Exhibit A - Generator Maintenance Scope.xlsx

XLSX spreadsheet 27 KB Posted

Attached to
Generator Service
Solicitation number
15018-0-2026-BP
Issued by
Dane County, Mattoon Village, Wisconsin

About this file

This is a generator maintenance scope of work document for multiple City of Madison agencies and departments. The document outlines comprehensive preventive maintenance requirements for 22 generators across various city facilities including sewer utility lift stations, parking garages, police and fire stations, engineering operations, streets department, and fleet services. The generators range from 20 kW to 650 kW in capacity, with fuel types including natural gas and diesel. Maintenance is organized into three service categories: Basic PM (preventive maintenance) performed twice yearly, Oil Analysis performed once yearly, and Load Testing/Major PM performed once yearly, with the Major PM service replacing one scheduled Basic PM in those years. The anticipated service schedule spans from 2026 through 2031, with generators stratified into three groups (A, B, C) based on major PM timing. Note that Bartillon and Truax generators are excluded from 2026 service and will receive only basic PM once that year.

The maintenance scope includes detailed inspection, lubrication, fuel system checks, cooling system maintenance, battery and electrical testing, exhaust system inspection, mechanical checks, and automatic transfer switch (ATS) testing. Major PM services include oil and filter changes, fuel filter replacement, coolant system flushing, load transfer testing with utility power failure simulation, and two-hour load bank testing at 25% increments up to 100% nameplate capacity. Four capacity tiers are identified: Tier 1 (Small, 0-100 kW) with 16 total generators, Tier 2 (Mid, 101-250 kW) with 3 generators, Tier 3 (Large, 251-500 kW) with 2 generators, and Tier 4 (Heavy, 501+ kW) with 1 generator. The scope specifies that load transfer testing requires coordination and advance scheduling with City Engineering, and all maintenance activities must be documented with recorded data including engine hours, pressures, temperatures, voltages, and frequencies.

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15018-0-2026-BP Generator Service.pdf PDF
15018 Form D2 - Pricing.xlsx XLSX spreadsheet

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Requirements

Basic PM to Include:
CategoryInspection ItemNotes
LubricationCheck engine oil level and top off as required.
LubricationInspect engine for oil leaks at seals, gaskets, and drain plugs.
Fuel SystemCheck fuel supply level and condition; verify tank integrity and vent condition.Diesel Only
Fuel SystemInspect fuel lines, pumps, and connections for leaks or sweating.Diesel Only
Fuel SystemDrain water and sediment from fuel water separators/primary filters.Diesel Only
Fuel SystemVerify gas supply pressure at inlet and confirm pressure is within manufacturer's specified range.Natural Gas Only
Fuel SystemInspect gas lines, fittings, and flexible connectors for leaksNatural Gas Only
Fuel SystemInspect gas regulator and shutoff valve for proper operation and signs of damage or corrosion.Natural Gas Only
Cooling SystemCheck coolant level and radiator cap integrity.
Cooling SystemCheck and record freeze protection (glycol concentration); adjust as required.
Cooling SystemInspect fan drive belts for condition and proper tension; adjust as required.
Cooling SystemInspect coolant hoses, pipes, and radiator core for leaks or damage.
Cooling SystemInspect water pump for shaft play, mounting security, and weep hole leakage.
Cooling SystemCheck operation of jacket water heater and control thermostats.
Cooling SystemVerify thermostat operation and coolant flow during engine exercise.
Cooling SystemInspect radiator for debris/obstruction and check fan shroud for integrity.
BatteriesClean and protect battery terminals; inspect cables for security.
BatteriesCheck and record starting battery float voltage and specific gravity.
BatteriesCheck electrolyte levels and add distilled water as required.
BatteriesPerform a battery load test and record voltage drop on start.
ElectricalCheck battery charger for proper operation and record voltages.
ElectricalInspect starter motor, cables, and solenoid for condition and security.
ElectricalVisually inspect exciter assembly, stator, and field windings for cleanliness.
ExhaustInspect manifold, exhaust pipes, flexes, and turbochargers for leaks or soot.
MechanicalInspect louvers, vents, and louver actuators for obstruction and proper operation.
MechanicalInspect enclosure seals, weatherstripping, and housing for integrity and weather-tightness.
MechanicalInspect fan guard and air inlet screens for cleanliness and security.
MechanicalCheck governor linkage and fuel rack/air-fuel mixer for proper operation.
ControlsVerify operation of auto-start sequence.
ControlsVerify operation and accuracy of AC and engine instruments/meters.
OperationPerform a 15-minute no-load exercise run.
OperationMonitor and record system frequency and voltage; adjust if necessary.
ATSVisually inspect ATS components, connections, and cabinets.
ATSCheck indicator lamps and verify all insulating parts are free of cracks.
ATSInspect all main current arcing contacts for pitting or heat discoloration.
ATSCalibrate and adjust all time delay devices and power sensing controls.
Major PM Includes:
CategoryService ItemNotes
FoundationInclude all items from the Basic PM Scope.
LubricationDrain engine oil and refill with fresh, manufacturer-approved oil.
LubricationReplace all engine oil filters and document date of replacement.
Fuel SystemReplace primary and secondary fuel filters (if applicable).Diesel Only
Fuel SystemClean fuel sediment bowls and inspect fuel tank vents for obstructions.Diesel Only
Fuel SystemRemove and inspect spark plugs, clean and regapNatural Gas Only
Air SystemReplace engine air filter(s) and inspect induction piping for integrity.
Air SystemClean and service crankcase breathers as required.
Cooling SystemFlush cooling system and replace with fresh coolant.
Cooling SystemReplace coolant filter(s) and service radiator fins as necessary.
Cooling SystemPerform coolant litmus test and document results.
ElectricalInspect and tighten all high-voltage power cable terminations.
ATSPerform a simulated utility power failure to initiate a connected load transfer test; observe and record all pertinent voltage, current, and time data on both generator and ATS.Coordinate notifications and schedule with City Engineering before load transfer.
Oil Analysis Includes:
CategoryService ItemNotes
Engine OilTest for wear metals, total base number, and viscosity.
Engine OilTest for fuel dilutionDiesel Only
Load Test Includes:
CategoryService Item
Load BankConnect resistive load bank and perform a 2-Hour Load Test.
Load BankApply load in 25% increments; run for 15 minutes at each step.
Load BankRun unit at 100% nameplate capacity for a minimum of 1 hour.
Load BankRecord and report engine hours, oil pressure, coolant temp, voltage, and frequency at 15-minute intervals.

Anticipated Schedule

Basic PMOil AnalysisLoad Testing & Major PMNotes:
Frequency:2x Yearly1x Yearly1x Yearly
2026B, C (once)A, B, CAExclude Bartillon and Truax Generator from 2026 Service. Do basic PM once in 2026.
2027A, B, CA, B, CB
2028A, B, CA, B, CC
2029A, B, CA, B, CA
2030A, B, CA, B, CB

Note: On Load Testing/Major PM years, that service will replace one scheduled Basic PM service.

Generator Details

"Group"Major PM When?AgencyPropertyAddressIn ServiceFuel_TypeVoltage_and_PhaseWattsIndoor/Outdoor
A2026, 2029Sewer UtilityLift Station - Carroll622 N Carroll St., Madison, WI 537032019Natural GasKohlerKG4533MFGMGC0004208 V 3 ph45 kWOutdoor
A2026, 2029Sewer UtilityLift Station - Fremont2405 Fremont Ave., Madison, WI 537042019Natural GasCummins125GGHJK170270882208 V 3 ph40 kWOutdoor
A2026, 2029Sewer UtilityLift Station - James3135 James St., Madison, WI 537142019Natural GasCumminsC45 N6H190623179208 V 3 ph45 kWOutdoor
A2026, 2029Sewer UtilityLift Station - Cherokee #15121 Comanche Way, Madison, WI 537042019Natural GasKohlerKG4033MDGMGJ0051208 V 3 ph40 kWOutdoor
A2026, 2029Sewer UtilityLift Station - Woodley2712 Waunona Way, Madison, WI 537042019Natural GasGeneracQT02524GNSNA3001575231208 V 3 ph45 kWOutdoor
A2026, 2029EngineeringEngineering Ops - Garage1600 Emil St.,Madison WI537132017Natural GasOlympianG300LG6GXJ04496480 V 3 Phase300 kWOutdoor
A2026, 2029StreetsStreets West1501 W Badger Rd, Madison, WI 537131981DieselOnan155.00FE-15R/23785LG810583202208 V 3 ph155 kWOutdoor
B2027, 2030MWUIT Network Operations Center119 E Olin Ave., Madison, WI 537132003DieselCumminsDGDB-5689823H040682650208 V 3 ph100 kWOutdoor
B2027, 2030Sewer UtilityLift Station - Debs Rd407 Debs Rd., Madison, WI 537042020Natural GasKohler20RESCL339VGVFP0237240 V 1 ph20 kWOutdoor
B2027, 2030Sewer UtilityLift Station - Arbor Hills2714 W. Beltline Highway2021Natural GasGeneracSG00080GG169.0N18HPSYA3008283178208 V 3 ph80 kWOutdoor
B2027, 2030Sewer UtilityLift Station - Harper3402 Harper Rd. Madison, WI 537042023Natural GasGeneracSG0050GG264.5S18TPYYA3011952391208 V 3 ph50 kWOutdoor
B2027, 2030ParkingGarage - South Livingston111 S Livingston St. Madison, WI 537032018Natural GasCumminsC60 N6E180360406208 V 3 ph60 kWIndoor
B2027, 2030ParkingGarage - State St Capitol214 N Carrol St., Madison, WI 537032019Natural GasCumminsC60 N6HG170217933208 V 3 ph60 kWIndoor
B2027, 2030ParkingGarage - State St Campus/Frances430 N Frances St, Madison, WI 537032019Natural GasCumminsC30 N6HK180446598208 V 3 ph30 kWIndoor
C2028, 2031Sewer UtilityLift Station - Thurber3325 Thurber Ave., Madison, WI 537142024Natural GasCumminsC20N6A230197917208 V 3 ph20 kWOutdoor
C2028, 2031Sewer UtilityLift Station - Veith4100 Veith Ave., Madison, WI 537042024Natural GasGeneracSC0080GGZ269.0N18HPSYA3013404212208 V 3 ph80 kWOutdoor
C2028, 2031CDDBartillon Men's Shelter1902 Bartillon Dr., Madison, WI 537042026Natural GasGilletteSP-6500-3-4N2TBD480 V 3 ph650kWOutdoor
C2028, 2031FleetFleet Services - Nakoosa4151 Nakoosa Trail, Madison, WI 537142024DieselCumminsC150D2REG220119573480 V 3 ph150 kWOutdoor
C2028, 2031PolicePolice - Midtown District4020 Mineral Point Rd, Madison,WI 537052018Natural GasMTU Onsite12V0183GS400NA480 V 3 ph400 kWOutdoor
C2028, 2031PolicePolice - East District809 Thompson Dr., Madison, WI 537142023Natural GasGeneracSG0150GG269.0S18HPLYE3012053034208 V 3 ph150 kWOutdoor
C2028, 2031Sewer UtilityLift Station - Truax2701 Anderson St, Madison, WI 537042026Natural GasGeneracSG060208 V 3 ph60 kWOutdoor
C2028, 2031StreetsStreets East4602 Sycamore Ave,Madison,WI 537042024Natural GasGeneracSG1003013455813208 V 3 ph100 kWIndoor
HOLD FOR NOWFireFire Station 01316 W Dayton St., Madison, WI 537032015DieselCumminsDFEK-1514856G150849507208 V 3 ph500 kWIndoor - Basement
Capacity TierkW RangeABC
Tier 1 (Small)0 – 100 kW57416
Tier 2 (Mid)101 – 250 kW1023
Tier 3 (Large)251 – 500 kW1012
Tier 4 (Heavy)501+ kW0011

File details come from the government source that posted it. Updated .