts conforming to ASTM A194/A194M Grade 7. Butt welded joints to be full penetration consumable insert or backing ring type.

c. Fittings, size 1 1/2 inches and smaller to conform to ASME B16.3 , and to be threaded malleable iron, Class 150, and have Class 2,000 threaded. Joints may also be butt welded or flanged, as specified for sizes 2 inches and larger.

d. Flat-faced steel flanges: Where connections are made to Class 125 cast iron flanges with steel flanges, use only flat-faced Class 150 steel flanges. Unions: conform to ASME B16.39 , Class 1 and be rated for 300 psig WOG.

SECTION 41 65 10 Page 11 AMND 0005

2.2.13 Engine Installation Plan

Provide a detailed plan and engineering drawings on how the engine, gear drive, shaft, clutch, piping, and all other components associated with the engine will be installed. Submit a table of dimensions, elevations, locating to be verified for each operating equipment for approval, survey and record the necessary dimensions for installation of engine mounting, shaft connection, gear drive connection and mounting, and all other equipment. All installation to be in accordance with codes and standards and manufacturer recommendations. Show angle for drive shaft, gear drive, and engine connections. If Engine Installation plan is determined to require additional details or revisions, it to be updated and resubmitted. Provide for all machinery and equipment at least 30 days prior to beginning the erection and installation. The installation procedure includes dates and schedule of work. Methods and procedures to accelerate the sequence of work submitted for approval. Submit the installation procedures, installation instructions, and alignment tolerances of all equipment and mating components. Engine installation to satisfy all requirements for NFPA 37 .

2.2.14 Pre-Functional Checklist

Submit developed checklist for checks, recordings, measurements, settings, alarms and safety, and verifications to be performed prior to start up. Acceptance will be required by signatures from all parties.

2.2.15 Functional Checklists

Submit developed checklist for checks, recordings, measurements, settings, alarms and safety, and and verifications to be performed after start up. Acceptance will be required by signatures from all parties.

2.3 DUCT SYSTEMS

2.3.1 Metal Ductwork

Provide metal ductwork construction, including all fittings and components, in accordance with SMACNA 1966 and as specified.

a. Provide ductwork in accordance with Seal Class A. Seal all joints to minimize leaks.

b. Provide sealants in accordance with fire hazard classification and that are suitable for the range of air distribution and ambient temperatures to which exposed. Do not use pressure sensitive tape as a sealant. Provide duct sealant products emissions in accordance with CDPH SECTION 01350 (limit requirements for either office or classroom spaces regardless of space type) or VOC content in accordance with SCAQMD Rule 1168 (HVAC duct sealants are classified as "Other" within the SCAQMD Rule 1168 sealants table). Provide validation of indoor air quality for duct sealants.

c. Make spiral lock seam duct, and flat oval with duct sealant and lock with not less than three equally spaced drive screws or other approved methods in accordance with SMACNA 1966. Apply the sealant to the exposed male part of the fitting collar so sealer is on the inside of the joint and fully protected by the metal of the duct fitting. Apply

SECTION 41 65 10 Page 12 AMND 0005 one brush coat of the sealant over the outside of the joint to at least 2 inch band width covering all screw heads and joint gap. Dents in the male portion of the slip fitting collar are not acceptable.

d. Fabricate outdoor air exhaust ducts and plenums with watertight soldered or brazed joints and seams.

2.3.2 Corrosion Resisting (Stainless) Steel Sheets

Provide in accordance with ASTM A167.

2.3.3 Duct Liner

Unless otherwise specified, duct liners are prohibited.

2.4 EXHAUST SYSTEM

Provide a separate and complete system for each engine. Verify exhaust system satisfy requirements from engine manufacturer. Support exhaust piping to minimize vibration as recommended by manufacturer. Provide expansion joints in accordance with EJMA Standards. Make provisions 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, to connect the engine exhaust outlets. The exhaust connectors to incorporate engine-mating and silencer-mating flanges, eliminating the need for adapters. Provide the muffler and exhaust piping together capable of reducing the noise level at the exhaust discharge location to a point below the maximum sound levels, at a distance of 75 feet from the end of the exhaust piping directly along the path of discharge for horizontal discharged exhaust; or at a radius of 75 feet from the muffler/discharge piping, at 45 degrees apart in all directions, for vertically discharged exhausts, with the engine operating at 100 percent of service load. Reuse existing penetrations when possible. Cap, seal, and finish unused penetrations to match surrounding material.

Exhaust system to match route and functionality of pump No. three exhaust system.

2.4.1 Flexible Sections and Expansion Joints

Provide an expansion joint at each engine and muffler. Provide expansion joints as recommended by engine manufacturer. Flexible sections and expansion joints to have flanged connections. Provide flexible sections as multiple-ply stainless steel expansion bellows type with standard 1.5 and 3 inch allowable axial expansion. Provide elements in the flexible sections capable of absorbing vibration from the engine and compensating for thermal expansion and contraction.

2.4.2 Exhaust Muffler

Provide a chamber type exhaust muffler. Fabricate muffler of welded steel and designed for outside vertical mounting. Provide eyebolts, lugs, flanges, or other items as necessary to support the muffler in the location and position as indicated. The pressure drop through the muffler is not to exceed the recommendations of the engine manufacturer.

Fabricate outside mufflers from aluminized steel or stainless steel and have a drain valve, nipple, and cap at the low-point of the muffler.

Provide complete with any necessary soot boxes or inspection ports required for adequate operation and maintenance. Size the entire exhaust system appropriately so that the operation of the engine is not affected

SECTION 41 65 10 Page 13 AMND 0005 by the exhaust system.

2.4.3 Exhaust Piping

Slope downward horizontal sections of the exhaust piping a minimum of 1/8 inch per foot away from the engine to a condensate trap and drain valve.

Make changes in direction using long radius fittings. Exhaust piping not covered, provided in accordance with paragraph "PIPING INSTALLATION."

Insulate exhaust piping, mufflers, and silencers in accordance with ASTM C533 calcium silicate insulation, minimum of 3 inches thickness or an appropriate thickness to limit the surface temperature to values below 175 degrees F . Secure insulation with not less than 0.375 inch width Type 304 stainless steel bands spaced no farther apart than 8 inches on center.

Provide an aluminum jacket encasing the insulation. The aluminum jacket to have a minimum thickness of 0.016 inch with a factory-applied polyethylene and kraft paper moisture barrier. Secure jacket with not less than 1/2 inch wide stainless steel bands, spaced no farther apart than 8 inches on centers. Lap longitudinal and circumferential seams of the jacket not less than 3 inches . Install jackets on horizontal lines so that the longitudinal seams are on the bottom side of the pipe. Place seams of the jacket for the vertical lines on the off-weather side of the pipe. On vertical lines, the circumferential seams of the jacket to overlap so that the lower edge of each jacket overlaps the upper edge of the jacket below. Provide vertical exhaust piping with a hinged, gravity-operated, self-closing rain cover. When the exhaust pipe exits the building, the pipe will be isolated from the wall by means of thimbles in accordance with NFPA 37 . Pipe system to be adequately supported as described in paragraph 3.2.1 Supports.

2.5 EMISSIONS

The finished installation in accordance with Federal and local regulations and restrictions regarding the limits of emissions such as carbon monoxide, hydrocarbon, and nitros. Engine to meet EPA Tier 2 Emissions Standards. Engine to not include or require Diesel Exhaust Fluid (DEF).

PART 3 EXECUTION

3.1 PROPOSED INSTALLATION PROCEDURES

Submit the proposed installation procedures as specified and proposed.

Coordinate the installation of the equipment furnished and related pumps and gear reducers with the Contracting Officer.

3.2 PIPING INSTALLATION

Sections of pipe within a building are not to exceed 20 feet in length between flanged fittings. Except where otherwise specified, use flanged fittings to allow for complete dismantling and removal of each piping system from the facility without disconnecting or removing any portion of any other system's equipment or piping. Make connections to all equipment with flexible connectors and isolation valves. Complete bending of pipe with pipe benders, and no malformation will be visible on bent pipe.

Support piping and permit to expand and contract without damage to joints or hangers. Install drain valves of 0.6 inch at each low point in the piping. Install shutoff valves in appropriate locations in order to isolate sections of the system. Install isolation valves on both sides of fuel filters and any other equipment that will be maintenanced. Piping to

SECTION 41 65 10 Page 14 AMND 0005 be labeled with the direction of flow and contents. Refer to Section 33 52 10 FUEL SYSTEMS SERVICE PIPING for further details.

3.2.1 Supports

Provide hangers, inserts, and supports of sufficient size to accommodate any insulation in accordance with MSS SP-58 . Space supports in accordance with ASME B31.1 . Piping supports are not to be attached to metal decking. Supports are not to be attached to the underside of concrete filled floors or concrete roof decks unless approved by the Contracting Officer.

3.2.1.1 Ceiling and Roof

If necessary, support exhaust piping with appropriate sized Type-41 single pipe roll and threaded rods; all other piping supported with appropriately sized Type 1 clevis and threaded rods.

3.2.1.2 Wall

Made by suspending the pipe from appropriately sized Type 33 brackets with the appropriate ceiling and roof pipe supports.

3.2.2 Flanged Joints

Provide Class 125 type, drilled, and of the proper size and configuration to match the exhaust outlet of the engine. Provide gasketed and made square and tight.

3.2.3 Cleaning

After fabrication and before assembly, clean all piping interiors of debris.

3.2.4 Pipe Sleeves

Fit pipes passing through ceilings, floors, or walls with sleeves. Each sleeve to extend through and be securely fastened in the structure and cut flush with each surface. Make sleeve of steel or cast-iron pipe. The inside diameter of each sleeve to be a minimum of 0.6 inch larger than the outside diameter of the passing pipe or pipe covering, and where pipes pass through combustible materials, 1 inch larger than the outside diameter of the passing pipe or pipe covering. Pack annular space with oakum, and caulk at ends with silicone construction sealant. For engine exhaust piping sleeves, provide fire resistant, basalt piping sleeve that is rated for minimum 1,200 degrees F.

3.3 ELECTRICAL INSTALLATION

Install in accordance with NFPA 70 and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide vibration isolation for all conduit, cable trays, and raceways attached to the engine.

3.4 ONSITE INSPECTION AND TESTS

Perform tests as outlined by specifications and by manufacturer after complete installation of engine and associated equipment. Record data taken during runs at 30-minute intervals and include all available pressure and temperature data which is monitored by the instrumentation

SECTION 41 65 10 Page 15 AMND 0005 furnished with the engine. Prepare and submit a test report summarizing the test findings and any identified deficiencies.

3.4.1 Contractor Supplied

Provide all equipment and supplies required for the inspections and tests including fuel and test instruments.

3.4.2 Instruments

Verify readings of panel gauges, meters, displays, and instruments provided during all test runs by test instruments of greater precision and accuracy than the operational equipment. Calibrate instruments used in the tests by a recognized standards laboratory within 30 days prior to testing.

3.4.3 Sequence

Follow the testing sequence as specified. Follow manufacturer instructions. Make measurements and record all parameters necessary to verify that each engine meets specified parameters. If the results of any of the test sequences are not satisfactory, make adjustments or replacements and the test sequence repeated until satisfactory results are obtained.

3.4.3.1 Piping Test

a. Flush lube-oil and fuel-oil piping with the same type of fluid intended to flow through the piping, until the out-flowing fluid is free of obvious sediment and emulsions. Provide usable fluids used for testing to Drainage District in properly labeled containers.

b. Hydrostatically pressure test lube oil, fuel-oil and coolant piping at 150 percent of the maximum anticipated working pressure, but in no case less than 150 psig for a period of at least 2 hours to demonstrate the piping has no leaks. If piping is to be insulated, perform the test before the insulation is applied. Conduct tests and inspections in the presence of the contracting officer.

3.4.3.2 Initial Inspection

a. Visually inspect engine mounting bolts and check for proper application and torque.

b. Demonstrate the correct functioning of the high lubricating oil temperature circuit by removing the temperature-sensing elements from the engine and immersing the elements in a vessel containing controlled-temperature hot oil and recording the temperature at which the elements activate.

c. Demonstrate correct functioning of the high coolant-fluid outlet temperature circuit by removing the temperature-sensing elements of the circuit from the engine and immersing the elements in a vessel containing controlled-temperature hot coolant-fluid and recording the temperature at which the elements activate.

3.4.3.3 Electric Protective Device Tests

Visually and mechanically inspect, adjust, test, and calibrate in

SECTION 41 65 10 Page 16 AMND 0005 accordance with the manufacturer's published instructions. Document device ratings, settings, and other operational data.

3.4.3.4 Safety Run Test

Complete and submit two rounds of engine testing, Safety Run Test (Pre-pump Connection) and Safety Run Test (Post-pump Connection) . If the engine fails tests in any way, the system to be adjusted or fixed, and tests repeated, until the engine passes all tests. The first round of testing (Pre-pump Connection) to to be completed after engine installation, but before connection to the shafts, gear drive, and pump.

After this test is approved by the Contracting Officer, complete the system and tests of the fully functioning system. If there is insufficient water available to operate the plant and perform the engine tests, the Contracting Officer may delay the test for up to 2 months.

Coordinate with the Contracting Officer. The commissioning agent to create a detailed report/checklist of the engine startup tests. Complete startup in the presence of the Contracting Officer. It is recommended to have a representative of the engine manufacturer onsite when completing tests. The safety run test consists of the following sequence of tests:

a. Start engine, record starting time and all of the engine manufacturer's recommended after-starting checks and inspections performed following a reasonable warm-up period.

b. Operate the engine for at least 2 hours at 75 percent rated speed or set RPM for Post-pump Connection testing.

c. Verify proper operation of all controls.

d. Verify proper operation and set points of all gauges and instruments and record setpoints.

e. Verify proper operation of all ancillary equipment.

f. Activate manual emergency stop switch and the time to stop the engine recorded.

g. Start the engine and record the starting time, the engine manufacturer's after-starting checks and inspections performed and recorded, and the engine operated for at least 15 minutes at 75 percent of rated speed.

h. Manually adjust the governor to increase engine speed past the overspeed limit. Record engine RPM at shutdown.

i. Temporarily remove the time-delay low-lube oil pressure alarm bypass from the engine safety circuits and an attempt made to start the engine. Record the results.

j. Attach a manifold to the engine oil system containing a shutoff valve in series with a connection for the engine's oil pressure sensor, followed by an oil pressure gauge, ending in a bleed valve.

Move the oil pressure sensor from the engine to the manifold and its normal location on the engine temporarily sealed. Place manifold shutoff valve in the open position and the bleed valve closed.

k. Start engine and record the starting time, the engine manufacturer's after-starting checks and inspections performed and

SECTION 41 65 10 Page 17 AMND 0005 recorded and the engine operated for at least 15 minutes at 75 percent of rated speed.

l. The manifold shutoff valve to be closed. Slowly bled off pressure in the manifold through the bleed valve while observing the pressure gauge. Record the pressure at which the engine shuts down. Capture oil spillage from the bleed valve. The oil system to be refilled, manifold removed, and engine's oil pressure sensor reinstalled on the engine following the test.

m. Start engine and record the starting time, the engine manufacturer's after-starting checks and inspections performed and recorded and the engine operated for at least 15 minutes at 100 percent of rated speed. Record the maximum sound level in each frequency band at a distance of 75 feet from the end of the exhaust piping directly along the path of discharge for horizontally discharged exhausts. Record the maximum sound level in each frequency band at a distance of 75 feet from the silencer at 45 degrees apart in all directions around the unit.

n. Run through fail tests to ensure engine functions as intended when systems fail.

o. Complete any other tests recommended by commissioning agent or manufacturer.

3.4.3.5 Final Inspection

a. Remove lube-oil filter. Oil and filter will be examined by the engine manufacturer for excessive metal, abrasive foreign particles, and other indications of engine distress. Any corrective actions will be verified for effectiveness by running the engine for 8 hours at full rated speed, then re-examine the oil and filter.

b. Inspect engine and all engine mounting bolts checked for tightness and visible damage.

c. Inspect all engine and pump system components to ensure the system functions as intended.

3.5 MANUFACTURER'S FIELD SERVICE

Furnish a qualified engineer from the manufacturer to supervise the complete installation of the engine, provide guidance, and assist in performance of the on-site tests.

3.6 ACCEPTANCE

Final acceptance of the engine will not be made until the Contractor has successfully completed all tests, corrected all defects in installation material, and installation procedures and the test report has been completed and submitted.

-- End of Section --

SECTION 41 65 10 Page 18 AMND 0005

2.5 EMISSIONS