POM-400.docx
DOCX document 46 KB Posted
- Attached to
- BACKUP GENERATOR SERVICE Federal contract opportunity
- Solicitation number
- 140R1725Q0053
About this file
The document is a comprehensive Engine Generator Operation and Testing Log and Maintenance Schedule from the Bureau of Reclamation, detailing rigorous procedures for maintaining emergency power supply systems (EPSS) at critical infrastructure sites. The maintenance guidelines are categorized into two levels (Level 1 and Level 2) based on the criticality of the power system, with Level 1 applying to systems where failure could result in loss of human life or serious injuries, such as dam safety and plant support systems.
The maintenance schedule provides extensive, detailed instructions for inspecting and maintaining various generator components, including fuel systems, lubrication systems, cooling systems, exhaust systems, battery systems, electrical systems, and engine/generator assemblies. The documentation specifies precise frequencies for inspections and maintenance tasks, ranging from weekly to annual checks, and includes procedures for visual inspections, testing, cleaning, and replacing components as needed. Specific requirements include monthly load testing at 30% nameplate rating, comprehensive system checks, and periodic thorough evaluations of electrical and mechanical systems to ensure optimal generator performance and reliability.
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| File | Type | Posted |
|---|---|---|
| Sol_140R1725Q0053_Amd_0004.pdf | ||
| Sol_140R1725Q0053_Amd_0003.pdf | ||
| Sol_140R1725Q0053_Amd_0002.pdf | ||
| Sol_140R1725Q0053_Amd_0001.pdf | ||
| Sol_140R1725Q0053.pdf |
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Text version
ENGINE GENERATOR OPERATION AND TESTING LOG
| ENGINE GENERATOR OPERATION AND TESTING PROCEDURES SUMMARY (See Pages 2 thru 6) | |||
| Item | Item | ||
| Number | Function | Number | Function |
| 1. Perform maintenance per Pages 2 thru 4. | 8. | Record initial oil pressure and battery-charging rate. | |
| 2. Record running time meter reading at start and end of test. | 9. | Record oil pressure, battery charging rate, and water or air |
temperature after 15 minutes running time
| 3. Simulate normal power failure from a “cold start” by use of | 10. | Record prime mover and ac instruments, just prior to transfer. the test switch in the automatic transfer switch or by opening | 11. | Return test switch to normal or reestablish normal power normal power supply to EPSS. | supply after a minimum running time of 30 minutes under |
| 4. Observe and record time delay or start. | 30% load (or after 4 hours under 80% load). | ||||
| 5. Record cranking time (terminated when engine starts). | 12. | Record time delay on retransfer. | |||
| 6. Transfer load to EPS (30% monthly) (80% every three years) | 13. | Record time delay on shutdown for units so equipped. | |||
| 7. Record ac voltage, frequency, amperage. | 14. | Place unit in automatic operation mode. |
ENGINE GENERATOR OPERATION AND TESTING LOG SUMMARY
Performed by
Items
Date
Fill in Appropriate Readings, add comments on condition and maintenance completed.
1. Maintenance completed Pages 2-4
2. Run Time Meter
3. Power fail test
4. Time Delay Start
5. Crank time
6. Transfer Switch
7. (a) ac volt
(b) Hz
(c) ac amp.
8. (a) Oil press.
(b) dc amp.
9. (a) Oil press.
(b) dc amp.
(c) W/A temp.
10. (a) Oil press.
(b) dc amp.
(c) W/A temp.
(d) ac volts
(e) Hz
(f) ac amp.
11. Restore normal
12. T/D retransfer
13. T/D stop
14. Auto mode
Comments:
POM-400 (2-05)
Bureau of Reclamation Page of 6
ENGINE GENERATOR MAINTENANCE SCHEDULE
· Level 1EPSS maintenance, inspection, and testing is required where failure of the emergency power supply system could result in the loss of human life or serious injuries (NFPA 110, Section 4.4.1). This includes engine-generators required for Dam Safety purposes and for support of plant systems related to personnel safety. Level 1 EPSS maintenance, inspection, and testing also applies to EPSS at plants essential to power-system blackstart restoration plants and to plants where significant damage would occur upon failure of the emergency power supply system.
· Level 2 EPSS maintenance, inspection, and testing is applicable where failure of the emergency power supply system is less critical to human life and safety and where greater flexibility than Level 1 is permissible (NFPA 110, Section 4.4.2). Level 2 maintenance, inspection, and testing applies where the emergency power supply system is not essential for Dam Safety purposes, where blackstart capability is not required, and where no significant damage to the plant would occur if the system fails.
Component (as applicable) Procedure X – Action R – Replace, if needed
| Frequency | |
| W = Weekly | S = Semiannually |
| M = Monthly | A = Annually |
| Q = Quarterly | Nos. indicate hours |
Check if complete Visual Inspection
Check
Change
Clean
Test
Level 1
Level 2
1. Fuel
(a) Main supply tank level
X
| W |
| M |
(b) Day tank level
| X |
| X |
| W |
| M |
(c) Day tank float switch
X
| X |
| W |
| Q |
(d) Supply or transfer pump operation
X
| X |
| W |
| Q |
(e) Solenoid valve operation
X
| X |
| W |
| Q |
(f) Strainer, filter, dirt leg, or combination
X
| Q |
| Q |
(g) Water in system
X
X
| W |
| Q |
(h) Flexible hose and connectors
X
R
| W |
| M |
(i) Tank vents and overflow piping unobstructed
X
| X |
| A |
| A |
(j) Piping
X
| A |
| A |
(k) Gasoline in main tank (when used) or diesel fuel
R
| A* |
| A* |
2. Lubrication System
(a) Oil level
| X |
| X |
| W |
| M |
(b) Oil change
R
| 50 hours or A |
| 50 hours or A |
(c) Oil filter(s)
X
| 50 hours or A |
| 50 hours or A |
(d) Lube oil heater
X
| W |
| M |
(e) Crankcase breather
X
| R |
| X |
| Q |
| S |
3. Cooling System
(a) Level
| X |
| X |
| W |
| M |
(b) Antifreeze protection level
| X |
| S |
| A |
(c) Antifreeze
X
| A |
| A |
(d) Adequate cooling water to heat exchanger
X
| W |
| M |
(e) Rod out heat exchanger
X
| A |
| A |
(f) Adequate fresh air through radiator
X
| W |
| M |
(g) Clean exterior of radiator
X
| A |
| A |
(h) Fan and alternator belt
| X |
| X |
| M |
| Q |
(i) Water pump(s)
X
| W |
| Q |
(j) Condition of flexible hoses and connection
| X |
| X |
| W |
| M |
(k) Jacket water heater
X
| W |
| M |
(l) Inspect duct work, clean louvers
| X |
| X |
| X |
| A |
| A |
(m) Louver motors and controls
X
| X |
| X |
| A |
| A |
4. Exhaust System
(a) Leakage
| X |
| X |
| W |
| M |
(b) Drain condensate trap
X
| W |
| M |
* Maximum time between fuel renewals – more frequent replacement may be necessary
ENGINE GENERATOR MAINTENANCE SCHEDULE (con’t)
Component (as applicable).
Procedure X – Action R – Replace, if needed
| Frequency | |
| W = Weekly | S = Semiannually |
| M = Monthly | A = Annually |
| Q = Quarterly | Nos. indicate hours |
Check if
Visual Inspection
Check
Change
Clean
Test
Level 1
Level 2
(c) Insulation and fire hazards
X
| Q |
| Q |
(d) Excessive backpressure
| X |
| A |
| A |
(e) Exhaust system hangers and supports
X
| A |
| A |
(f) Flexible exhaust section
X
| S |
| S |
5. Battery System
(a) Electrolyte level
X
| W |
| M |
(b) Terminals clean and tight
| X |
| X |
| Q |
| Q |
(c) Remove corrosion, case exterior clean and dry
X
X
| M |
| M |
(d) Specific gravity or state of charge
| X |
| M |
| M |
(e) Charger and charge rate
X
| M |
| M |
(f) Equalize charge
X
| M |
| M |
6. Electrical system
(a) General inspection
X
| W |
| M |
(b) Tighten control and power wiring connections
X
| A |
| A |
(c) Wire chafing where subject to movement
| X |
| X |
| Q |
| S |
(d) Operation of safeties and alarms
X
| X |
| S |
| S |
(e) Boxes, panels, and cabinets
X
| S |
| S |
(f) Circuit breakers, fuses Note: Operate circuit breakers by hand manually.
| X |
| X |
| R |
| X |
| X |
| A |
| A |
(g) Transfer switch main contacts
X
X
| A |
| A |
(h) Operate transfer switch electrically in both directions using the automatic control system
X
M
M
(i) Calibration of voltage-sensing relays/devices
X
| X |
| A |
| A |
(j) Wire insulation breakdown
| X |
| 3 years or 500 hours |
| 5 years or 500 hours |
7. Engine/Generator
(a) General inspection
X
| W |
| M |
(b) Service air cleaner
| X |
| X |
| S |
| S |
(c) Governor oil level and linkage
| X |
| X |
| M |
| M |
(d) Governor oil
X
| A |
| A |
(e) Ignition system – plugs, points, coil, cap, rotor, secondary wire insulation
R
X
X
A
A
(f) Choke setting and carburetor adjustment
X
| S |
| S |
(g) Injector pump and injectors for flow rate pressure, and/or spray pattern
A
(h) Run generator loaded minimum of 30% nameplate rating monthly for 30 min.
M/30 Min.
M/30 Min.
(i) Run generator loaded minimum of 80% nameplate rating every 3 years for 4 hours
3 years/4 hours
3 years/4 hours
ENGINE GENERATOR MAINTENANCE SCHEDULE (con’t)
Component (as applicable).
Procedure X – Action R – Replace, if needed
| Frequency | |
| W = Weekly | S = Semiannually |
| M = Monthly | A = Annually |
| Q = Quarterly | Nos. indicate hours |
Areas all
Visual Inspection
Check
Change
Clean
Test
Level 1
(j) Valve clearance
| X |
| 3 years or 500 hours |
| 3 years or 500 hours |
(k) Torque bolts
| X |
| 3 years or 500 hours |
| 3 years or 500 hours |
8. Generator
(a) Brush length appearance, free to move in holder
| X |
| X |
X
| S |
| S |
(b) Commutator and slip rings
X
X
| A |
| A |
(c) Rotor and stator
X
X
| A |
| A |
(d) Bearing(s)
X
R
| A |
| A |
(e) Bearing grease
| X |
| R |
| A |
| A |
(f) Exciter
| X |
| X |
X
| A |
| A |
(g) Voltage regulator
| X |
| X |
X
| A |
| A |
(h) Measure and record resistance readings of windings with insulation tester (Megger)
A
| 9 (a) General condition of EPSS, | |
| . | any unusual condition of |
vibration, leakage, noise, temperature, or deterioration
W
M
(b) Service room or housing housekeeping
X
| W |
| M |
10. Restore system to automatic operation condition
X
| W |
| M |
ENGINE GENERATOR MAINTENANCE LOG
RECORD RESULTS OF PAGES 1-4
Performed by
W M Q
Weekly Monthly Quarterly Frequency S - Semiannually A – Annually Nos. indicate hours
Item No.
Service Frequency
Date
Level 1
Fill in Appropriate Readings, add comments on conditions and maintenance completed.
| 1. (a) |
| W |
| M |
| (b) |
| W |
| M |
| (c) |
| W |
| Q |
| (d) |
| W |
| Q |
| (e) |
| W |
| Q |
| (f) |
| Q |
| Q |
| (g) |
| W |
| Q |
| (h) |
| W |
| M |
| (i) |
| A |
| A |
| (j) |
| A |
| A |
| (k) |
| A |
| A |
| 2. (a) |
| W |
| M |
| (b) |
| 50 or A |
| 50 or A |
| (c) |
| 50 or A |
| 50 or A |
| (d) |
| W |
| M |
| (e) |
| Q |
| S |
| 3. (a) |
| W |
| M |
| (b) |
| S |
| A |
| (c) |
| A |
| A |
| (d) |
| W |
| M |
| (e) |
| A |
| A |
| (f) |
| W |
| M |
| (g) |
| A |
| A |
| (h) |
| M |
| Q |
| (i) |
| W |
| Q |
| (j) |
| W |
| M |
| (k) |
| W |
| M |
| (l) |
| A |
| A |
| (m) |
| A |
| A |
| 4. (a) |
| W |
| M |
| (b) |
| W |
| M |
| (c) |
| Q |
| Q |
| (d) |
| A |
| A |
| (e) |
| A |
| A |
| (f) |
| S |
| S |
| 5. (a) |
| W |
| M |
| (b) |
| Q |
| Q |
ENGINE GENERATOR MAINTENANCE LOG
RECORD RESULTS OF PAGE 1-4
Performed by
(continued)
W M Q
| Frequency | |
| Weekly | S - Semiannually |
| Monthly | A – Annually |
| Quarterly | Nos. indicate hours |
Item No.
Service Frequency
Date
Level 1
Fill in Appropriate Readings, add comments on conditions and maintenance completed.
| (c) |
| M |
| M |
| (d) |
| M |
| M |
| (e) |
| M |
| M |
| (f) |
| M |
| M |
| 6. (a) |
| W |
| M |
| (b) |
| A |
| A |
| (c) |
| Q |
| S |
| (d) |
| S |
| S |
| (e) |
| S |
| S |
| (f) |
| A |
| A |
| (g) |
| A |
| A |
| (h) |
| M |
| M |
| (i) |
| A |
| A |
| (j) |
| 3/500 |
| 5/500 |
| 7. (a) |
| W |
| M |
| (b) |
| S |
| S |
| (c) |
| M |
| M |
| (d) |
| A |
| A |
| (e) |
| A |
| A |
| (f) |
| S |
| S |
| (g) |
| A |
| A |
| (h) |
| M/30 min. |
| M/30 min. |
| (i) |
| 3/4 |
| 3/4 |
| (j) |
| 3/500 |
| 3/500 |
| (k) |
| 3/500 |
| 3/500 |
| 8. (a) |
| S |
| S |
| (b) |
| A |
| A |
| (c) |
| A |
| A |
| (d) |
| A |
| A |
| (e) |
| A |
| A |
| (f) |
| A |
| A |
| (g) |
| A |
| A |
| (h) |
| A |
| A |
| 9. (a) |
| W |
| M |
| (b) |
| W |
| M |
| 10. |
| W |
| M |
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