Attachment A_SOW Generator Maintenance.pdf

United States Department of Agriculture

Agricultural Research Service

STATEMENT OF WORK

Emergency Standby Generators

Inspection, Preventive Maintenance and Testing

U.S. National Poultry Research Center 934 College Station Road Athens, Georgia 30605

1. Scope of Work

The contractor shall provide all professional services necessary to complete the physical inspection, and preventive maintenance of the two emergency generator sets located at the SEPRL site. In the event of an emergency such as an equipment failure during the term of this contract, the contractor must be able to respond to the location with qualified personnel within 24hrs. All maintenance will be conducted according to the equipment manufacturer’s suggested maintenance schedules and will meet or exceed the equipment manufacturer and industry standard requirements. Contractor will provide detailed inspection and maintenance reports for each device serviced. All work must be conducted so that critical facilities do not lose power.

The contractor must include all services and field labor, equipment (including rigging and material handling equipment), materials, testing and personal protective equipment necessary to perform the work.

Description of generator sets to be serviced: Qty 2 Kohler Model 2000REOZMD 2000kW 12.47 kV diesel enclosed generator sets on 7900-gallon subbase fuel tanks. Generator set means the entire system including the enclosure, silencers, dampers, and fuel tanks.

The preventive maintenance site visits must be four quarterly services consisting of one major and three minor service visits per year. The major service will be completed first.

1.1 Quote

The contractor shall provide a detailed quote and cost breakdown for the entire project including submittals for proposed equipment and materials. Contractor must be registered in System for Award Management, (SAM), prior to submitting a quote.

1.2 Site Visit

Contractors are strongly encouraged to visit the site to confirm locations, dimensions, and conditions of the generators before a quote is submitted. The site visit shall be for the purpose of observing conditions relevant to the completion of this project. No consideration will be given to claims based on lack of knowledge of existing conditions, except where contract documents make definite provisions for adjustment in cost or extension due to existing conditions not readily foreseeable.

2. Codes and Standards

Applicable Codes and Standards apply and are not limited to the following.

ANSI - American National Standards Institute.

NEC - National Electrical Code NFPA-70E Standard for Electrical Safety In The Workplace OSHA - Occupational Safety and Health Administration ADA – Americans with Disabilities Act

All work must meet Local, State and Federal codes, and latest IBC codes.

3. Project Summary

Perform inspection, maintenance, and testing of medium voltage emergency generator sets described in the section 1. Contractor must submit a work schedule in industry recognizable format to the Contracting Officers Representative (COR) within 14 days of contract award. The Government will review the plan prior to the start any maintenance activities.

1) Work must be accomplished during normal business hours. If outages are required, off-hours work may be allowed (subject to approval).

2) All work must be scheduled in advance and approved by USDA prior to starting.

3) Contractor must perform all work according to the approved schedule and SSSP.

4) All work must be in compliance with NFPA 70E and NEC.

5) All work must be in accordance with the equipment manufacturers’ requirements.

6) Detailed reports of all work and tests must be provided to USDA at the time of service or within

3 business days.

The facility will be occupied during maintenance activities. All work must be scheduled in advance and coordinated with the facility representative to minimize the disruption to traffic, daily operations and research programs.

4. Safety

The contractor must submit a Site Safety Specific Plan (SSSP) in industry recognizable format to the COR within 14 days of contract award. The Government will review the SSSP prior to the start any maintenance activities.

Safety and health matters, as they relate to the work, are the exclusive responsibility of the contractor.

The contractor shall furnish, erect, and maintain barricades, warning lights, signs, guards, or take other precautions that may be required by law or local authorities for the protection and security of the grounds, facilities, and personnel.

5. Contractor Requirements

See Tables 1 and 2 for Contractor Service Requirements

The contractor must provide a complete maintenance service for the two medium voltage emergency generator sets including all labor, supervision, tools, materials, equipment, apparatus, transportation, rigging and other equipment and services necessary to accomplish the work in accordance with the intent and meaning of this statement of work. The contractor must respond on site to emergency situations within 24hrs.

The project work must be performed in accordance with the following guidelines:

1) Contractor must verify all equipment and site conditions prior to beginning work.

2) The contractor must always be responsible for protecting his work and ensuring the safety of his crew and ARS employees.

3) The contractor must use only trained and qualified personnel (as defined by OSHA and USDA)

4) The contractor must provide documentation of training and certification for all personnel working on this site prior to starting work.

5) The contractor must use an OSHA compliant Lockout/Tagout program.

6) The contractor must comply with all USDA Safety and Biosecurity requirements.

7) The contractor must provide all PPE, barricades, and other safety material required to perform this work safely and comply with regulations.

8) The contractor must render the work area safe before leaving the work site. All covers must be replaced, and all cabinets closed.

9) Contractor must remove and dispose of all project-related materials from all work areas daily.

10) Contractor is required to manage the project and consult with the Government prior to beginning all work.

11) Contractor must perform work in a manner that minimizes the impact to daily operations of the facilities and workers. The buildings will be occupied during this work.

12) All work is to be performed according with building codes, ordinances and laws of the Authority having jurisdiction on the project. When the requirements of the building codes, ordinances, and laws conflict with any other part of the building codes, ordinances and laws, the most restrictive requirement shall prevail.

6. Submittals

1) Submittals and O&M documentation must be provided for all materials used on this project.

2) Submittals must be provided detailing all preventive maintenance to be performed during each visit.

3) Submittals must be provided for all service check lists and reporting forms to be used on this project.

4) Contractor’s Site-Specific Safety Plan (SSSP) must be provided to and approved by USDA before the project can begin.

5) Contractor must provide list of qualified personnel and their documentation prior to starting work.

7. Damage to Property:

The Contractor must protect the work, the site, and all existing property and structures within the limits of the construction activities or that may be affected thereby until acceptance of the work. Any damage to property shall be repaired to pre-damaged condition to the satisfaction of the USDA.

8. Inspection and Acceptance A government representative must inspect and approve the work. The Contractor must schedule inspection a minimum of 2 days in advance.

9. Period of Performance

The completion of this project shall not exceed 365 days from date of notice to proceed. A request for time extension must be submitted to the Contracting Officer in writing. Each request must include specific and detailed reasons in support of the schedule alteration.

9.1 Work Hours:

Contractor work hours must be Monday through Friday, 7:00 A.M. to 3:30 P.M. except on Government holidays for most of the work. Work requiring outages, may be required to be performed after hours (pre-arranged at least 48 hours in advance).

Any changes to work schedule must be submitted to Contacting Officer for written approval prior to the schedule change.

10. Guaranty

The contractor must provide and submit a single guarantee stating that all portions of the work are in accordance with Contract requirements. Guarantee all work against faulty and improper material and workmanship for a period of one (1) year from date of final acceptance by the USDA, except where manufacturer guarantees or warranties are for longer terms. The contractor must correct any deficiencies which occur during the guarantee period within 24 hours after notification.

Table 1.

Scheduled Maintenance for Emergency Use Generator

Inspection and Maintenance Period

Service Item

Quarterly Walk around check (Check leakage of fuel, oil, and coolant.)

Check the following:

Fuel Tank Oil Level Engine Oil Level Coolant Level Starting Air Tank Air Pressure Ingress of Fuel and Water In Engine Oil Fuel Control Link Air Compressor Oil Level – refill if needed

Air Cooler - Check Water Leak

Maintenance Operation:

1) Operate the engine at no load for 5 to 10 minutes. (Check startability, color of exhaust smoke, abnormal vibration, abnormal noise, abnormal smell and gauge indication {oil pressure gauge, coolant temperature gauge, oil temperature gauge, exhaust temperature gauge, tachometer, and others.)

2) Operate the engine at 50% load or higher for 30 minutes or longer. (Check startability, color of exhaust smoke, abnormal vibration, abnormal noise, abnormal smell and gauge indication {oil pressure gauge, coolant temperature gauge, oil temperature gauge, exhaust temperature gauge, tachometer, and others}. Check the movement of rack of the fuel injection pump including the governor, check temperature of damper, check damper visually.)

Every 6 Months Check - LLC Concentration in Coolant

Clean - Inside of Coolant Tank

Yearly Engine Body – Check and Adjust/Replace the following:

1) Belt and Belt

2) Bolts and Nuts on Engine

3) Damper

4) Valve Clearance (Check the valve mechanism parts at the same time)

5) Vibration-Isolating Rubber

6) Foundation Bolts

7) Couplings

Fuel System – Check and Adjust

1) Fuel Injection Nozzle Spray Condition and Injection Pressure

2) Fuel Injection Timing

3) Fuel Pipe

Drain –

1) Fuel Tank

2) Water Separator

Lubrication System – Check and Adjust

1) Oil Pipe

2) Engine Oil Pressure

3) Analyze Engine Oil Properties

Cooling System – Check/Disassemble and Clean

1) Solenoid Valve and Pressure Reducing Valve of Cooling

System

2) Strainer (Including with Ball Tap) of Cooling Water

Check – Water Pump Inspect Coolant Properties – (Change Coolant Based on Analysis Results)

Air Intake System – Clean, Check and Replace

1) Air Cleaner Element

2) Pre-cleaner

Electrical System – Check

1) Starter

2) Alternator

3) Specific Gravity of Battery Electrolyte

4) Air Heater

Air Stater System – Check/Clean/Drain

1) Starter Air Strainer

2) Starting Air Tank Safety Valve Operation

3) Air Starter Valve

4) Solenoid Valve and Pressure Reducing Valve

5) Air Distribution Valve

6) Air Compressor Belt Tension

Protection System – Check the following:

High coolant temperature, low oil pressure, overspeeding, start stalling, cooling water supply fault, undervoltage, overvoltage, overcurrent, low coolant level in tank, low fuel level in tank, low air pressure in tank

Auxiliary Devices – Check the following:

Engine control devices, fuel transfer pump, governor motor, room ventilating fan, solenoid, lifting pump, water tank ball tap, water heater, oil heater, oil priming pump, and others

Replace –

1) Engine Oil, Oil Filter, and Bypass Oil Filter

2) Water Separator Element

3) Fuel Filter

Analyze – Engine Oil Clean – Gauze Filter Change – Coolant Drain Water – Exhaust Muffler Check – Thermostat Check – Turbocharger Overhaul – Starting Air Compressor

Table 2.

Kohler Generator Service Schedule

System—Component

Action Interval Visually Inspect Check Change Clean Test

Fuel System

Day tank level X X Quarterly

Flexible lines and connections X Quarterly

Fuel level switch X X Quarterly

Main tank supply level X Quarterly

Solenoid valve operation X X Quarterly

Transfer pump operation X X Quarterly

Water in system, remove • • Quarterly

Filter(s) • Quarterly

Gasoline supply N/A

Fuel piping X Quarterly

Tank vents and return lines for obstructions X Yearly

Lubrication System

Oil level • • Quarterly

Crankcase breather • • Quarterly

Change oil • Yearly

Replace filter(s)* •

Cooling System

Radiator fan bolt torque (1500 -2800REOZDC, 2500 -2800REOZDB, and 3000/3250REOZD with unit-mounted radiator)

X

Yearly

Air cleaner to room/enclosure X Quarterly

Block heater operation X Quarterly

Coolant level • • Quarterly

Flexible hoses and connectors X X Quarterly

Water pump(s) • Quarterly

Fan and alternator belts • • Quarterly

Coolant temperature protection level • Six Months

Lubricate fan bearings (1350 kW and larger) X X Six Months

Air ducts, louvers X X Yearly

Coolant • Yearly

Heat exchanger X Yearly

Louver motors and controls X X X Yearly

Radiator exterior X Yearly

Water supply to heat exchanger X Yearly

Exhaust System

Drain condensate trap X Quarterly

Leakage X X Quarterly

Insulation, fire hazards X Quarterly

Flexible connector(s) X Six Months

Excessive back pressure X Yearly

Hangers and supports X Yearly

DC Electrical System

Battery charger operation, charge rate X Quarterly

Battery electrolyte level X Quarterly

Battery specific gravity, charge state X Quarterly

Recharge after engine start X Quarterly

Remove corrosion, clean and dry battery and rack X X Quarterly

Clean and tighten battery terminals X X Quarterly

Tighten DC electrical connections X Six Months

Legend:

• Follow procedures and frequencies indicated in the engine manufacturer’s manual.

R Replace as necessary X Action