17-T-0138_Attachment_3.pdf

APPENDIX 3

Appendix 3 - Page 1 of 4

Reactor Servicing Facility diesel generator (Code 2370) CAT C15 350 kW Diesel Generator Serial # NAP00606

Preventative maintenance (PM) on the diesel generator shall be performed each calendar quarter (1st quarter 1 Jan – 31 Mar) as scheduled by the contract POC. Four preventative maintenances (PMs) will be performed during the year (three Minor PMs and one Major PM). Generator will be run against a load bank for all PMs. The amount of load will be specified and applied by PNS. CAT coolant and CAT oil will be used for the CAT C15 generator as specified in the Major and Minor PM checklists.

Quarterly (Minor) PM will include the following checks:

1. Service/clean air filter

2. Check/adjust engine oil level (Use CAT COLD WEATHER DEO-ULS 0W-40 OIL)

3. Check radiator for air restriction and dirt

4. Check coolant level (Use CAT Extended Life Coolant)

5. Check/correct anti-freeze concentration (protection rating) (Use CAT Extended Life Coolant)

6. Perform air inlet restriction test

7. Inspect coolant hoses for leakage and deterioration

8. Inspect/adjust all hoses, belts, linkages, and injector system

9. Inspect fuel lines (internal and external, as applicable) for leakage and deterioration

10. Check block heater operation

11. Inspect exhaust system for leakage and deterioration

12. Ensure battery charger is operating properly

13. Check battery electrolyte levels and specific gravity

14. Check battery terminals and check tightness of cables

15. Check ground connection

16. Adjust output voltage and frequency (as necessary)

17. Check/adjust governor linkage/controls

18. Check engine gauges for metering and proper operation

19. Inspect primary fuel filter/water separator and drain if necessary.

20. Operate the diesel under load for a minimum of 30 minutes and check for proper operation.

Running the diesel loaded must be coordinated with the Shipyard POC for the load bank.

Shipyard will provide and operate the load bank. Check for fuel or coolant leaks, check and record voltage and frequency output, check and record battery charging voltage, engine oil pressure, and engine operating temperature, check for unusual engine vibration, check/inspect air louvers.

The yearly (Major) PM includes all the necessary checks from the quarterly (minor) PM in addition to the yearly required checks. Checks shall include the following:

1. Change engine oil level (Use CAT COLD WEATHER DEO-ULS 0W-40 OIL)

2. Change oil filters

3. Change fuel filters (For primary fuel/water separator, use filter with sight glass)

4. Clean crankcase breather

5. Change air filters

6. Vacuum/blow dust out of main generator (30 psi max)

7. Clean engine

8. Remove accumulated soot from exhaust mufflers if there are clean out ports christina.ellis Typewritten Text N39040-17-T-0138 Attachment 3

Appendix 3 - Page 2 of 4

9. Check tightness of mounting bolts and vibration isolators

10. Check radiator for air restriction and dirt

11. Flush cooling system (Use CAT Extended Life Coolant)

12. Check/correct anti-freeze concentration (protection rating) (Use CAT Extended Life Coolant)

13. Perform coolant system pressure test

14. Perform air inlet restriction test

15. Inspect coolant hoses for leakage and deterioration

16. Inspect fan hub, drive pulley and water pump (Repair/replace if necessary)

17. Inspect/adjust all hoses, belts, linkages, and injector system

18. Inspect fuel lines (internal and external, as applicable) for leakage and deterioration

19. Check block heater operation

20. Inspect exhaust system for leakage and deterioration

21. Inspect alternator

22. Check battery charger is operating properly

23. Change batteries

24. Check battery electrolyte levels and specific gravity

25. Check battery terminals and check tightness of cables

26. Check ground connection

27. Inspect main generator windings

28. Measure and record generator winding resistance

29. Remove, clean and adjust magnetic pickup if necessary

30. Adjust output voltage and frequency (as necessary)

31. Check/adjust governor linkage/controls

32. Clean and calibrate injectors, fuel pump and aneroid

33. Check and adjust valves

34. Test fuel for water and algae/bacteria growth

35. Test oil for suspended solids

36. Test coolant for pH, suspended solids, and specific gravity

37. Check engine gauges for metering and proper operation

38. Check engine and generator shutdown alarm systems for proper operation

39. Inspect primary fuel filter/water separator and drain if necessary.

40. Operate the diesel under load for a minimum of 30 minutes and check for proper operation.

Running the diesel loaded must be coordinated with the Shipyard POC for the load bank.

Shipyard will provide and operate the load bank. Check for fuel or coolant leaks, check and record voltage and frequency output, check and record battery charging voltage, alternator voltage (with charger secured), engine oil pressure, and engine operating temperature, check for unusual engine vibration, check/inspect air louvers.

Triennial checks shall be performed in addition to the quarterly and yearly checks as appropriate and as noted below. (The first triennial check for the CAT C15 is due in 2018).

1. Inspect turbo charger

2. Replace coolant thermostat

3. Replace all belts and hoses

4. Grease main generator bearing

Generator Serial Number Generator (Pre-Start) Generator Hours

(Completion) Date

Appendix 3 - Page 3 of 4

DIESEL GENERATOR MINOR PREVENTATIVE MAINTENANCE (QUARTERLY)

MAINTENANCE SAT UNSAT MAINTENANCE SAT UNSAT

Operate the Generator Under Load for a Minimum of 30 Minutes and Check for Proper Operation as follows:

SAT UNSAT

Service/Clean Air Filters Inspect/Adjust all Hoses, Belts, Linkages, and Injector System

Output voltage ______VAC

Check/Adjust Engine Oil Level (Use CAT Cold Weather DEO-ULS 0W40 Oil)

Inspect Fuel Lines (Internal and External, as Applicable) for Leakage or Deterioration

Output Frequency ________Hz

Check Radiator for Air Restriction and Dirt

Check Jacket (Block) Heater Operation Engine Oil Pressure ____

Check Coolant Level (Use CAT ELC only)

Inspect Exhaust System for Leakage or Deterioration Engine Operating Temperature _____ F

Check/Correct Anti-Freeze Concentration.

Ensure Battery Charger is Operating Properly and Record Charging Voltage ________V

Alternator Voltage ______V (W/charger secured)

Perform Air Inlet Restriction Test

Check Battery Electrolyte Levels and Specific Gravity Unusual Vibration or Noise

Inspect Coolant Hoses for Leakage or Deterioration.

Clean Battery Cable and Check Tightness of Cables Check for Coolant or Fuel Leaks

Check Ground Connection Adjust Output Voltage and Frequency at the regulator

Check/Adjust Governor Linkage/Controls

Inspect Fuel Primary Filter Water Separator and Drain if Needed

COMMENTS:

Generator Serial Number Generator (Pre-Start) Generator Hours (Completion) Date

Appendix 3 - Page 4 of 4

DIESEL GENERATOR MAJOR PREVENTATIVE MAINTENANCE (YEARLY)

MAINTENANCE ITEMS SAT UNSAT MAINTENANCE ITEMS (cont.) SAT UNSAT

Change Engine Oil (Use CAT Cold Weather DEO‐ULS 0W‐40 Oil)

Measure and record the generator winding resistance

Main stator Ohms

PMG Stator Ohms Exciter Stator Ohms

Change Oil Filters A‐B _____ B‐C _____ A‐C _____

1‐2 _____ 2‐3 _____ 1‐3 _____ F1‐F2 ______ Change Fuel Filters (Use Fuel/Water

Separator Filter Equipped With Sight Glass)

Clean Engine Blow Dust out of Main Generator (max 30 psi) Check Mounting Bolts and Vibration Isolators for correct torque Flush Cooling System (Use CAT ELC Only) Inspect Fan Hub, Drive Pulley, and Water Pump and Repair/Replace if needed Perform Coolant System Pressure Test Remove accumulated soot from the Exhaust Muffler(s) Check/Correct Anti‐Freeze Concentration Check Engine and Generator Shutdown and Alarm Systems Check Radiator for Air Restriction and Dirt Clean Battery Cables and Check Tightness of Cables Inspect Coolant Hoses for Leakage or Deterioration

Check Battery Electrolyte Levels and Specific Gravity

Check Block Heater Operation Ensure Battery Charger is Operating Properly and Record Charging Voltage ________V Inspect Alternator Perform the operational test with assistance from PNS personnel.

Remove, Clean, and Adjust Magnetic Pickup Operate the generator under load for a minimum of

30 minutes and check for proper operation. Record values in the space provided.

SAT UNSAT

This space intentionally left blank

Adjust Output Voltage/Frequency if necessary

Change Batteries Output Voltage _______VAC Check Ground Connection Output Frequency ________Hz Change Air Filter Engine Oil Pressure ________psi Perform Air Inlet Restriction Test Engine Operating Temperature ________°F Check/Adjust Governor Linkage/Controls Alternator Voltage (Charger secured) ________V

Inspect/Adjust all Hoses, Belts, Linkages, and Injector System

Unusual Vibration or Noise

Inspect Fuel Lines (Internal and External, as Applicable) for Leakage or Deterioration

Check for Coolant or Fuel Leaks

Check and Adjust Engine Valves & Rotators Grease Main Generator Bearing (2018, every 3 years) Inspect Exhaust System for Leakage or deterioration

Inspect Turbocharger (2018, every 3 years)

Replace belts and hoses (2018, every 3 years)

Clean Crankcase Breather Replace Coolant Temperature Regulator (thermostat) (2018, every 3 years) Clean Injectors, Fuel Pump, and Aneroid SAMPLES SAMPLED

This Space Intentionally Left Blank Fuel Sample ‐ Test fuel for water and algae/bacteria growth Oil Sample ‐ Test oil for suspended solids Coolant Sample ‐ Test coolant for pH, suspended solids, specific gravity (freeze protection)