Appendix_1.pdf

APPENDIX 1 (Rev 1)

EMERGENCY POWER SYSTEM DIESEL GENERATOR INVENTORY:

Manufacturer: Caterpillar (CESG-2) Caterpillar (CESG-3) Caterpillar (future units)

Model No.: 3512C 3512C C32 2

Serial/Order No.: YBD00416 YBD00417

JSJ03842

JSJ03844

JSJ03845

Load Rating:

Standby

1500 kW/1875 kVA 1500 kW/1875 kVA 1000 kW/1250 kVA

Power Factor: 0.8 0.8 0.8

Frequency: 60 Hz 60 Hz 60 Hz

Full Load in Amperage:

2255 A 2255 A 1504 A

Output Voltage: 460 VAC 460 VAC 460 VAC

Phase; 3 Phase, Ungrounded

3 Phase, Ungrounded

3 Phase, Ungrounded

Current Location 1: Dry Dock - 2 Dry Dock - 3 Berths

(6,11,13)

1 Note: Location of equipment is based on time of issuance of this statement of work.

Locations may change during the period of performance without warning. Units shali be identified using unique identification numbers to ensure proper maintenance and documentation.

2 Note: 1.0MW C32 Caterpiiiar Units (SEA) wiil be arriving at PNS during the first two quarters of 2019 and wiii be covered by this SOW. These units wili be stationary at Berths

6,11 and 13. See Note 1 above.

Appendix 1 Rev 1 - Page 1 of 8

MODEL NO. SERIAL NO. DG EQUIPMENT ID CURRENT LOCATION1

DQFAC-5868099/H070094769 MP 19588 Dry Dock No.1

DQFAC-5962180/A080144107 MP 19437 Berth 13

DQFAC-5781325/A070016080 USN 51-19432 Berth 11

MUSE DIESEL GENERATOR SPECIFICATIONS

Load Rating Standby 900 kW/1125 kVA

Power Factor: 0.8

Frequency: 60 Hz

Full Load in Amperage: 1353 A

Voltage: 480 V

Phase: 3 Phase, Ungrounded

1 Note: Location of equipment is based on time of issuance of this statement of work Locations may change during the period of performance without warning. Units shaii be identified using unique identification numbers to ensure proper maintenance and documentation.

A.-l. preventive maintenance fPM^ fSchedulecQ.

The Contractor shall perform, at a minimum, all services required at intervals of every six (6) months lAW the applicable Diesel Engine and Generator Set

Operations and Maintenance Manual(s). (Note: Semi-annual is defined as every six (6) months, but not more than seven (7) months or less than five (5) months.)

A-1.1 It shall be the responsibility of the Temporary Services Electrical General

Foreman (or a designated representative) to notify the Contractor no less than fifteen (15) days prior to the desired preventative maintenance service date.

Semi-annual maintenance shall be conducted every six (6) months beginning with the first day of the contract year. Annual maintenance (or any services

Appendix 1 Rev 1 - Page 2 of 8 required at greater intervals) shall be conducted in conjunction with the semi annual maintenance that immediately precedes a period of extended use (e.g.

submarine engineered overhaul, etc.) or with the last semi-annual maintenance of the Contract Year (if the annual maintenance has not yet been completed).

When selecting when to perform maintenance, consideration shall be given to limit the impact to production and Ship’s Force personnel.

A-1.2 The Contractor shall perform preventative maintenance services as recommended in the manufacturer’s maintenance manual. The Government will provide available maintenance manual(s); however, if the Government does not have the maintenance manual(s), the Contractor shall be responsible for obtaining the maintenance manual(s). All replacement parts, materials, environmental compliance and Contractor personnel transportation used for preventive maintenance services shall be included in the contract unit price for preventive maintenance service.

A-1.3 The Contractor shall provide requested maintenance services to the emergency diesel generator and all components within the unit enclosure which includes the diesel engine, diesel generator, electrical system for the enclosure, diesel generator and enclosure breakers, internal and external transfer fuel system and tanks, ventilation, air intake louvres and motors and the enclosure itself.

A-1.4 The Contractor shall provide requested fluid testing for the emergency diesel generator internal fuel tank and external fuel tank for microbial, sulfur content, bottom sediment, water bacteria culture and API gravity. Also, shall provide emergency diesel oil system analysis for wear element, infra-red, PQ, particle count, oil viscosity and gas chromatography. Also, shall provide emergency diesel generator coolant analysis for % Glycol, freeze point, boil point, pH, Nitrite, Moly, conductivity, color, appearance, odor, foam and oil. When requested perform a Level II Coolant Analysis.

Appendix 1 Rev 1 - Page 3 of 8

A-2. MAINTENANCE SERVICE DOCUMENTATION.

The Contractor shall fill out maintenance service documentation for all PM and

RM services provided. Table 1A/1B and/or Table 2A/2B shall be completed for maintenance records. Each maintenance service document shall contain the information listed below, as applicable to PM or RM services, and shall be submitted within five (5) working days after completion of the maintenance services. Either electronic or hard copy delivery is acceptable.

a. PDF copy of the Product Status Report of the Electronic Control Module

(ECM).

b. PDF copy of diesel generator parameters for the annual maintenance (i.e.

Caterpillar Units).

c. Date and time of service call notification and arrival at Government location.

d. Manufacturer, model, serial number and location of the equipment involved.

e. For PM, the labor hours spent and tasks performed.

f. For RM, labor hours and associated labor rates worked.

g For PM and RM, all replacement parts used by part number, part name, quantity and cost per unit.

h. Description of malfunction and work/service performed, and corrective action taken if action is a repair.

i. If the diesel generator was run/operated;

(1) Start and stop time (24HR).

(2) Start and stop hour meter reading of equipment.

(3) Reason for operation of the diesel engine.

j. Legibly printed name of Contractor personnel who accomplished work.

k. A total dollar amount due for services rendered based on the above work performed.

Appendix 1 Rev 1 - Page 4 of 8 appendix 1 (Rev 1)

TABLE1A

Location:

MAINTENANCE

Check/Adjust Engine Oil Level (Use CAT Cold Weather DEO-ULS OW-40 Oil) Check Radiator for Air Restriction and Dirt Check Coolant Level (Use CAT ELC only) Check/Correct Anti-Freeze Concentration Perform Air Inlet Restriction

I Test

Inspect Coolant Hoses for Leakage or Deterioration.

Check Ground Connection(s)

Unusual Vibration or Noise

VENDOR COMMENTS

SAT UNSAT

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

Check Jacket (Block) Heater Operation

Inspect Exhaust System for Leakage or Deterioration

Ensure Battery Charger is Operating Properly and Record Charging Voltage, —v Check Battery Electrolyte Levels and Specific Gravity (As Applicable)

Clean Battery Cable and Check Tightness of Cables

Adjust Output Voltage / Frequency at the regulator if necessary (460VAC, 60Hz)

Check for Coolant or Fuel Leaks

SAT UNSAT

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

SAT UNSAT

VAC

Output Frequency. Hz

Engine Oil Pressure___ psi

Engine Operating Temperature.

Alternator Voltage_____ V (W/charger secured)____________ ________________ Inspect Fuel Primary Fiiter Water Separator and Drain if Needed ____________________________ Perform Single Sample Fuel Analysis for internal and external fuel tanks. Provide results to PNS POC per par 2.2.____________________________________ Perform Single Sample Coolant Analysis for the diesel generator coolant system. Provide resuits to PNS POC per para 2.2._____________________ Perform Single Sample Oil Analysis for diesel generator oil system. Provide results to PNS POC per para 2.2.

Appendix 1 Rev 1- Page 5 of 8

TABLE1B

MUSE MP-800-HS-LV 900KW

Location;.

S/N:

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

UNSATUNSATMAiNTENANCEUNSATMAINTENANCE

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

Output voltage Service/Clean Air Filters

Inspect Fuel Lines (Internal and External, as Output FrequencyCheck/Adjust Engine Oil Level

Applicable) for Leakage or Deterioration

Engine Oil PressureCheck Jacket (Block) Heater OperationCheck Radiator for Air Restriction and Dirt Engine Operating TemperatureInspect Exhaust System for Leakage or Deterioration Check Coolant Level

Check/Correct Anti-Freeze y (W/chargerAlternator Voltage secured) Ensure Battery Charger is Operating Properly and Record Charging Voltage VConcentration Inspect Fuel Primary Filter Water Separator

Needed Perform Single Sample Fuel Analysis for internal and external fuel tanks. Provide results to PNS POC per para 2.2.

Check Battery Electrolyte Levels and Specific Gravity (As Applicable)

Perform Air Inlet Restriction Test

Clean Battery Cable and Check Tightness of CablesInspect Coolant Hoses for Leakage or Deterioration.

Perform Single Sample Coolant Analysis for the diesel generator coolant system. Provide results to PNS POC para 2.2.

Perform Single Sample Oil Analysis for diesel generator oil system. Provide results to PNS POC per para 2.2.

Adjust Output Voltage / Frequency at the regulator if necessary (460VAC, 60Hz)

Check Ground Connection(s)

Check for Coolant or Fuel LeaksUnusual Vibration or Noise

VENDOR COMMENTS;

Appendix 1 Rev 1- Page 6 of 8

MAINTENANCE ITEMS

Change Engine Oil (Use CAT Cold Weather DEO-ULS OW-40 Oil)

Change Oil Filters Change Fuel Filters (Use Fuel/Water Separator Filter Equipped With Sight Glass)____________________________ ___________ Clean Engine if necessary___________ Blow Dust out of Main Generator if necessary (30 psi max) Flush Cooling System (Use CAT ELC Only)

Perform Coolant System Pressure Test Check/Correct Anti-Freeze Concentration Check Radiator for Air Restriction and Dirt Inspect Coolant Hoses for Leakage or Deterioration

Check Block Heater Operation Inspect Exhaust System for Leakage or deterioration Inspect Alternator Remove, Clean, and Adjust Magnetic Pickup (As Required)

Adjust Output Voltage/Frequency if necessary (460VAC, 60Hz)

Change Batteries

Check Ground Connection Change Air Filter Perform Air Inlet Restriction Test Inspect/Adjust all Hoses, Belts, Linkages, and Injector System

Inspect Fuel Lines (Internal and External, as Applicable) for Leakage or Deterioration Check and Adjust Engine Valves & Rotators (as Required)

Clean Crankcase Breather

Triannual Maintenance PM's Inspect Turbocharger (every 3 years)

Replace belts and hoses Replace Coolant Temperature Regulator (thermostat)

(every 3 years I

(every 3 years)

SAT

SAT

UNSAT

UNSAT

MAINTENANCE ITEMS (cont.)

Measure and record the generator winding resistance

Main stator Ohms

PMG Stator Ohms

Exciter Stator Ohms

F1-F2

Check Mounting Bolts and Vibration Isolators for correct torque Inspect Fan Hub, Drive Pulley, and Water Pump and Repair/Replace if needed________ _________________________ Check Engine and Generator Shutdown and Alarm Systems Check Battery Terminals and Check Tightness of Cables Check Battery Electrolyte Levels and Specific Gravity Check Operation of Battery Charger and Record Charging Voltage

V

Perform the operational test with assistance from PNS personnel.

Operate the generator under load for a minimum of thirty (30) minutes Record Value and check for proper operation.

Record values In the space provided.

Output Voltage (Generator is set to VAC

460 VAC)___________________ __

Output Frequency hT Engine Oil Pressure ____________ _ psi

Engine Operating Temperature______ ®F

Alternator Voltage (Charger secured) V

SAT

Unusual Vibration or Noise

Check for Coolant or Fuel Leaks

UNSAT

SAMPLES

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)

Vendor provide sample results to PNS via the contract POC per para 2.2 when test results are available.

SAMPLED ✓

Appendix 1 Rev 1- Page 7 of 8

TABLE 2B:

□ MUSE MP-800-HS-LV 900KW

Location: ____________________ S/N:

Generator Hours (Pre-Start) Generator Hours (Completion)

Check Engine and Generator Shutdown and Alarm Systems Perform Coolant System Pressure Test

Check Battery Terminals and Check Tightness of Cables Check/Correct Anti-Freeze Concentration

Check Battery Electrolyte Levels and Specific Gravityand DirtRadiator for RestrictionCheck Check Operation of Battery Charger and Record Charging Voltage Inspect Coolant Hoses for Leakage or Deterioration

Check Block Heater Operation Perform the operational test with assistance from PNS personnel Exhaust System for Leakage or deteriorationInspect

Inspect Alternator

DIESEL GENERATOR MAIOR PREVENTATIVE MAINTENANCE (YEARLY)

Date

MAINTENANCE ITEMS SAT UNSAT

Change Engine Oil

Change Oil Filters Change Fuel Filters (Use Fuel/Water Separator Filter Equipped With Sight Glass) Clean Engine if necessary Blow Dust out of Main Generator if necessary (30 psi max) Flush Cooling System (Per OEM Recommendation)

Remove, Clean, and Adjust Magnetic Pickup (As Required)

Adjust Output Voltage/Frequency if necessary (460VAC, 60Hz)

MAINTENANCE ITEMS {cant.)

Measure and record the generator winding resistance

Main stator Ohms

A-B.

B-C.

A-C

PMG Stator Ohms

1-2.

2-3.

1-3

Exciter Stator Ohms

F1-F2

Check Mounting Bolts and Vibration Isolators for correct torque Inspect Fan Hub, Drive Pulley, and Water Pump and Repair/Replace if needed

SAT UNSAT

Operate the generator under load for a minimum of thirty (30) minutes and check for proper operation.

Record vaiues in the space provided.

Record Vaiue SAT UNSAT

Change Batteries Output Voitage (Generator is set to

460 VAC)

VAC

Check Ground Connection Output Frequency

Change Air Filter Engine Oil Pressure psi

Perform Air Inlet Restriction Test Engine Operating Temperature

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

Inspect Fuel Lines (Internal and External, as Applicable) for Leakage or Deterioration Check and Adjust Engine Valves & Rotators (as Required)

Clean Crankcase Breather

NOTES;

Alternator Voltage (Charger secured)

Unusual Vibration or Noise

Check for Coolant or Fuel Leaks

SAMPLES SAMPLED

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)

Vendor provide sample results to PNS via the contract POC when test results are available.

Appendix 1 Rev 1- Page 8 of 8