SOW_-_5-year_Generator_Preventive_Maintenance_Inspection_18_May_2016.pdf

STATEMENT OF WORK (SOW)

CATERPILLAR GENERATOR MAINTENANCE

BENEFIELD ANECHOIC FACILITY, BUILDING 1030

EDWARDS AIR FORCE BASE, CALIFORNIA

18 May 2016

I. OBJECTIVE. The objective of this Statement of Work (SOW) is to secure the services of a contractor to perform preventive maintenance on the Caterpillar 3516, 2000kW Generator, Serial Number SBJ00430 at Building 1030, Edwards Air Force Base, California.

II. SCOPE OF WORK.

1. A Certified Caterpillar Service Contractor shall furnish all labor, materials, equipment, transportation, and supervision required to perform the following preventive maintenance on the Caterpillar Generator at Building 1030.

1.1 PM Level 1 - Multi Point Inspection (Required every 12 months) Perform comprehensive detailed inspection of units.

Check/Adjust all fluid levels and pressures for correct operation.

Check and inspect air cleaner restriction gauge and air filter element.

Check primary source fuel tank for water with water finding paste.

Check day tank, fuel tank, fuel line fittings for leaks.

Check cooling system hoses, caps, clamps for brittleness, leaks, cracks, and weakness.

Check battery voltages, charging rates, fluids, and specific gravities / ICV's.

Test engine cranking batteries under start up load for voltage drop.

Check block heater elements and inlet/outlet t-stats for proper output and operation.

Inspect engine fan drive and belts and adjust for proper tension and condition.

Check turbo charger rotation / end play if so equipped.

Check generator brushes for proper tension/setting as equipped.

Check and document control panel instruments for proper operation and values.

Grease bearings, fan shafts, linkages, and equipment fittings as required.

Take hot oil sample and submit for analysis.

Test safety alarms and contacts.

Run unit under load for up to 15 minutes when authorized by site authority.

1.2 PM Level 2 - Annual Service-Major w/ Multi Point Inspection (Required every 12 months) Perform all items from PM Level 1.

Change crankcase oil, oil filter(s), fuel filter(s), water separator(s), coolant filter(s), and air filter(s) as equipped.

1.3 PM Level 3 – Cooling System Service (Required every 36 months) Drain old coolant.

Contain waste coolant.

Replace all coolant hoses and clamps (upgrade block heater hoses to steel braided as recommended).

Replace the radiator pressure cap(s) Replace the engine thermostat(s) and associated gasket(s).

Replace the engine fan belt(s) and alternator drive belt(s).

Refill system with proper amount of glycol antifreeze and conditioners.

Rod and clean oil cooler or heat exchanger as equipped (if required).

Test run unit to operating temperature, under load when authorized by site personnel.

Return unit back to original mode of operation.

1.4 PM Level 5 - Annual Loadbank Test (Required every 12 months) Connect resistive load bank (as applicable) to generator.

Run Test with requested load for 2 hours test duration Record readings at 30% of nameplate rating for 30 minutes Record readings at 50% of nameplate rating for 30 minutes Record readings at 75% of nameplate rating for 30 minutes Record reading at 100% of nameplate rating for 30 minutes Disconnect load bank from unit.

Return unit back to original mode of operation.

1.5 PM Level 6 - Engine/Generator Inspection and Adjustment (Required every 36 months) Adjust engine valves and set to factory specifications Check ignition and injector timing where applicable Inspect and adjust slip ring and brushes where applicable Check rear generator bearings, lubricate as necessary Inspect generator wiring Inspect space heaters Inspect coupling and guards Inspect generator fan drive Inspect meters and voltage regulator as required Test run engine generator

1.6 PM Level 7 - Engine Battery Replacement Program (Required every 36 months) Remove and replace engine cranking batteries.

Test engine cranking batteries under start up load for voltage drop.

Dispose of old battery(s).

Test run unit without load.

Return unit back to original mode of operation.

1.7 Inspection Reports

A report of any maintenance performed and findings must be submitted to the customer prior to the acceptance of work performed.

1.8 Unanticipated Emergency Maintenance

In the event of system failure or trouble, emergency service may be required.

2. All work must be performed by experienced personnel who are qualified to perform the scope of work and meet the requirements in this SOW.

III. PROPOSED/ESTIMATED MAINTENANCE SCHEDULE

Year 1

POP: (Jul 1, 2016 – Sept 30, 2016)

Year 2 POP: (Oct 1, 2016

– Sept 30, 2017)

Year 3 POP: (Oct 1, 2017

– Sept 30, 2018)

Year 4 POP: (Oct 1, 2018

– Sept 30, 2019)

Year 5 POP: (Oct 1, 2019

– Sept 30, 2020)

PM

Level 1 - January 2017 January 2018 January 2019 January 2020

PM

Level 2 July 2016 July 2017 July 2018 July 2019 July 2020

PM

Level 3 - - January 2018 - -

PM

Level 5 July 2016 July 2017 July 2018 July 2019 July 2020

PM

Level 6 - - - - January 2020

PM

Level 7 - January 2017 - - -

IV. REFERENCES.

1. It is the contractor’s responsibility to ensure that all work performed is in accordance with all Air Force, Federal, state, county and local statutes, laws, codes, regulations, safety requirements, instructions, manuals, handbooks, guidance, and policy letters to include, but not limited to:

a. National Fire Protection Association (NFPA)

b. National Electrical Manufacturers Association (NEMA)

c. American Society for Testing and Materials (ASTM)

d. Underwriters Laboratories (UL)

e. Uniform Building Codes (UBC)

f. Contractors State License Board (CSLB)

II. REQUIREMENTS.

1. The contractor shall perform an initial site survey to be coordinated with and escorted by 412 EWG/EWS. During the site survey, the contractor shall examine the area and site conditions and submit a request for information to the Contracting Officer (CO) regarding any questions or concerns.

2. The contractor’s Contract Manager (CM) shall be responsible for the overall performance of this contract and shall possess the necessary experience to provide direct oversight of all project design and planning activities. The CM shall provide overall contract management, including full authority to act on behalf of the contractor, review material submittals, and attend all status meetings, site visits and inspections. The CM and alternates, who shall act for the contractor when the CM is absent, shall be designated prior to commencement of work, in writing to the CO.

3. Upon completion of work and prior to its acceptance, the Air Force will conduct an review of the provided preventive maintenance report to confirm that the inspection was conducted in accordance with this SOW.

4. Materials and installation shall be in compliance with and meet or exceed all applicable codes and standards of this SOW.

5. Contractor shall be licensed and bonded to meet the requirements described in this

SOW.

6. Contractor shall use all new material to meet the requirements described in this

SOW.

7. The contractor shall become familiar with all details of the work, verify dimensions in the field, and advise the 412 EWG/EWS of any conflicting issues before performing any work.

8. Work shall be performed in accordance with the manufacturer’s published diagrams, recommendations, and equipment warranty requirements.

9. Contractor shall repair/replace any property damaged by contractor employees and/or sub-contractors while performing work under this contract.

10. The contractor shall comply with the Environmental Management Systems in place at Edwards Air Force base while performing work under this contract.

11. All personnel shall wear appropriate Personal Protection Equipment (PPE) while on the construction site.

12. Contractor shall coordinate construction effort with the 412 EWG/EWS to prevent any delays or interruptions of Government work within the facility.

13. Job site cleanliness will be maintained at all times. Materials, tools, and waste shall be removed from the work site at the end of each work day. Waste resulting from contract work shall be disposed of at a proper disposal site off Edwards Air Force Base by the contractor in strict accordance with applicable federal, state, county, and local laws. Barricades, safety cones and safety tape will be utilized to isolate the job site from normal personnel traffic.

III. POINTS OF CONTACT

Ms. Debra Owens at 661-277-1688 located in Bldg. 1020, room 220, Site Support Division, Edwards AFB, CA.

Mr. Mike Springer at 661-275-5463 located in Bldg. 1020, room 220, Site Support Division, Edwards AFB, CA.

Mr. Larry Oribio at 661-277-4523 located in Bldg. 1020, room 223, Site Support Division, Edwards AFB, CA.

IV. BASE ACCESS

1. The contractor shall coordinate through the POCs identified above to obtain the necessary passes and/or identification for all employees for entry onto Edwards Air Force Base, and into the 412 Electronic Warfare Group Compound. The Government reserves the right to refuse to issue an entrance pass to any person for any reason deemed valid by the Government.

V. ACCESS TO WORK SITE

1. At least one week before work is started, the contractor shall arrange with the Site

Support Division (412 EWG/EWS) a sequence of procedures, means of access and space for storage of materials and equipment. Contractor’s use of the premises shall be confined to the areas approved by the Site Support Division (412 EWG/EWS).

Contractor shall park all vehicles in the main Bldg. 1020 parking lot except when loading or unloading equipment and/or materials – no exceptions.

VI. SITE CONDITIONS

1. The contractor shall examine and familiarize itself with the site and physical conditions, as well as all local conditions of the site and surrounding area and any other factor which may affect the contractor’s work or costs thereof, all of which are being considered in the contractor’s price.

STATEMENT OF WORK (SOW)