FA5209-16-T-0099_Performance_Work_Statement.pdf

DEPARTMENT OF THE ARMY

UNITED STATES ARMY GARRISON JAPAN

DIRECTORATE OF PUBLIC WORKS

UNIT 45006 APO AP 96343-5006

PERFORMANCE WORK STATEMENT

FOR OVERHAUL MAINTENANCE OF

DIESEL ENGINES, ELECTRIC GENERATORS,

AND AUXILIARY EQUIPMENT,

SUBSTATION, FACILITY No. 138, CAMP ZAMA, JAPAN

(FEWR No. JF-40032-4J)

4 August 2016

Table of Contents

SECTION 1 Description of Services/General Information Page 2 thru 8

SECTION 2 Services Summary Page 9

SECTION 3 Government Furnished Property and/or Services Page 10

SECTION 4 Appendices Page 11

A1-1 thru A4-24

Appendix A:

A1-1. The Location of Job Site A1-1

A1-2. List of Equipment and Systems A1.2-1 thru A1.2-2

A2. Minimum Required Maintenance Items A2.1-1 thru A2.1-7

A3. List of Minimum Required Replacement Parts for A3-1 thru A3-5

Maintenance Work

A4. Referenced Drawings for Replacement Parts A4-1 thru A4-24

SECTION 1 –DESCRIPTION OF SERVICES/GENERAL

INFORMATION

1. DESCRIPTION OF SERVICES. The contractor shall provide all necessary personnel, supervision, management, tools, equipment, transportation, materials, and any other items or services necessary to perform overhaul maintenance of diesel engines, electric generators, and other auxiliary equipment and systems, at the substation plant, facility number 138, Camp Zama (CZ). This service shall be performed in accordance with this Performance Work Statement (PWS), the attached appendices, manufacturer specifications, and commercial standards.

1.1. MAINTENANCE.

1.1.1. Maintenance Service. The contractor shall provide overhaul maintenance for diesel engines, electric generators, and other auxiliary equipment and systems to ensure reliable, functional, and continuous operations. The list of equipment and systems for maintenance is provided in Appendix A1-2 and the minimum required maintenance and manufacture’s specifications is provided in Appendix A2-1.

The list of required replacement parts is provided in Appendix A3 and the reference drawings are provided in Appendix A4. Maintenance service and minimum required replacement parts for those generator control panels shall be performed and replaced with due consideration of their manufactured date and running hours at no additional cost to the U.S. Government.

1.1.2. Maintenance Schedule. The contractor shall provide a overhaul maintenance schedule to the

Contracting Officer’s Representative (COR) for approval within 15 calender days from notification of actual starting date. The maintenance schedule shall include the following;

(1) Proposed maintenance services

(2) Schedule date for start of each work element

(3) Schedule date for completion of each element

(4) Number of man–hours needed for each work element

The minimum required work elements are listed in Appendix A2-1 of this PWS. The approved schedule will be used by the COR(s) to survey the contractor’s work.

1.1.3. Maintenance Reports. The report for maintenance shall be prepared in both English and Japanese and submitted to the COR(s) within 30 calendar days after the completion date. The reports shall be submitted in booklet-type form, and include as a minimum the following information:

(1) Type of required maintenance

(2) Engine and generator number

(3) Actual running hours of each engine

(4) Date work started

(5) Name of people who performed

(6) Equipment item checklist

(7) Description of each service performed (per item no. of each maintenance requirement, see

Appendix A2-1).

(8) Drawings/sketches for specified service areas

(9) Pictures/photographs such as deteriorated parts, replacement of new parts, etc

(10) Test and analyzed data results

(11) Recommendation for effective future maintenance programs/schedules and operation

(12) Date of work completion

(13) As backup data in conjunction with information per (7) above, a type of engineering work w/man-hours observed and any materials & parts used for an individual work unit w/a trade name/product name as well as quantitative information

(14) Signature of manufacturer’s representative

1.2. INTERFERENCE WITH GOVERNMENT OPERATIONS: One engine shall remain operational at all times. Services requiring complete plant stoppage should be minimized to prevent any disruptions in the mission.

2.0. GENERAL INFORMATION.

2.1. CONTRACTOR PERSONNEL.

2.1.1. Contract Manager. The contractor shall provide a contract manager who shall be responsible for all requirements in this PWS. The name of this person and an alternate(s) who shall act for the contractor when the manager is absent, shall be designated in writing to the Contracting Officer (KO). The contract manager or alternate shall have full authority to act for the contractor on all matters relating to this contract. The contractor shall provide the contract manager’s names, email addresses, and telephone numbers. The contract manager or alternate shall be proficient in English and have a good understanding of the requirements pertaining to this contract for interpretation and implementation of directives (written and oral), issued in English by the KO, or COR.

2.1.2. Contractor Employees. Contractor personnel shall be easily recognizable as contractor employees. This may be accomplished by wearing distinctive clothing bearing the name of the company or by wearing appropriate badges which contain the contractor’s company name and the employee’s name.

2.1.2.1. The contractor is required to provide mechanics/electricians who have adequate experience in maintenance of the similar sized diesel engines, generators and control panels listed under this contract.

The contractor or sub-contractor’s personnel shall possess the following certificates or licenses or their equivalent at all time while performing work.

Engineering License for Electric Generation Systems of Private Use (自家用発電設備専門技術者

資格)

Individual being trained exclusively for Hanging Techniques by Hoists/Cranes (玉掛技能講習修

了)

Inspector License for Firefighting Equipments/Systems, 1st Class (第１種消防設備点検資格)

Electrical License, 2nd Class (電気工事士２種)

The required certificates/licenses shall be current and updated when changes occur.

2.1.3. Removal of Contractor’s Employees. The contractor shall utilize only experienced, responsible and capable employees in the performance of this contract. The KO may require that the contractor remove any of his/her employees who endanger persons or property, or whose continued employment under this contract is inconsistent with the interests of the U.S. Government.

2.1.4. Third Country Nationals (TCN). The Security Forces on each base control entry to the base.

Under certain circumstances, the TCN might be denied entry. It is the contractor’s responsibility to coordinate with Security Forces at each base when there is a question about particular entry circumstances.

2.1.5. U.S. Government and/or Master Labor Contract Employees. The contractor shall not hire employees of the U.S. Government and/or Master Labor Contract employees in violation of the

Procurement Integrity Act. See FAR Section 3.104. Further, the contractor shall not employ any

Department of Defense employee, either military or civilian, unless such person seeks and receives approval in accordance with Department of Defense 5500.7-R, Joint Ethics Regulation.”

2.1.6. Military Personnel. The contractor is cautioned that off-duty active military personnel hired under this contract may be subject to permanent change of station (PCS), change in duty hours, or deployment. Military Reservists and National Guard members may be subject to recall to active duty.

Abrupt absence of these personnel could adversely affect contractor’s ability to perform; however, their absence at any time shall not constitute an excuse for non-performance under this contract.

2.1.7. Roster. The contractor shall provide a complete roster of all personnel (including the contract manager and alternate contract manager) to the COR prior to start of performance. The roster must include all employee names, email addresses, and telephone numbers. The contractor shall maintain a current listing of employees, providing updates as changes occur.

2.2. QUALITY CONTROL. The contractor shall develop and maintain a quality control program to ensure the services are performed in accordance with commonly accepted commercial practices. The contractor shall develop and implement procedures to identify, prevent and ensure non-recurrence of defective services. At a minimum, the contractor shall develop quality control procedures addressing the areas identified in paragraph 2, Services Summary.

2.3. QUALITY ASSURANCE. The Government will evaluate the contractor’s performance in accordance with the Quality Assurance Surveillance Plan (QASP) by appointing a COR to monitor performance to ensure services are received.

2.4. GOVERNMENT REMEDIES. The KO shall follow FAR 52.212-4, Contract Terms and Conditions-

Commercial Items, for the contractor’s failure to perform satisfactory services or failure to correct non-conforming services.

2.5. CONTRACTING OFFICER (KO) AUTHORITY. Only the KO has authority to enter into, administer, terminate or modify the terms and conditions herein. Any changes made by persons other than the KO will be considered an unauthorized commitment and subject to ratification actions in accordance with FAR 1.602-3.

2.6. CONTRACTING OFFICER’S REPRESENTATIVE (COR). The contractor shall coordinate all aspects of this requirement with the COR. Completed work shall be subject to inspection and acceptance by COR. This designation will be made in writing by the KO at the time of contract award, or prior to commencement of COR duty. The COR shall NOT direct or redirect any contractor action(s). This can only be done by the KO.

2.7. AVAILABILITY OF FACILITY.

2.7.1. Hours of Service. The contractor’s personnel will perform scheduled work on weekdays, Monday through Friday (exclusive of the U.S. Federal and other designated holidays listed below), during normal duty hours, 0800 - 1700 hours unless prior arrangements have been made with the COR).

2.7.2. Legal American Holidays and Other Designated Holidays.

American Holidays

1 January New Year’s Days

3rd Monday in January Martin Luther King Jr.’s Birthday

3rd Monday in February President’s Day

Last Monday in May Memorial Day

4th of July* Independence Day

1st Monday in September Labor Day

2nd Monday in October Columbus Day

11 November* Veterans Day

4th Thursday in November Thanksgiving Day

25 December* Christmas Day

Other Designated Holidays

1, 2 & 3 January New Year’s Days

29, 30 & 31 December Year End Days

*Holidays falling on a Saturday will be observed on the preceding Friday, Holidays falling on a

Sunday will be observed on the following Monday.

2.7.3. Arrangements of the Performance Time. Should the contractor decide to perform any of the required services before or after normal duty hours, the contractor will request approval prior to performance from the COR and shall do so at no additional cost to the Government.

2.8. SECURITY AND SAFETY REQUIREMENTS.

2.8.1. Installation Base Passes. The U.S. Government will issue all required Installation/Base Passes and Controlled Area Badges to contractor personnel at no cost to the contractor. Vehicle insurance certificates are required to obtain Base Passes and must cover the automobile liability insurance in the types and minimum amounts of (a) Bodily Injury - ¥30,000,000 per person per occurrence, in addition to the Japanese Compulsory Insurance (JCI), and (b) Property Damage - ¥3,000,000 per occurrence. The prime contractor shall be responsible for all passes issued to his/her own or subcontractor’s employees under this contract. The contractor shall return all applicable passes upon termination of employment or completion of this contract to the Japanese Pass Section, and a certificate of receipt shall be obtained.

NOTE: Contractor personnel are required to comply with U.S. Army Regulation 190-5 for personnel pass requirements. Contractors are also required to comply with U.S. Army Garrison Japan Regulation

190-13 for vehicle pass requirements. These regulations are available for the selected contractor’s review upon personnel and/or vehicle pass issuance.

2.8.2 Security Requirements. The contractor shall ensure each employee obtains all the required passes and identification items for access to U.S. Government’s installations. These items are issued by the

Security Forces Pass and Registration Section. The contractor and employees shall return identification cards to Security Forces within 24 hours of termination or completion of this contract. All other

Government identification for terminated employees shall be returned to the KO within 24 hours of termination.

2.8.3. Off Limit Signs. The contractor shall provide warning and/or ”OFF LIMITS” signs in both

English and Japanese and post them at the entrances of jobsite, and barricades around the jobsite while the equipment and/or systems are being serviced. The contractor shall control all personnel desiring access into jobsite areas when work is in progress.

2.8.4. Photography Permission. The contractor shall obtain COR approval prior to commencing any photography.

2.8.5. Reports of Damages, Destruction, Injury, or Death

2.8.5.1. The contractor shall report all incidents of damage or destruction to property, or personal injury or death to any person, arising out of and during the performance of this contract. The term “property” includes equipment, freight, or property of any type, whether Government owned or not. The term

“Contractor” includes the contractor, its agents, servants or employees.

2.8.5.2. The contractor shall submit these reports to the KO through the COR as follows:

(a) A preliminary report shall be made as soon as practicable after the time the incident occurs. The report may be either verbal or facsimile.

(b) A complete written report shall be submitted within 4 days (96 hours) after occurrence of the incident. A copy of this report shall be furnished to the COR.

2.8.6. Security Danger Warning, Accident Prevention, Fire Prevention and Fire Protection

Requirements. The contractor shall comply with all pertinent requirements of the U.S. Army and

USAG-J Fire Protection and Safety Regulations or Laws of Japan, whichever is more stringent, to insure compliance by all subcontractors.

2.8.7. Accident Prevention Plan and a Job Hazard Analysis. The contractor shall not commence work at the job site until an Accident Prevention Plan and a Job Hazard Analysis are submitted for review and approved by the COR. The contractor is responsible for reviewing section 1 and 34 of EM 385-1-1, the US Army Corps of Engineers’ Safety and Health Requirements Manual, http://140.194.76.129/publications/eng-manuals/em385-1-1/2008_English/toc.html.

2.8.8. Reserved.

2.8.9. Environmental Regulations. The contractor shall comply with all U.S. Government and

Japanese environmental laws (whichever are most stringent) to protect the health and safety of employees/residents, and preserve the local and global environment. The contractor shall comply with the Japan Environmental Governing Standards (JEGS) and shall minimize or eliminate environmental pollution and energy/utility waste.

2.8.10. Environmental and Hazardous Material Handling. The contractor shall comply with the

Japan Environmental Governing Standards (JEGS) to protect the health and safety of employees/residents and minimize or eliminate environmental pollution.

The Contractor shall follow the installation Spill Prevention Control and Countermeasure (SPCC) Plan

(https://intranet.zama.army.mil/CmdStaff/usagj/pw/docs/SPCCP.pdf) and Oil and Hazardous Substance

(OHS) pollution Contingency Plan (https://intranet.zama.army.mil/CmdStaff/usagj/pw/docs/OHSPC.pdf) in case of a spill or release of POL and/or hazardous substances. The Contractor shall immediately notify

Fire and Emergency Services, Directorate of Emergency Services, U.S. Army Garrison Japan of any spills http://140.194.76.129/publications/eng-manuals/em385-1-1/2008_English/toc.html that occur on the installation through the Emergency Phone Number. The contractor will be liable for containment and clean-up of the site.

2.8.11. Delivery and Storage of Materials. All materials delivered and placed in storage shall be protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants by the contractor.

2.8.12. Disposal of Materials. All debris and unserviceable materials generated under this contract such as industrial waste, non-recyclable materials and equipment/material not listed on hand-receipts shall be disposed of off-base by the contractor in accordance with the laws of Japan. Hand receipt items require turn-in action by the contractor when the listed items have to be replaced.

2.8.13. Responsibility for Damages. Any damages caused to U.S. Government property during the course of performing this contract shall be restored, replaced and/or repaired to its original condition at no additional cost to the U.S. Government.

2.9. CLEANLINESS. The contractor is responsible for cleanliness of the service areas. This includes, but is not limited to, washing, sweeping, dusting and other janitorial services necessary to maintain the area in a clean and sanitary condition. The contractor shall furnish such supplies as required.

2.10. COMMERCIAL WARRANTY. The contractor shall provide the Government with their commercial warranty. The Government shall receive the same warranty service as the contractor’s most favored customers. If the services fail to be performed or otherwise fail due to workmanship or materials, the contractor shall correct the affected area(s) at no additional cost to the U.S. Government. The

Government reserves the right to reject any unserviceable or substandard item and to require replacement with a serviceable like item or acceptable quality item or to require full credit for the item.

2.11. CONSERVATION OF UTILITIES. The contractor shall instruct employees in utility conservation practices. The contractor shall be responsible for operating under conditions, which preclude the waste of utilities. The contractor shall comply with additional energy policies upon notification by the KO.

2.12. CONTRACTOR MANPOWER REPORTING. The office of the Assistant Secretary of the

Army (Manpower & Reserve Affairs) operates and maintains a secure Army data collection site where the contractor will report ALL contractor manpower (including subcontractor manpower) required for performance of this contract. The contractor is required to completely fill in all the information in the format using the following web address: https://cmra.army.mil/. The required information includes:

(1) Contracting Office, Contracting Officer, Contracting Officer’s Technical Representative

(2) Contract number, including task and delivery order number

(3) Beginning and ending dates covered by reporting period

(4) Contractor name, address, phone number, e-mail address, identity of contractor employee entering data

(5) Estimated direct labor hours (including sub-contractors)

(6) Estimated direct labor dollars paid this reporting period (including sub-contractors)

(7) Total payments (including sub-contractors)

(8) Predominant Federal Service Code (FSC) reflecting services provided by contractor (and separate predominant FSC for each sub-contractor if different)

(9) Estimated data collection cost https://cmra.army.mil/

(10) Organizational title associated with the Unit Identification Code (UIC) for the Army Requiring

Activity (the Army Requiring Activity is responsible for providing the contractor with its UIC for the purposes of reporting this information)

(11) Locations where contractor and sub-contractors perform the work (specified by zip code in the

United States and nearest city, country, when in an overseas location, using standardized nomenclature provided on website)

(12) Presence of deployment or contingency contract language

(13) Number of contractor and sub-contractor employees deployed in theater this reporting period (by country)

As part of its submission, the contractor will also provide the estimated total cost (if any) incurred to comply with this reporting requirement. Reporting period will be the period of performance not to exceed

12 months ending 30 September of each government fiscal year and must be reported by 31 October of each calendar year. The contractor may use a direct XML data transfer to the database server or fill in the fields on the website. The XML direct transfer is a format for transferring files from a contractor’s systems to the secure web site without the need for separate data entries for each required data element at the web site. The specific formats for the XML direct transfer may be downloaded from the web site.

(NOTE: XML = Extensible Markup Language)

SECTION 2

2. SERVICES SUMMARY.

The following Services Summary (SS) identifies the performance objectives and performance thresholds for critical tasks associated with providing support services for this requirement. The performance threshold briefly describes the minimum acceptable levels of service required for each requirement.

These thresholds are critical to mission success.

SS Number and

Performance Objective PWS Paragraph

Performance

Threshold

Method of

Assessment

SS #1. Maintenance Services Para 1.1.1 through

1.1.2.

No defects are allowed. 100% Inspection

SS #2. Maintenance Reports 1.1.3.

One (1) day delay is allowed per submission.

Customer

Complaints

SECTION 3

RESERVED

SECTION 4

4. APPENDICES.

Appendix A1-1 The Location of Job Site A1-1

Appendix A1-2 List of Equipment and Systems A1.2-1 thru A1.2-2

Appendix A2 Minimum Required Maintenance Items A2.1-1 thru A2.1-7

Appendix A3 List of Minimum Required Replacement Parts A3-1 thru A3-5 for Maintenance

Appendix A4 Referenced Drawings for Replacement Parts A4-1 thru A4-24

A1.2-1

Diesel Engine No. of Equipment 2 Type Diesel Fuel Engine, Water cooled, 4 cycle, Exhaust Gas Turbo w/Air Cooler Model S12A2 No. of cylinders 12 cylinders Cylinder dia x stroke 150mm x 160mm Engine Start Compressed Air Start Type Ignition Type Start-up & Stop-down: Pressurized Spark by Diesel Fuel

Operation Under Rated Load: Diesel Turbo charger Exhaust gas turbine w/Air Cooler

Engine Primary Cooling Water Lubrication Oil Cooler Secondary Cooling Water Air Cooler Secondary Cooling Water Primary Cooling Water Cooler Secondary Cooling Water

Lubrication Type Power Injection Type (By Engine Connected Gear Pump) Direction of Engine Rotation Clockwise Weight 5800 kg (Dry) Manufacture Date December, 2000 Maker Mitsubishi Heavy Industries, Co., Ltd.

Synchronous Alternating Current Generator No. of Equipment 2 Model TAKL-SEK Capacity 750 kVA Voltage 6,600 V Rotary Speed 1,500 min¯¹ Phase ·Frequency 3Ø, 50Hz Power Factor 0.8 Excitation Type Brush-less Weight 2,490 kg Maker TOSHIBA

Generator Panels NP-1 No.1 Generator Control Panel NP-2 No.1 Generator Automatic Transfer Switch NP-3 Synchronous Panel NP-4 No.2 Generator Control Panel NP-5 No.2 Generator Automatic Transfer Switch NP-6 High Voltage Distribution Panel NP-7 Auxiliries Control Panel Maker TOSHIBA

A1-2. List of Equipment and Systems

Cooling System

A1.2-2

<<AUXILIARY EQUIPMENT FOR FUEL DELIVARY AND COOLING SYSTEM>>

Radiator (outdoor)

No. of Equipment 2 Model EK-2432 / 1596 Noise Under 85 dB(A) at 1 M from muffler Maker NAJIKO Co., Ltd

Expansion Tank for radiators No. of Equipment 2 Type Indoor wall mounted Capacity 200 liter Maker Mitsubishi Heavy Industries, Co., Ltd.

<<AUXILIARY EQUIPMENT FOR PNEUMATIC ENGINE START-UP SYSTEM>>

Air Storage Tank Unit

No. of Equipment 2 ea + 1 back up Type Cylinder Type Capacity 200 liter x 3.2 Mpa Maker KANAZAWA IRON WORKS., Ltd.

Air Compressor for Start-up No. of Equipment 2 Model S5A Type L-Type, 2 Stages Capacity 19.1 m³/h No. of Cylinder 2 Speed 1150 min⁻ˡ Motor 200V, 50 Hz, 4P, 3.7 kW Location Within Units Maker SANWA IRON WORKS Co., Ltd.

Solenoid Valve No. of Box 1 Model REV-2006EXA@6 Type Air Location Within Engine Units Maker SAGINOMIYA Co., Ltd

<<AUXILIARY EQUIPMENT FOR EXHAUST GAS SYSTEM>>

Exhaust Gas Silencer

No. of Equipment 2 Model EK-2432 / 1596 Capacity Under 85 dB(A) at 1 meter from muffler Resistance Value 1.0 kPa Maker NAJIKO Co., Ltd

A2.1-1

A2-1. Minimum Required Maintenance Items - Detail Requirement

Large Small Equipment Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Preparation for service Provide required protection for services 工事前養生 工事前範囲に必要な場所の養生実施 Operating conditions Checked by operating records 過去の運転状態の確認 発注者の記録にて確認 Shut down conditions Engine should be stopped by the stop switch

停止時の確認 停止ｽｲｯﾁONで確実に機関が停止することを確認

Check operating condition of lubricating oil priming pump 停止後、潤滑油ﾌﾟﾗｲﾐﾝｸﾞﾎﾟﾝﾌﾟ運転確認

Interior Quality of lubrication oil by visual inspection 内部点検 潤滑油の汚れ目視点検 Interior Quality of lubrication oil by visual inspection 内部点検 潤滑油の汚れ目視点検

Pressure for valve opening Jet test using test pump 開弁圧力調整 ﾃｽﾄﾎﾟﾝﾌﾟによる噴射試験 Inspection Visual inspection and replacement of O-ring 点検 目視点検、Ｏﾘﾝｸﾞ交換 Appearance Visual inspections 外観点検 目視点検 Gaps for tappets Check and adjust gaps ﾀﾍﾟｯﾄ間隙調整 間隙確認、調整

Sponge filter Replace ｽﾎﾟﾝｼﾞﾌｨﾙﾀ交換 交換 Leakage Perform check up under operation 水漏れ有無点検 運転時確認 Coupling bolts Tighten bolts ｶｯﾌﾟﾘﾝｸﾞﾎﾞﾙﾄ締付確認 締付確認 Leakage Visual inspections 水漏れ有無点検 目視点検 Operating condition under modulation control Per hot water temperature 作動状況の確認 温度指示による Oil level and pressure Replenishment as required. Quality analysis 油量､油圧点検 補給（随時）､性状分析(１ヶ月毎)：客先殿所掌 Overhaul Check drainage. No contaminations 分解清掃 ﾄﾞﾚﾝ排出後異物､水分の混入の有無に注意

Air Intake System

(給気系統)

Fuel Oil System

(燃料油系統)

Engine and Engine Accessories

Engine Block （シリンダー・ブロック）

Oil Pan （オイルパン）

Engine （機関本体）

Engine (機関本体)

Fuel Oil Injection Valve (燃料噴射弁)

Engine Common （共通）

Ready to Start （機関分解前の確認）

Lubrication Oil System

(潤滑油系統)

High Pressure Fuel Oil Pipe (燃料高圧管)

Fuel Oil Injection Pump (燃料噴射ポンプ)

Intake & Exhaust Valve Lever （吸排気弁レバー）

Oil Filter (潤滑油フィルター)

Cooling Water Secondary Pump

（二次冷却水ポンプ）

Cooling Water Primary Pump （一次冷却水ポンプ）

Temp Control Valve for Hot Water (温水回収温度調整弁)

Engine Oil (機関潤滑油)

Super Charger （過給機）

Cooling Water System

(冷却水系統)

Engine Accessories (機関付属機

器)

A2.1-2

Large Small Equipment Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Elements No damages and contaminations. Cleaning ｴﾚﾒﾝﾄ点検 損傷、異物の有無確認、清掃 Back wash operations Adjustment of valves. Check operating conditions 逆洗動作確認 ﾊﾞﾙﾌﾞ調整、動作状況確認 Check the sludge checker Check for any damages and contaminations. Cleaning ｽﾗｯｼﾞﾁｪｯｶ点検、清掃 損傷・異物の有無確認、清掃 Mesh wires of bypass valve and valve opening Cleaning of mesh wires. Adjustment of valve opening ﾊﾞｲﾊﾟｽ弁金網清掃、ﾊﾞﾙﾌﾞ開度調整 金網清掃、ﾊﾞﾙﾌﾞ調整実施 Paper filters Replace ﾍﾟｰﾊﾟｰﾌｨﾙﾀ交換 交換 Centrifuge filter Cleaning and replacement 遠心ろ器清掃（ｷｬｯﾁﾍﾟｰﾊﾟｰ交換） 清掃、ｷｬｯﾁﾍﾟｰﾊﾟｰ交換

Suction strainers Cleaning 吸入ｽﾄﾚｰﾅ清掃 清掃 Check and clean Check drainage. No contaminations.

点検清掃 ﾄﾞﾚﾝ排出後異物・水分混入の有無確認、清掃 Check and clean Check drainage. No contaminations.

点検清掃 ﾄﾞﾚﾝ排出後異物・水分混入の有無確認、清掃 Oil leakage Visual inspections 油漏れ有無点検 目視点検 Oil leakage Visual inspections 油漏れ有無点検 目視点検

Operating conditions Check cranking rotation speed 運転状況確認 ｸﾗﾝｷﾝｸﾞ速度確認 Anchor bolts Tighten anchors for starter and brackets.

取付ﾎﾞﾙﾄ増締め ｽﾀｰﾀおよびﾌﾞﾗｹｯﾄ取付部増締め Appearance Check operating conditions.

外観点検 作動状況確認 Working pressures. Check pressure gauges.

作動圧力点検 圧力指示確認 Working conditions of drain valves Check working conditions.

ﾄﾞﾚﾝ弁動作確認 動作確認 Appearance, Oil level Visual inspections 外観、油量点検 目視点検 Operating conditions. Appearance check, Check working conditions.

運転状況確認 外観､作動状態点検 Appearance, Oil level Visual inspections 外観、油量確認 目視点検 Connectors. Visual and feeler inspections ｺﾈｸﾀ部点検 目視、触手点検 Link levers. Visual and feeler inspections ﾘﾝｸ､ﾚﾊﾞｰ点検 目視、触手点検

A/F Control Link (A/F制御リンク)

Oil Filter (潤滑油フィルター)

Mist Blower (ミストブロワ)

Lubrication Oil Cleaning System

(潤滑油清浄装置)

Lubrication Oil System

(潤滑油系統)

Fuel Oil Filter, No.2 (燃料油第二フィルタ)

Fuel Oil Transfer Pump (燃料油移送ポンプ)

Fuel Oil Return Pump (燃料油返送ポンプ)

Fuel Oil System

(燃料油系統)

Engine Accessories (機関付属機

器)

Fuel Oil Filter, No.1 (燃料油第一フィルタ)

Starter Air Pressure Reducing Valve (始動空気減圧弁)

Starter Air System

(始動空気系統

Air Starter (エアスターター)

Relay Valve (リレーバルブ)

Engine Controller (制御機器)

Control Air System (制御空気)

A/F Control (A/F制御)

Air Compressor (始動空気圧縮機) Air Compressor

(計装用空気圧縮機)

Air Tank (始動空気槽)

Actuator of Governor (ガバナアクチュエータ)

Governor (ガバナ)

A2.1-3

Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Appearance Check leakage.

外観点検 漏れ点検 Appearance, Working conditions. Check meter gauges.

外観、作動状態点検 指示値確認 Pressure gauges. Check meter gauges.

圧力計点検 指示値確認 Sensors Check meter gauges.

ｾﾝｻ点検 指示値確認

Open and closed valve conditions. Make sure all valve conditions.

諸弁の開閉確認 開閉位置確認 Start up operating conditions. Make sure start up condition without any troubles.

始動状況確認 異常なく始動すること Operating conditions. Measure all gauges.

性能試験記録 既設の計器指示値にて計測 Emission monitoring. Analyze smoke gas under diesel and/or gas modes.

ばい煙計測 計測（ﾃﾞｨｰｾﾞﾙ、ｶﾞｽﾓｰﾄﾞ）

Debris. Visual inspections 堆積、付着がないこと 目視 Water. Visual inspections 浸水、付着がないこと 目視 Oil. Visual inspections 付着がないこと 目視

Rusts, damages and dirt. Appearance check 錆、損傷、汚れ等がないこと 外観点検 Loosen bolts and corrosion. Appearance check 緩み、腐食等がないこと 外観点検 Rusts, damages and dirt. Appearance check 錆、損傷、汚れ等がないこと 外観点検 Loosen terminals, Color changing. Appearance check 締付部の緩み、変色がないこと 外観点検 Damages, colors, corrosion, and leakages Appearance check 外傷、変色、腐食、水 ・ 油漏れ 外観点検 Insulation resistance must have over 0.5MΩ. Insulation resistance test

500Vﾒｶﾞｰで 0.5MΩ以上であること,断線、地絡、損傷が無い 絶縁抵抗測定・抵抗計（テスター）

Dirt. Appearance check 汚れがないこと 外観点検 Insulation resistance must have over 5MΩ. Insulation resistance test

絶縁抵抗が5ＭΩ以上であること 絶縁抵抗測定・抵抗計（テスター）1000Ｖ絶縁抵抗計

Water (水分)

Oil (油など)

Engine Meter (計器)

Covers (カバー類)

Terminal Box, Earth Wire (端子箱、接地線)

Environmental (周囲環境)

Pressure & Temperature Sensor (圧力・温度センサー)

Outside Coating of Stator (固定子の外被)

Bolts (据付、各部のボルト)

Stator (固定子)

Adjustment & Ready (調整・運転準備)

Meter (計器)

Wiring Coil (巻線)

Engine Common （共通）

Solenoid Valve (電磁弁)

Wiring, Piping (配線、配管)

Engine Meter Panel (機関計器盤)

Operation Test (試運転)

Wiring Coil (巻線)

Debris (異物)

Space Heater (スペースヒーター) Temperature Meter (温度計測温素子)

Exterior (外観)

Fuel Oil Flow Meter (燃料油流量計)

Alternating Current Generator

A2.1-4

Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Insulation resistance must have over 0.5MΩ. Insulation resistance test

絶縁抵抗が0.5ＭΩ以上であること 絶縁抵抗測定・抵抗計（テスター）500Ｖ絶縁抵抗計

Loosen bolts Appearance check 緩みがないこと 外観点検

Rusts, damages and dirt. Check interior and exterior.

錆、損傷、汚れ等がないこと 外・内部点検 Insulation resistance must have over 0.5MΩ. Insulation resistance test

絶縁抵抗が0.5ＭΩ以上であること 絶縁抵抗測定・抵抗計（テスター）500Ｖ絶縁抵抗計

Bearing Appearance check 軸受 異常がないこと Bearing Housing Appearance check 軸受ハウジング 異常がないこと Grease Check for wear debris and unusual discoloration グリース 磨耗粉の流出と劣化、異常な変色がないこと

Journal Check for wear and discoloration. Make sure that outer diameter is within the tolerance level.

軸ジャーナル部 損傷、磨耗、変色がないこと。外径寸法基準以内であること

Axial current insulation Insulation resistance test 軸電流防止絶縁 500V絶縁抵抗系にて10kΩ以上であること

Appearance check 汚れ、割れ、損傷等がないこと

Out put power. Must be standard level.

出力 定格値以内のこと Abnormal noise and smell. Check under start up and continuous operating conditions.

運転音、異臭 始動時、運転時に異音、異臭がしない事 Vibration Must be standard level.

振動 基準値以内であること Temperatures (bearings, coils and draft) Must be standard level.

各部温度 (軸受け、巻線、通風) 基準値以内であること

Abnormal conditions. Appearance check 錆、変形、破損、汚損、腐食等異常がない事 外観点検 Abnormal conditions. Visual, hearing and smell inspections.

錆、変形、破損、汚損、腐食、 粉塵の堆積、結露、及び異臭、がない事。 視聴臭覚点検 Malfunctions and damages. Appearance check, Check working conditions.

動作不良、破損、損傷等がないこと。 外観、作動状態点検 Abnormal noise. Appearance check, Check working conditions.

異常音がないこと 外観、作動状態点検 Open and close conditions Appearance check, Check working conditions.

開閉操作に異常がないこと。 外観、作動状態点検

Interior of Panels (盤内部全般)

Ventilation Fan (盤換気ファン)

Rotor （回転子）

Wiring Coil (巻線)

Wiring Coil (巻線)

Other (その他)

回転計発電機(T/G)

(形式:QVAH-02)

Wiring Coil (巻線)

Rolling Bearing(ころ がり軸受)

Exterior of Panels (盤外部全般)

Door, Key (扉、鍵)

Lubrication System (潤滑油装置)

General (外観・内部一般)

Bearings （軸受）

All Generator Panels (全ての電気盤)

Bolts (締付けボルト)

Switches, Indicators, etc.

(盤面器具)

Speed Sensing Equipment (速度検出器)

Alternating Current Generator

(交流発電機）

Dynamo （励磁装置

Direct Current Dynamo

（励磁機）

Operating Condition (運転状況)

A2.1-5

Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Loosen connections, color changing by heat, damages Visual and feeler inspections 接続ネジ緩み，過熱変色、汚損等がない事。 目視、触覚 Damages, color changing by heat, cracks, dirt Visual inspections 破損、過熱変色、亀裂、汚損等がない事 目視 Loosen connections, color changing by heat, damages Visual and feeler inspections 締付部の緩み、過熱変色、汚損等がない事 目視、触覚 Damages on connectors, loosen screws Visual and feeler inspections 端子の損傷、ネジの緩みがないこと 目視、触覚

Required items by manufacturers Check connectors, Insulation resistance test, Operation test 各機器メーカー推奨のチェックシート掲載項目 締付部の緩み、絶縁測定、作動状況確認等 Operating condition, damages Inspections 動作不良、破損、損傷等がないこと 一般点検

Damages, Marks of over heat Visual inspections

破損、損傷、過熱痕跡等がないこと 目視

Damages, Contact failures Visual inspections, Operation tests 破損、損傷、接触不良等がないこと 目視、作動状態点検 Working conditions, Damages Visual inspections, Operation tests 動作不良、破損、損傷等がないこと 目視、作動状態点検 Anti-falling Visual and feeler inspections 脱落防止に異常がないこと 目視、触覚 Working conditions, Damages Visual inspections, Operation tests 動作不良、破損、損傷等がないこと 目視、作動状態点検 Working conditions, Damages Visual inspections, Operation tests 動作不良、破損、損傷等がないこと 目視、作動状態点検 Deforms, color changing by heat, damages Visual inspections, Operation tests 変形、過熱変色、損傷等がないこと 目視、作動状態点検 Fusing, Rusts on clip Visual inspections, Operation tests 溶断、クリップに錆がないこと 目視、作動状態点検 Dusts, Contact failures Visual inspections, Operation and quality tests 内部のほこり、接触不良がないこと 目視、作動状態点検, 動作特性試験 Rusts, Color changing, Zero gauging Visual inspections, Operation tests 錆、変色がないこと、零点確認 目視、作動状態点検 Damages, Contact failures Visual inspections, Operation tests 破損、損傷、接触不良等がないこと 目視、作動状態点検 Damages Visual inspections, Operation tests 破損、損傷等がないこと 目視、作動状態点検 Damages Visual inspections 破損、損傷等がないこと 目視 Damages, Marks of over heat Visual inspections 破損、損傷、過熱痕跡等がないこと 目視

Capacitor Trip System (コンデンサトリップ装置)

Low Voltage Contactor (低圧接触器類)

Control & Auxiliary Circuit (制御、補機回路)

Protective Relay (保護継電器)

Meter (計器類) Switches

(スイッチ類)

Electric Equipment (器具類)

Transducer (変換器)

Earth Wire (接地線)

Main Circuit & Connection (主回路、締付部)

Rectifier (整流器類)

Circuit Breaker (配線用遮断器)

Timer (タイマー)

Overload Relay (過負荷継電器)

Sub Transformer (補助変圧器)

VCB

(高圧真空遮断器)

Main Circuit & Connection (主回路、締付部) Insulator, Support

(碍子、支持物)

Fuse

(ＶT & 低圧ヒューズ類)

Electric Wiring (配線)

Circuit Breaker (遮断器類)

Main High Voltage Equipment

(高圧主機器)

Relay (補助リレー類)

VT & CT

(計器用変成器)

A2.1-6

Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Damages, Deforms Visual inspections 破損、損傷､変形等がないこと 目視 Damages, Disconnections Visual inspections, Operation tests 損傷、断線等がないこと 目視、作動状態点検 Damages, Burned-out bulbs Visual inspections, Operation tests グローブ破損、球切れがないこと 目視、作動状態点検 Marks of over heat, Abnormal noise, working conditions Visual inspections, Operation tests 過熱痕跡のないこと、異常音が無く正常に回転する事 目視、作動状態点検

Color changing on print circuit panels, loosen connectors and screws Visual inspections, Operation tests

基板の過熱変色,コネクタ、ネジ等の緩みがないこと 目視、作動状態点検

Color changing on print circuit panels, Working conditions Visual inspections, Operation tests of protection relays

基板の過熱変色がないこと及び動作確認 目視、保護継電器動作試験

Color changing, Damages Visual and feeler inspections 変色、汚損, 基板の過熱変色がないこと 目視、触覚 Voltage from Current Generator Operation test 発電機電圧が安定であること 確認運転 Damages, Corrosions, Deforms, Loosen connectors Visual inspections 損傷、腐食、変形、汚損、端子部の緩みがないこと 目視 Working conditions Measurement of working time 基準値の±5％以内であること 動作時間測定

Damages, Color changing Visual inspections

汚損、変色がないこと 目視 Conditions of spacers and coils Visual inspections スペーサーの枯れ、コイルのがたがないこと 目視 Damages, Color changing Visual inspections 汚損、変色がないこと 目視 Damages, Dirt on insulations Visual inspections 破損、絶縁部の汚れがないこと 目視 Abnormal conditions Visual inspections 器具、部品の異常がないこと 目視 Loosen connections, Color changing by overheat Visual and feeler inspections 端子緩み、過熱変色がないこと 目視、触覚

Make sure that there is no big difference compared to the previous measurement Insulation resistance test 前回測定値から異常に低下していないこと 絶縁抵抗測定（1000Vメガー）+ （500Vメガー）

Ventilation Fan (盤換気ファン)

Electric Equipment (器具類)

Resistor (抵抗器類)

Lamp, Display (表示灯、集合型表示灯、盤内灯)

Control Boards (EANA, EACP)

(制御装置)

Controller (制御装置)

Automatic Controllers (自動制御装置類)

Automatic Synchronized Starter

Automatic Load Balancer (自動負荷平均装置)

Capacitor (コンデンサ類)

Initial Excitation Circuit (初期励磁回路（抵抗器。整流器）)

AVR

(自動電圧調整器)

SVA

(静止形電圧設定器)

Sub Transformer for Excitation (励磁用補助変圧器)

Reactor for Excitation (励磁用リアクトル)

Converter for Excitation (励磁用変流器)

Wiring (配線)

Excitation System （励磁装置類）

Main Circuit (主回路)

Insulation (絶縁)

Rectifier for Excitation (励磁用整流器)

A2.1-7

Division Division Parts Maintenance Items Maintenance Description Note/Remarks (大区分) (小区分) (点検部分) (点検整備項目) (実施要領) （備考）

Working conditions Operation test 始動・停止動作が仕様通りであること 確認運転 Regulation levels Operation test ±10%程度可変できること 確認運転 Working conditions Operation test 連動開閉動作が正常であること 開閉動作確認 Requirements Check display, alarm, trip and stop 仕様通りであること 表示、警報、ﾄﾘｯﾌﾟ, 停止の確認 Requirements Operation test under automatic mode 仕様通りであること 自動ﾓｰﾄﾞによる確認運転 Requirements Operation test 仕様通りであること 確認運転

Working condition under synchronize control Operation test

商用または他機との同期投入制御動作が正常 確認運転

Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転 Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転 Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転

Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転

Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転

Working condition under control Operation test 商用または他機との並列運転時に制御の動作が正常 確認運転

Working condition under control Operation test 自立運転時において制御の動作が正常 確認運転

Working condition under control Operation test 自立運転時において制御の動作が正常 確認運転

Working condition under control Operation test 自立運転時において制御の動作が正常 確認運転

Automatic Operation (自動運転)

Safety Mode Operation (故障保護動作)

Circuit Breaker (遮断器動作)

APRC

（発電電力一定制御）

Automatic Number Control (自動台数制御)

APBC

(有効電力分担制御)

APFC

(発電機力率一定制御)

Start Up & Stop Down (始動、停止動作)

Voltage Regulation (電圧調整範囲)

ALSC

(自動負荷移行制御)

Parallel Operating

Control (並列運転制御

Stand Alone Operating

Control (自立運転制御

AFC

(自動周波数制御)

Operating Test

(総合試験)

AVC

(自動電圧制御)

AQBC

(無効電力分担制御)

Loading Operation (負荷運転)

Automatic Synchronize Control (自動同期投入制御)

APRC

（受電電力一定制御）

A3-1

Parts Name Qty DWG No.

(図番) Parts No.

(部品番号) (部品名) (数量)

Cylinder Head Gasket シリンダーヘッドガスケット

Seal Washer シールワッシャー

Valve Stem Seal バルブステムシール

O-Ring O-リング

Rocker Cover Packing ロッカーカバーパッキン

Side Cover Packing (A) サイドカバーパッキン（A） Side Cover Packing (B) サイドカバーパッキン（B） Side Cover Packing (C) サイドカバーパッキン（C）

Seal Washer シールワッシャー

Gasket ガスケット

O-Ring O-リング

Gasket ガスケット

O-Ring O-リング

Packing パッキン

Packing パッキン

Joint Gasket ジョイントガスケット

A4-3 4

A4-4 12

A4-4 13

A4-5

A4-2 96

A4-2 24

A4-2 4 24

A4-3 48

A3. List of Minimum Required Replacement Parts

A4-1 24

A4-1 24

Reference No.

(照合番号)

A4-3 16

A4-3 2

A4-5

A4-4 8

A4-4 16

15 48

A4-4 414

A3-2

DWG No.

(図番) Parts No.

(部品番号) (部品名) (数量)

Reference No.

(照合番号)

Manifold Gasket マニホールドガスケット

Turbo Charger Gasket ターボチャージャーガスケット

Ring (A) リング(A) Ring (B) リング(B) Pre Filter (For Type 4LF764)

プレフィルター (4LF764型用)

O-Ring O-リング

Seal Washer シールワッシャー

Packing パッキン

Cupling カップリング

Packing パッキン

O-Ring O-リング

Seal Washer シールワッシャー

Governor Cartridge ガバナーカートリッジ

Seal Washer シールワッシャー

O-Ring O-リング

O-Ring O-リング

O-Ring O-リング

A4-11 33 4

A4-11 31 4

A4-11 32 2

A4-10 29 2

A4-10 30 8

A4-9 27 4

A4-10 28 4

A4-9 25 4

A4-9 26 4

A4-9 23 16

A4-9 24 4

A4-6

A4-7 21 4

A4-8 22 8

A4-5

20 8

19 A4-6 8

A4-5 4

A3-3

DWG No.

(図番) Parts No.

(部品番号) (部品名) (数量)

Reference No.

(照合番号)

Gasket ガスケット

O-Ring O-リング

O-Ring O-リング

O-Ring O-リング

O-Ring O-リング

O-Ring O-リング

Oil Filter オイルカートリッジ

Packing パッキン

Packing パッキン

V-Belt (A) V-ベルト(A) V-Belt (B) V-ベルト(B) Thermostat サーモスタット

Packing パッキン

Packing パッキン

Packing パッキン

O-Ring O-リング

O-Ring O-リング

A4-16 49 4

A4-17 50 4

A4-16 47 4

A4-16 48 4

A4-16 44 4

A4-16 46 24

A4-16 45 8

A4-15 42 2

A4-16 43 2

A4-14 41 4

A4-12 39 2

A4-13 40 8

A4-12 37 8

A4-12 38 16

A4-12 35 2

A4-12 36 6

A4-12 34 2

A3-4

DWG No.

(図番) Parts No.

(部品番号) (部品名) (数量)

Reference No.

(照合番号)

Cupling カップリング

O-Ring O-リング

O-Ring O-リング

O-Ring O-リング

Cupling カップリング

O-Ring O-リング

Gasket ガスケット

O-Ring O-リング

Seal Washer シールワッシャー

Gasket ガスケット

Gasket ガスケット

Nossle Tip ノズルチップ

Fuel Filter 燃料フィルターカートリッジ

Seal Washer シールワッシャー

Seal Washer シールワッシャー

Seal Washer シールワッシャー

Cooling Water Heater (220V3Φ2kW) 冷却水ヒーター(220V3Φ2kW)A4-22 67 4

A4-21 65 4

A4-21 66 16

A4-21 63 4

A4-21 64 4

A4-20 61 24

A4-20 62 24

A4-19 59 48

A4-20 60 48

A4-19 57 24

A4-19 58 24

A4-18 55 8

A4-18 56 12

A4-17 53 4

A4-17 54 2

A4-17 51 4

A4-17 52 4

A3-5

DWG No.

(図番) Parts No.

(部品番号) (部品名) (数量)

Reference No.

(照合番号)

Piston Ring (for low pressure) 低圧ピストンリング

Piston Ring (for high pressure) 高圧ピストンリング

High Pressure Valve 高圧弁

Low Pressure Valve 低圧弁

Packings ・O-Rings パッキン類・Oリング類

Air Filter Element エアーフィルターエレメント

V Belt for fan ファン用Vベルト

V Belt for motor モーター用Vベルト

L.O. Pressure Gauge 潤滑油圧力計

High Pressure Safety Valve 高圧安全弁

Check Valve 逆支弁

Parts List for Vacuum Breaker (VHA model) 真空遮断機部品表

A4-23 77 2

A4-23 78 2

A4-23 75 4

A4-23 76 2

A4-23 73 2

A4-23 74 2

A4-23 71 2

A4-23 72 2

A4-23 69 2

A4-23 70 2

A4-23 68 2

A4-24 1 - 7 -satoshi.yano2 Typewritten Text Appendix A4-1 satoshi.yano2

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Appendix A4-23

Ｎｏ 種別 (Equipment Name) 個数 (Number)

① 補助スイッチ (Auxiliray Switch) １個/台 (1)

② 制御回路基盤 (Control Circuit Board) １個/台 (1)

③ リミットスイッチ (Limit Switch) １個/台 (1)

④ インタロックスイッチ (Interlock Switch) １個/台 (1)

⑤ 制御コイル (Control Coil) ２個/台 (2)

⑥ オイルダンパ (Oil Damper) １個/台 (1)

⑦ 蓄勢ハンドル部 (Energy Storage Handle) １個/台 (1)

③リミットスイッチ

④インタロックスイッチ

① ⑦蓄勢ハンドル部

② ⑤制御コイル

⑥オイルダンパ

真空遮断器（ＶＨＡ形）部品表

Vacuum Breaker (VHA model) Parts List

Appendix A4-24