FA3016-16-N-0030_-_PWS_Rev_4.docx

STATEMENT OF NEED

PREVENTATIVE MAINTENANCE OF SOLAR GAS TURBINES

TOTAL ENERGY PLANT, Bldg. 4895

JBSA - LACKLAND, TEXAS

SCOPE OF WORK - Contractor shall provide all labor, tools, materials, parts, transportation and incidentals necessary to accomplish the work identified below on Solar Gas Turbines and ancillary equipment located in Building 4895, Total Energy Plant, Wilford Hall Ambulatory Surgical Center, JBSA - Lackland, TX 78236-5000.

DESCRIPTION OF WORK:

The Contractor shall provide all personnel, equipment, tools, supervision, vehicles, materials, storage and other items and services necessary to provide preventative maintenance of Solar gas turbines at Wilford Hall Ambulatory Surgical Center on Joint Base San Antonio – Lackland. All work shall be performed in accordance with industry and commercial practices, using commercial/industry standard equipment, materials, supplies and tools. The contractor shall comply with applicable federal, regional, state, and local laws and commercial standards.

1. UNSCHEDULED SITE VISITS. The Contractor shall provide four (4) unscheduled site visits for maintenance, trouble-shooting and component replacement during the performance period. Scheduled visits shall at a minimum consist of troubleshooting and repair of two SOLAR Taurus 60, Assembly Number 2-51651, TURBOTRONICS Control package, Allan Bradly AB 1771-A4B PLC; Rockwell software; Solar package Fire Detection System; Solar Turbotronics Model CTL001 Engine control computer and display; and Solar ladder logic pertaining to the solar turbines. Visits may also require changes to Programmable Logic Controller, the Government will not provide any laptop, software, training, cabling, ladder logic, or etc. to complete this requirement. Contractor shall respond within 24 hours of request for unscheduled site visit. Duration of site visit shall not exceed three (3) man days per call out.

2. SCHEDULED MAINTENANCE INSPECTIONS. Contractor shall perform two (2) basic maintenance inspections per unit, one (1) semiannual (4,000 hr) maintenance inspection per unit and one (1) annual (8,000 hr) maintenance inspection per unit for a total of four inspections per unit as described below. Contractor shall provide all consumable parts required including, but not limited to, oil filters, valve rebuild kits, O-rings, lubricants, gaskets, and turbine wash detergents.

2.1 BASIC MAINTENANCE INSPECTION:

-Review equipment log and unit operation with site personnel.

-Visually inspect control console electrical connections for cleanliness and security.

-Record all panel and package instrument readings. Note any malfunction indications, and check all oil-filled gages.

-Check air inlet system for obstructions and contamination. Record differential pressure (if gage installed).

-If self-cleaning air filter is used, check supply pressure and manually cycle through cleaning operation.

-If air dryer is used, check its operation.

-Record fuel pressure and adjust at off-skid regulator, as necessary.

-Check servo oil "pop-out" indicators, where applicable.

-Check oil cooler louver operation, where applicable.

-Check inlet guide vanes for position. Check linkage, and check cylinder for leakage.

-Assist customer in checking fire detectors for cleanliness and sensitivity, and fire retardant bottles for proper charge.

-Check and record magnetic speed pickup voltage output.

-Visually inspect unit for fuel, oil, and air leaks.

-Visually inspect mechanical integrity of fasteners, auxiliary motor couplings, bleed valve, and fuel control linkages.

-Inspect engine and package components for proper operating conditions. Note any unusual noises, vibrations, discolorations, cracks, chaffing lines. Check drain boss of combustor and turbine cases for leaks.

-Check batteries and charger for proper operation.

-Perform ingestive cleaning (water wash).

-Perform emissions testing with a hand held emissions tester such as a TESTO T350 XL with unit at least 80% loaded. Provide copy and review results with supervision.

-Check lube oil tank vent fan for proper operation, if applicable.

-Take lube oil sample for laboratory analysis.

-Check seal oil system (compressor sets only) if applicable:

a) Check seal oil "pop-out" indicators.

b) Check seal oil flow sight gage to ensure flow.

c) Check seal oil filter; record differential pressure.

d) Check overhead seal oil tank sight gage, if installed.

e) Check degassing tank oil level and temperature.

-Check dry gas seal system (compressor sets only) if applicable:

a) Check seal gas and buffer air flows.

b) Check seal gas and buffer gas filters and Record differential pressure.

c) Check primary seal leakage on the suction and discharge sides of each compressor.

-Review inspection with site personnel and provide copy of inspection report for logbook.

2.2 SEMI-ANNUAL MAINTENANCE INSPECTION:

-Perform all elements of a Basic Inspection.

-Test all gages; calibrate as necessary.

-Disassemble, clean, and rebuild gas valves, where applicable.

-Inspect fuel control system for security, leaks, and proper operation. Adjust as necessary. -Include the following, as applicable:

a) Governor

b) Gas fuel control valve

c) Fuel control actuator

d) Throttle valve

e) Gas fuel control poppet valve (replace as necessary)

f) Liquid fuel control assembly

g) All linkages and connections -Inspect engine air intake and exhaust systems for damage, leaks, and debris. Combustor inspection:

a) Inspect fuel nozzles/injectors for clogging, oxidation, cracks, and erosion. Clean or replace as necessary.

-Inspect combustor dome, liners, and first-stage turbine nozzle for cracks, erosion, war page, fret wear, deposits, or unusual hot spots and record observations.

-Inspect engine compressor variable vane mechanism for wear. Check for bent arms, loose linkages, and loose bushings. Ensure stop settings are correct. Check for damaged signal wires to actuator, as applicable.

-Inspect starter clutch (if applicable) to ensure lock-up in one direction and free rotation in the other direction.

-Check oil cooler for cleanliness; clean as necessary.

-Inspect/test auxiliary and backup equipment, as applicable:

-Remove and inspect igniter torch housing for cracks or excessive erosion. Inspect discharge tube for chafing wear.

-Remove and inspect igniter cable. Remove igniter plug and inspect for gap, erosion, or insulation oxidation. Replace with properly gapped new plug as necessary.

-Inspect thermocouple harnesses for breakage and general condition. Check integrity of support grommets.

-Inspect all package filter elements; clean or replace as applicable.

-Clean entire package.

-Test calibrates speed and temperature topping systems; calibrate as necessary. Calibrate temperature monitor(s) or pyrometer, as applicable.

-Test all safety warning and shutdown devices; adjust as necessary.

-Restart turbine and record acceleration time. Monitor electric/electronic control system for proper sequencing. Note control panel for malfunction indications. Troubleshoot and record corrective action.

-Conduct vibration survey.

2.3 ANNUAL MAINTENANCE INSPECTION:

-Perform all elements of Basic and Semi-annual Inspections.

-Internally inspect the accessory drive by removing blank cover or driven equipment.

-Inspect starter assembly for unusual wear or oil consumption. Verify correct system operation during start.

-Disassemble, clean, inspect, and reassemble the bleed valve. Verify that spring/shim is correct for unit location.

-Disassemble and inspect lube tubes. Replace springs, packing, and o-rings, where applicable.

-Inspect compensator and measure resistance, where applicable.

-Visually inspect exhaust bellows for cracks and distortion.

NOTE: The following tasks apply only to generator sets:

-Verify and record governor load gain voltage.

-Disassemble, clean and inspect coupling teeth and shear bolts for wear or damage. -Repack with fresh Solar coupling grease, and reassemble using new gaskets.

-Check gearbox-to-generator alignment; realign as necessary.

-Assist site personnel with cleaning the generator using a high-dielectric cleaner recommended for use by the generator manufacturer.

NOTE: The following tasks apply only to compressor sets.

-Remove seal oil pump (if applicable) from accessory drive and examine shaft splines for wear and evidence of seal leakage along the shaft. Replace or reinstall using a new gasket.

-Clean and inspect seal oil and buffer gas differential pressure regulating valves (or seal gas and buffer air differential pressure regulating valves), as applicable.

-Disassemble interconnect shafts; inspect splines for wear or abnormal condition. Reassemble using new a-rings.

-Check power turbine-to-gearbox, gearbox-to-compressor/pump, and compressor-to-compressor alignments, where applicable. Realign as necessary.Test and calibrate the vibration monitor system, if installed.

3. SITE CLEAN-UP. The Contractor shall also ensure that any debris and fluids generated on a daily basis are cleaned and all man-made debris is removed/disposed of to maintain a neat, safe, clean, and professional appearance.

4. REPORTS. Contractor shall provide a check sheet report to plant management upon conclusion of each site visit, scheduled and unscheduled. Contractor shall also provide written reports to plant management following those site visits for which the requirement for written reports is listed in the Basic Service Schedule. These reports shall cover engine condition, lube oil analysis and vibration analysis.

5. SITE SPECIFIC CONDITIONS. The Total Energy Plant is a secure area. All contractor personnel shall sign in and out when arriving or departing the compound. No smoking is permitted within the facility or within the 100 feet of the fuel off-loading station. This is a 24/7 facility. On site duty person will grant access. Precise instructions for access will be discussed only with contract awardee. No welding or open flame is permitted without a welding permit from the Lackland Fire Dept, 210-671-3496.