Appendix_2.pdf

APPENDIX 2 (Rev 1)

REFUELING COMPLEX DIESEL GENERATOR

Manufacturer Model# Serial Number KW Voltage Location

Caterpillar C15 NAP00606 350 480 DD2 Refueling Complex

A-1. PREVENTATIVE MAINTENANCE (PM) (Scheduled).

Preventative maintenance (PM) on the diesel generator shall be performed each calendar quarter (1st quarter 1 Jan - 31 Mar). Four preventative maintenances (PMs) shall be performed during the year (three Minor PMs and 1 Major PM). Generator shall be run against a load bank for all PMs.

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

A-2. MAINTENANCE SERVICE DOCUMENTATION

The Contractor shall fill out maintenance service documentation for all PM services provided.

Minor or major maintenance table shall be completed for maintenance records and shall be submitted within five (5) working days after completion of the maintenance services. Either electronic or hard copy delivery is acceptable.

The Minor (quarterly) checks shall consist of checking the diesel generator as noted below:

1. Service/clean air filter

2. Check/adjust engine oil level (Use CAT COLD WEATHER DEO-ULS OW-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. [Deleted]

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 thirty (30) minutes and check for proper operation. Running the diesel loaded must be coordinated with the Shipyard POC for the load

Appendix 2 Rev 1 - Page 1 of 5 bank, PNS shall 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 Major (yearly) checks shall consist of checking the diesel generator as noted below:

1.

2.

3.

4.

5.

6.

7.

8.

9.

Replace engine oil level (Use CAT COLD WEATHER DEO-ULS OW-40 OIL) Replace oil filters Replace fuel filters (For primary fuel/water separator, use filter with sight glass) Clean crankcase breather Replace air filters Vacuum/blow dust (30 psi max) out of main generator (as necessary) Clean engine (as necessary) [Deleted] Check tightness of mounting bolts and vibration isolators 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

Inspect fuel lines (internal and external, as applicable) for leakage and deterioration Check block heater operation Inspect exhaust system for leakage and deterioration

21. Inspect alternator

22. Check battery charger is operating properly

23. Replace batteries

Check battery electrolyte levels and specific gravity 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. [Deleted]

32. [Deleted]

33. Check and adjust engine valves and rotators

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 generator under load for a minimum of thirty (30) minutes and check for proper operation. Running the diesel loaded must be coordinated with the PNS POC for the load bank.

PNS shall 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).

18.

19.

20.

Appendix 2 Rev 1- Page 2 of 5 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. Triennial checks shall be performed during the yearly Major PM. (The last triennial check for the CAT CIS is was performed in 2018. Next triennial is due in 2021.).

1. Inspect turbo charger

2. Replace coolant thermostat

3. Replace all belts and hoses

Appendix 2 - Page 3 of 5

CATERPILLAR C15 350KWS/N: NAP00606

(Refueling Complex)

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

DIESEL GENERATOR MINOR PREVENTATIVE MAINTENANCE (QUARTERLY)

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

MAINTENANCE

Service/Clean Air Filters

Check/Adjust Engine Oil Level (Use CAT Cold Weather DEO-ULS OW-40 Oil)

SAT UNSAT MAINTENANCE

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

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

SAT UNSAT

Output voltage. VAC

Output Frequency. Hz

SAT UNSAT

Check Radiator for Air Restriction and Dirt

Check Jacket (Block) Heater Operation Engine Oil Pressure___ psi

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 (As Applicable)

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(s)

Adjust Output Voltage / Frequency at the regulator if necessary (480VAC, 60Hz)

Inspect Fuel Primary Filter Water Separator and Drain if Needed

VENDOR COMMENTS:

Appendix 2 Rev 1 - Page 4 of 5

CATERPILLAR C15 350KWS/N; NAP0060f (Refueling Complex)

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

DIESEL GENERATOR MAJOR PREVENTATIVE MAINTENANCE (YEARLY)

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

Change Engine Oil (Use CAT Cold Weather DEO-ULS OW-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-F2Change 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) 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 Check Engine and Generator Shutdown and Alarm Systems Check/Correct Anti-Freeze Concentration Check Battery Terminals and Check Tightness of Cables

Check Radiator for Air Restriction and Dirt Check Battery Electrolyte Levels and Specific Gravity Inspect Coolant Floses for Leakage or Deterioration Check Operation of Battery Charger and Record Charging Voltage

V

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

Inspect Alternator 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.

Record Value SAT UNSATAdjust Output Voltage/Frequency if necessary (480VAC, 60Hz)

Change Batteries Output Voltage (Generator is set to 480 VAC)

VAC

Check Ground Connection Output Frequency Hz

Change Air Filter Engine Oil Pressure psi

Perform Air Inlet Restriction Test Engine Operating Temperature •F

Inspect/Adjust all Hoses, Belts, Linkages, and Injector System Alternator Voltage (Charger secured)

V

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

Unusual Vibration or Noise

Check and Adjust Engine Valves 8i Rotators Check for Coolant or Fuel Leaks

Clean Crankcase Breather

SAMPLES SAMPLED •/'

Fuel Sample - Test fuel for water and algae/bacteria growth

Triannual Maintenance PM's SAT UNSAT St oil for suspended solids Inspect Turbocharger (2021, every 3 years) Replace belts and hoses (2021, every 3 years) Coolant Sample - Test coolant for pH, suspended solids, specific gravity (freeze protection)

Replace Coolant Temperature (2021; everY 3 years) Regulator (thermostat)

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

Appendix 2 Rev 1 - Page 5 of 5