7. PWS Appendix D List of Covered Equipment.pdf
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- FA520926Q00140002 - Operation and Maintenance of Combined Heat and Power (CHP) Plant at Yokota AB, Japan
- Solicitation number
- FA520926Q0014
About this file
This is a Long-Term Service Agreement (LTSA) maintenance document for INNIO Jenbacher engine-generator equipment covering a 10-year term with 80,000 operating hours (OPH) at approximately 8,000 hours per year. The agreement covers four containerized INNIO Jenbacher JMS 616 engine-generator sets (2,655 kW, 480kV, dual fuel), four Di.ANE XT control panels, and four HUG SCR (Selective Catalytic Reduction) systems. The contractor will provide comprehensive maintenance services including remote and on-site supervision, field service technician labor, parts, and special tooling utilizing customer-provided consumables.
The maintenance schedule is structured around OPH intervals with specific service requirements at each milestone. Routine services include Jenbacher parts, labor, and travel at 2,000 OPH (10 intervals), 4,000 OPH (11 intervals), 6,000 OPH (11 intervals), 10,000 OPH (3 intervals), 20,000 OPH (3 intervals), and 30,000 OPH (1 interval). Additional maintenance activities include spark plug replacements (20 intervals), annual remote monitoring, pre-chamber service at 8,000 OPH intervals, semi-annual container maintenance (20 services over the term), and monthly SCR system maintenance (120 services). A major overhaul is scheduled at 60,000 OPH. The detailed maintenance table specifies work orders across multiple equipment systems including engine components, generators, cooling systems, fuel gas systems, turbochargers, and emissions control equipment, with individual task assignments at designated OPH intervals. SCR oxidation element replacement and associated washing are excluded from the annual maintenance cost, and filters are replaced semi-annually.
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Text version
List of Covered Equipment
1. Four (4) INNIO Jenbacher JMS 616 containerized engine-generator sets
2. Four (4) INNIO Jenbacher Di.ANE XT control panels
3. Four (4) HUG SCR systems.
Description of Services
Contractor will perform Maintenance Services as further defined in the Contractors LTSA Proposal attached to and made part of this Agreement. Contractor Services shall include all required remote or on-site supervision, field service technician labor, parts, and special tooling while utilizing customer provided tooling and consumables to perform and complete Scheduled Services during Term of this
Agreement at the specified OPH intervals of the Covered Equipment and as scheduled by the Parties under this Agreement.
Type of Equipment: 4x J616 J01 – 2,655 kW - 480 kV – Dual Fuel
Term of Agreement: 10 Years ~ 8,000 year – 80,000 OPH total
SESA575837
Stamp
3.3.1 Maintenance table
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 3/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
1 Maintenance table Arbeitsschritte c t s <
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Daily inspection I 9003 0 ⇨ Inspecting the system ■ Leak test IW 8049 0 ⇨ Performing the leak test ■ ■ ■ ■ ■ ■ ■ ■ Inspection I 0103 6 ⇨ Checking engine connection in myPlant ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Measuring the catalytic converter differential pressure ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Measuring the pre-combustion chamber gas differential pressure
⇨ Check the CFast external memory card ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Inspecting the mixture/water heat exchanger ■ ■ ■ ■ ■ ■ ⇨ Inspecting the flame traps in the intercooler ■ ■ ■ ■ ■ ■ ⇨ Inspecting the blow-by pipe flame traps ■ ■ ■ ■ ■ ■ Maintenance after initial commissioning W 1000 6 ⇨ Checking the ignition voltage ■ ⇨ Inspecting the gas filter ■ ⇨ Lubricating the control rod linkage ■ Surge arrestor in the Junction Box IW 8029 A0 ⇨ Checking and cleaning the surge arrestor ■ ⇨ Measuring capacitance ■ ⇨ Replacing the unit ■ Jenbacher Control cabinet IW 8031 A0 ⇨ Replace the rubber buffer and filter mat ■ ■ ■ ■ ⇨ Inspect and clean filter fan including filter mat ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Inspect and clean the interior of the control cabinet ■ ■ ■ ⇨ Inspect and clean the cooling device for the control cabinet
Container IW 8040 A0 ⇨ Replacing the container intake air filter ■ ⇨ Checking the louvre shutters ■ ⇨ Tightening the bolted joints ■
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 4/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
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Condensate removal in the fuel gas system IW 8090 A0 ⇨ Manual condensate drain: Drain off condensate ■ ⇨ Automatic condensate removal: Check for leaks ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Exhaust gas system condensate drain line IW 8095 A0 ⇨ Inspecting the condensate drain line in the exhaust gas system
Generator W 8034 A0 ⇨ Relubricating the bearing(s) ■ ■ ⇨ Measuring the insulation/polarisation ■ ■ ■ ■ ■ ■ ■ ⇨ Daily check ■ ⇨ Overhauling the generator ■ ■ ⇨ Inspecting and cleaning the generator ■ ■ ■ ■ ■ ■ ⇨ Carrying out a vibration measurement and replacing the earth brush (if fitted)
⇨ Replacing the bearing(s) ■ ■ ■ Plate heat exchanger W 8043 A0 ⇨ Replace the O-rings and rubber seals ■ ■ ■ ⇨ Overhauling the plate heat exchanger ■ Gas train W 8045 A0 ⇨ Inspect the gas filter and replace if necessary ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Functional test/inspecting the gas train ■ ⇨ Overhauling the gas train ■ ■ ⇨ Replacing the gas filter ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Overhauling the gas pressure controller/gas regulator ■ ■ ⇨ Overhauling the prechamber differential pressure controller
⇨ Overhauling the zero pressure controller (optional) ■ ■ Cooling water W 8080 A0 ⇨ Cooling water analysis ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing the cooling water ■ ⇨ Checking the water pressure ■ ⇨ Replacing the O-rings ■ ■ ■ ■
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 5/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
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⇨ Replacing the hoses W 8080 A0 ■ ■ ■ ■ In-line air filter IW 8040 A6 ⇨ Replace filter cartridges ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replace rubber buffers ■ ■ ■ ■ Scavenging air fans IW 8083 A6 ⇨ Draining off the condensate manually ■ ⇨ Inspecting the motor cooling ribs ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Inspecting the impeller blades ■ ■ ■ ■ ■ ■ ■ ■ Engine cooling water pump W 0203 A6 ⇨ Relubricating the bearings (only for pumps with grease nipples)
⇨ Replacing the mechanical seal ■ ■ ■ ■ ■ ■ ⇨ Replacing the engine cooling water pump ■ ■ Spark plugs IW 0309 M0 ⇨ Checking the ignition voltage ■ ■ ⇨ Replacing or adjusting spark plugs ■ Camshaft/valve timing gear IW 8052 M0 ⇨ Examining the camshaft and valve timing gear (only on Type 6 engines)
⇨ Inspecting the camshaft ■ ■ ⇨ Replacing roller tappets or cup tappets ■ ■ Combustion chamber IW 8056 M0 ⇨ Inspecting and cleaning the combustion chamber ■ ⇨ Checking the fuel gas quality, in particular the silicon content for landfill gas engines
⇨ Checking the oil consumption ■ ⇨ Check for oil ingress into the engine due to a faulty blow-by filter and inspect the intake line for "Oil wetness"
NOx IW 8057 M0 ⇨ Measure NOx value and if necessary adjust LEANOX setting
⇨ Replacing the NOx sensor (if installed) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Ignition W 0303 M0
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 6/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
O h ev er y 1, O h
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⇨ Cleaning the pick-ups W 0303 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing the spark plug connector seal ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Inspecting the ignition system ■ ■ ■ ■ ■ ■ ■ Vibration damper W 0601 M0 ⇨ Replacing the vibration damper ■ ■ ■ ■ Gas quantity controller W 0705 M0 ⇨ Replacing the sealing rings ■ ■ ■ ⇨ Cleaning the gas quantity controller ■ ■ ■ ⇨ Replacing the gas quantity controller ■ ■ Mixture bypass valve W 0802 M0 ⇨ Mixture bypass valve – replacement ■ ■ ■ Revision W 2100 M0 ⇨ Replacing the rubber rails of the engine and generator ■ ■ ■ ⇨ Replacing the camshaft ■ ■ ⇨ Inspecting the crankshaft ■ ■ ⇨ Inspecting the crankcase ■ ■ ⇨ Inspecting the gear train ■ ■ ⇨ Inspecting the cylinder heads ■ ■ ⇨ Replacing piston, piston rings and piston pins ■ ■ ⇨ Replacing a cylinder liner ■ ■ ⇨ Replacing the crankshaft main bearings/crankshaft thrust bearings
⇨ Replacing big-end bearing shells ■ ■ ⇨ Replacing the vibration damper ■ ■ Starter motor W 8032 M0 ⇨ Replacing the starter motor ■ ■ ■ ■ ■ ■ ■ Piston W 8047 M0 ⇨ Replacing the O-ring at the piston cooling nozzle ■ ■ ■ ⇨ Replacing piston, piston rings and piston pins ■ ■ ■ ⇨ Overhaul the piston cooling nozzles ■ ■ ■ Conrod W 8048 M0
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 7/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
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⇨ Replacing the connecting rods W 8048 M0 ■ ■ ■ ⇨ Replacing big-end bolts ■ ■ ■ ⇨ Replacing big-end bearing shells ■ ■ ■ Cylinder liner W 8049 M0 ⇨ Replacing a cylinder liner ■ ■ ■ ⇨ Replacing the O-rings ■ ■ ■ ⇨ Replacing the scraper ring (if fitted) ■ ■ ■ Exhaust gas manifold W 8051 M0 ⇨ Inspect the exhaust-gas collection line and insulation ■ ■ Pre-lubrication pump W 8054 M0 ⇨ Electric motor - inspecting the brushes ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Electric motor - replacing the brushes ■ ■ ■ ■ ⇨ Overhauling the pre-lubrication pump ■ ■ Crankcase W 8061 M0 ⇨ Replacing the O-rings ■ ■ ■ Lubricating oil IW 0101 M6 ⇨ Change the lubricating oil ■ ⇨ Replacing O-rings ■ ■ ■ ■ ⇨ Replace hoses ■ ■ ■ ■ Crankcase ventilation IW 0513 M6 ⇨ Replacing the filter element ■ ■ ■ ■ ■ ⇨ Replacing the preliminary separator element ■ ⇨ Inspecting the crankcase ventilation ■ ⇨ Gathering operational data ■ ■ ⇨ Servicing the crankcase ventilation ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing the blow-by hoses ■ ■ ■ ■ Control rod assembly, throttle valve, actuator W 0200 M6 ⇨ Inspecting and relubricating the control rod assembly ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing the O-rings ■ ■ ■ ■ ■ ⇨ Replacing the throttle valve bearing, throttle valve, throttle valve shaft and related adjusting lever
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 8/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
O h ev er y 1, O h
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8, O h
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⇨ Replacing and lubricating the joint head W 0200 M6 ■ ■ ■ ■ ■ ■ ⇨ Replacing the regulator and related adjusting lever ■ ■ Valve clearance W 0400 M6 ⇨ Measure and document the valve stem projection ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Check and adjust valve lash ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Prechamber/prechamber gas valve W 0501 M6 ⇨ Replacing the sealing ring and O-rings ■ ■ ⇨ Replacing the prechamber gas valve ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Inspect the prechamber and the spark-plug sleeve ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replace prechamber (6 hole, 8-hole version) ■ ■ ■ ■ ■ ■ ■ ⇨ Inspecting the spark-plug sleeve ■ ■ ■ ■ ■ ■ ■ Exhaust-gas turbocharger W 8026 M6 ⇨ Inspecting the compressor side of the exhaust gas turbocharger
⇨ Overhauling the exhaust-gas turbocharger ■ ■ ■ ■ ■ ■ ⇨ Replacing the exhaust gas turbocharger ■ ■ ⇨ Replacing the exhaust gas turbocharger ■ ■ ⇨ Replacing O-rings ■ ■ ■ ■ Oil filter cartridge W 8038 M6 ⇨ Changing the oil filter insert ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing O-rings ■ ■ Lubricating oil pump W 8046 M6 ⇨ Replacing O-rings ■ ■ ■ ■ ⇨ Changing the lubricating pump ■ ■ Replace the crankshaft main bearings and thrust bearings
W 8050 M6
⇨ Replace crankshaft main bearings ■ ■ ■ ⇨ Replace crankshaft thrust bearings ■ ■ ■ Cylinder head W 8053 M6 ⇨ Tightening the nuts on the prechamber retaining bracket
⇨ Replace the cylinder head with a new or overhauled cylinder head
Module number: AJ34 Module number: 1479924 Engine version: J111
Password:
Module type: JGC 616 GS-N.L Author(s): Responsible: Release date: 05/07/2021
Index: 1 Page No.: 9/1 INNIO proprietary notice: CONFIDENTIAL Use or disclosure of data contained on this sheet is subject to the restrictions stated in the notice on the cover or on the first page.
Arbeitsschritte c t s <
O h ev er y 1, O h
1, O h
2, O h
4, O h
6, O h
8, O h
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⇨ Replace the cylinder head with a new or overhauled cylinder head
W 8053 M6 ■ ■ ■
⇨ Replacing the rocker cover moulded gasket ■ ■ ■ ■ ■ ■ ■ ⇨ Replacing the O-rings on the cylinder head ■ ■ ■ Safety valve ------ ⇨ Inspect safety valve ■ ■ Gas and smoke alarm system ------ ⇨ Inspect gas and smoke alarm system ■ ■
| Pages from NES WES LTSA - ESPC - 03.26.2025 - Executed |
| Yokota AB_CHP_Jenbacher 3.3.1 Maintenance Schedule for Engines |
File details come from the government source that posted it. Updated .