PWS Generator_ATS Service.pdf

STATEMENT OF WORK

Inspection, Preventative Maintenance and Repair of Emergency Generators and ATS

1.0 INTRODUCTION

The work includes but is not limited to: provide all equipment, fluids, tools, labor, and to perform regular and periodic examination, semi-annual and annual preventative, 24 hour emergency call back diagnosis and repair of the emergency generator systems and Automatic Transfer Switches (ATS) at the VA Medical Center in Manchester, NH located at 718 Smyth Road. The proposed term of the service is one year from the date of the award. There will be four additional renewal option years to be re-evaluated and awarded annually.

2.0 DEFINITIONS/ACRONYMS

• Engineer - Supervisor or designee.

• CO - Contracting Officer

• COR - Contracting Officer's Representative.

• WHEN Hours- Weekends, Holidays, Evenings, and Nights. Anytime outside of Normal Business Hours (Monday-Friday 7:00am-4:30pm)

• ESR - Engineering Service Report. A documentation of the services rendered for each incidence of work performance under the terms and conditions of the contract.

• Authorization Signature - COR signature; indicates work status is accepted as stated in ESR.

• VAMC - Department of Veterans Affairs Medical Center.

• PM- Preventive Maintenance.

• ATS- Automatic Transfer Switch.

3.0 EQUIPMENT TABLE

VA New England Healthcare System Manchester VA Medical Center

718 Smyth Road Manchester, NH 03104

4.0 SCOPE

This project includes the following tasks:

4.0 Task 1 – Scheduled preventative maintenance: Generators

Provide regularly scheduled annual and semi-annual preventative maintenance services for all the emergency generator systems at the Medical Center noted in the equipment table. Service includes the following:

1. SEMI-ANNUAL CHECK (ENGINE NOT RUNNING)

a. Conduct visual check around the generator. Check the engine, radiator, and generator for debris, foreign objects, loose or broken fittings, guards, and components. Repair as necessary.

b. Check the battery’s liquids specific gravity, do battery load test, top up\fill if necessary.

Maintain electrolyte level, clean batteries if necessary, check for tight connections.

c. Clean battery terminals and lugs.

d. Battery charger- Check for proper operation.

Automatic Transfer Switch (ATS)

Make: Model: S/N: Location:

Asco 7000 Series 2156425-002 RE BLDG 20- NE 103

Asco 7000 Series 2156425-001 RE BLDG 20- NE 103

Kohler GM52041 N19F083-878 BLDG 20- NE 103

Kohler GM52041 N18B083-760 BLDG 20- NE 103

Russelectric Transfer Switch 11274-1B BLDG 20- NE 104

Russelectric Transfer Switch 11274-1A BLDG 20- NE 105

Kohler Transfer Switch 274992-001 BLDG 15- D02

Kohler Transfer Switch 276347-001 BLDG 15- D02

Kohler Transfer Switch 276348-001 BLDG 15- D02

Westinghouse- 5925-2307 Transfer Switch-

ATSBP30100BS

06T0950 BLDG 18- 105

Westinghouse- 5925-2309 Transfer Switch-

ATSBP30100BS

06T0950 BLDG 18- 105

Westinghouse- 5925-2311 Transfer Switch-

ATSBP30100BS

06T0950 BLDG 18- 105

Russelectric RTS03 38553-6A/B BLDG 7- G16

Russelectric RTS03 38553-7A/B BLDG 7- G16

Asco Transfer Switch 207492RE BLDG 20- NE 105

e. Check all “V” and fan belts to make sure there are no hair line cracks on the belts, replace if cracked or worn. Inspect for worn, broken, or loose belts (alternator, fan, drive, etc.).

f. Check and adjust tension on all V and fan belts.

g. Check coolant level and top up\fill if necessary.

h. Check specific gravity of coolant. Replenish as necessary to maintain manufacturers recommended level and specific gravity of coolant additive.

i. Block heater- Check for proper operation. Maintain 32°C (90°F) coolant temperature in the block at all times.

j. Check operation and components of water jacket heating system.

k. Engine Crankcase- Check the oil Maintain the oil level between the add and full marks on the engine stopped side of the dipstick.

l. Governor- Check and maintain the oil level (if required).

m. Fuel System- Check for leaks and drain water separator (if equipped). Keep fuel tank full. Check fuel filter indicator (if equipped).

n. Gauges- check the condition of all gauges. Repair or replace any broken gauge.

o. Generator and Control Panel- Visual Inspection- check for loose, broken, or damaged wiring or components.

p. Test fuel day tanks for water. Record water levels in tanks.

q. Drain condensate from exhaust condensate trap.

r. Clean air filter element. Inspect all fuel, oil, and water piping for secure mounting.

s. Inspect exhaust piping and muffler insulation.

t. Inspect crankcase breather tube.

u. Check all control panel indication LED’s.

2. SEMI-ANNUAL CHECK (ENGINE RUNNING)

a. Turn off the generator circuit breaker and run the generator unloaded for 15 minutes. Check the generator for unusual conditions, such as: excessive vibration, excessive black or white smoke. The following indicators on the control panel also need to be checked and verified while the generator is running: fuel level, oil pressure, water temperature, rpm, voltage, and frequency.

b. With the engine running and the generator circuit breaker open:

i. Jumper water temperature switch

ii. Jumper oil pressure switch

iii. Jumper coolant low-level switch

c. Press emergency stop push button.

i. Each time the switch is “jumpered” or the emergency stop button is pressed the engine should stop and the corresponding failure lamp should illuminate. Reset the shut-down mechanisms after each test.

d. Start unit and run with load bank connected for 1 hour at minimum 30% load. 70% preferred.

Any generator operating under 30% load must be supplied with a load bank by the Contractor.

e. Frequency (rpm) and generated voltage- check and record readings. NOTE: The operating voltage of a cold (just started) generator will be slightly higher than the operating voltage of a generator that has been under load and warm. The full load voltage of a generator will decrease a maximum of 1% when the generator stabilizes at 100°C (212°F). Most of the voltage decrease occurs in about 30 minutes. Generally, temperatures of generators stabilize within two hours.

f. Read and record verify all engine and alternator indicators. Check for proper operating oil pressure. Check for proper operating fuel pressure. Check the oil level. Maintain the oil level between the add and full marks on the engine running side of the dipstick.

g. Check exhaust for excessive black or white smoke. (See manufacture’s manual)

h. Check turbocharger for vibrations, check for any abnormal noise during operation.

i. Check generator bearing for noise and overheating.

j. Check exhaust manifold, muffler, and piping for leaks and secure mountings.

k. Check fuel day tank for overheating.

l. Leaks and noises- Check for leaks and unusual noises. NOTE: Engine must be stopped before making necessary repairs.

m. Check exhaust backpressure at the Diesel particle filter (Dpf.), if above 24 Inches H20 / 6 kPa, Dpf filters to be removed and cleaned. Or in accordance with the manufacturer’s recommendations.

3. SEMI-ANNUAL CHECK (ENGINE STOPPED AFTER RUNNING)

a. Inspect engine water, fuel, and oil systems for leaks while engine is hot.

b. Fill out maintenance checklist and report deficiencies.

c. Confirm that circuit breaker is in closed position, and generator is set in automatic.

4. SEMI-ANNUAL CHECK (ENGINE NOT RUNNING)

a. Perform complete semi-annual ‘engine not running’ schedule (Section 4).

b. Change fuel and air filters every 250hrs or once a year whichever is sooner

c. Change coolant filters every 250hrs or once a year whichever is sooner

d. Inspect battery charging Alternator and V belt.

e. Inspect engine and generator wiring harness for wear and damages.

f. Inspect supports and spring isolators for soundness and stability.

g. Inspect unit thoroughly for loose fasteners.

h. Clean radiator air passages and exhaust air ducts.

i. Clean intake louvers and ducts.

j. Inspect unit for corrosion. Remove any corrosion, prime and paint.

k. Inspect fan drive idler pivot arm assembly and shock absorber.

l. Inspect Belt driven fan hub.

m. Take fuel oil samples, analyze and report composition and cleanliness.

n. Take fuel samples, analyze and report composition and cleanliness

5. ANNUAL CHECK (ENGINE RUNNING)

a. Perform complete semi-annual ‘Engine running’ schedule (Section 2).

6. ANNUAL CHECK (ENGINE STOPPED AFTER RUNNING).

a. Perform complete semi-annual ‘Engine stopped after running’ schedule. (Section 3).

b. Change crankcase oil and filters every 200 hours or once a year, whichever is sooner.

c. Fill out maintenance checklist and report deficiencies.

d. Confirm that circuit breaker is in closed position, and generator is set in automatic.

e. Engine Crankcase Breather- Clean.

f. Engine mounts- Inspect

g. Engine protective devices- Check.

h. Engine speed/timing sensor- Clean/inspect.

i. Engine valve lash- Check.

j. Engine valve rotators- Inspect.

k. Fuel System Primary Filter (Water Separator) Element- Replace.

l. Fuel System secondary filter- Replace.

m. Generator Bearing- Lubricate.

n. Generator Set Vibration- Inspect.

o. Hoses and Clamps- Inspect/Replace.

p. Rotting Rectifier- Check.

q. Starting Motor- Inspect.

r. Water Pump- Inspect.

7. OUT YEAR CHECKS

a. Second Year Checks:

i. Inspect Turbocharger:

1. Inspection to include bearings, seals, exhausts, and air impellers.

2. Change all gasket and seals.

ii. Inspect Rotating rectifier:

1. Inspect and clean rotating rectifier per manufacturer’s recommendations.

2. If replacement is warranted, provide a written recommendation to the COR for action to include all material and labor.

iii. Replace batteries:

1. Replace batteries with minimum Caterpillar Deep Cell batteries per manufacturer’s recommendations.

2. Provide two (2) batteries for each generator.

3. Replace cooling system temperature regulators with seals.

4.1 Task 2 – Scheduled Preventative Maintenance/Inspection: ATS.

1. Annual PM Inspection

a. Perform a visual inspection of the automatic transfer switch and its surrounding environment.

b. Vacuum the switch interior to remove any dirt or dust deposits. Wipe all bus bars, insulators, cables, and so forth with a clean dry lint free cloth.

c. Inspect the enclosure, transformer, terminals, terminal boards, and insulators for signs of overheating from internal or external sources. Check for voltage creepage over insulating surface, evident by tracing or carbonization.

d. Check the switch interior carefully for moisture, condensation build up, or signs of any previous wetness.

e. Inspect the switch for any signs of overheating.

f. Check for signs of rodent nesting in the enclosure.

g. Carefully inspect all devices for any visibly worn-out, cracked, or missing parts.

h. Open and close contacts several times to verify they are working properly.

i. Verify that all key interlocks and door interlocking provisions are working properly.

j. Check all bus bar joints and terminal lugs for any pitting, corrosion, or discoloration resulting from high temperatures or subject to high fault conditions.

k. Inspect all insulating material.

4.2 Task 3- Annual Load Bank Testing. Generators.

1. Perform Annual Load Bank test on the Generators. The contractor shall provide an annual load bank test on all emergency generators at the Medical Center. An annual load bank test to allow the generator engine under a full load for a four-hour period of time.

4.3 Task 4- Repairs and Emergency Call Back Service:

1. Contractor shall have technician on site within One (1) hour, during normal business hours and two

(2) hours, during hours of request by telephone or otherwise from contacting officer, Chief

Engineer and/or designees for emergency services. Response will be in the event of a shut down or emergency trouble developed between regularly scheduled maintenance services. Overtime emergency call back service shall be limited to minor adjustments and repairs required to protect and provide immediate safety of the equipment and persons in and about the generators.

2. The contractor shall be responsible to make all repairs and adjustments necessary. Repairs are defined as unscheduled work required to (1) prevent a breakdown or malfunction of an item of equipment; (2) put a system or a subsystem back in service after a breakdown or malfunction. The emergency generator systems of the medical center must remain operational 24/7. Alternative measures for providing equivalent emergency power during repairs are the responsibility of the

Contractor.

3. Repairs shall be completed within 24 hours after the need for repair has been identified by the contractor or by the Government. All repairs shall be in accordance with the equipment manufacturer’s requirements and\or applicable laws, regulations, codes, etc.

a. An extension may be granted at the discretion of the COR on a case by case basis. Each request for an extension must include and explanation for the delay, and estimated time of completion, and evidence to clearly show that the contractor has made every effort to repair the system as timely as possible.

4. The Contractor shall furnish all supplies, materials, and equipment to perform regularly scheduled service, emergent service, and repairs.

a. All parts and materials shall be of the original manufacturer’s design and specification, or equal thereto.

b. The Contractor shall have and maintain on hand locally a supply of spare parts sufficient for normal maintenance and expedient emergency repairs of the generators.

5. Space is not available for storage of equipment or materials. If need the Contractor should make arrangements for storage as part of this contract.

5.0 PERFORMANCE REQUIREMENTS

2. The Contractor, under this Scope of Work (SOW), will be responsible for all supervision, labor, tools, lubricants, cleaning products, and manufacturer replacement parts and equipment required to carry out all services as outlined in this SOW. The medical center is considered a critical facility;

therefore, all emergency generator equipment shall be kept in first class condition and proper working order 24/7.

3. The Contractor will be required to evaluate the existing equipment and provide the COR with a proposed maintenance schedule in advance of service.

4. Contractor must submit to the COR for review, work sheet/checklist that will be used for performing and documenting maintenance service.

5. All personnel working in the vicinity shall wear and /or use safety protection equipment and exercise the appropriate cautions while all work is performed. Any questions or injuries shall be brought to the attention of the COR, and Safety Manager or Safety Officer.

6. Safety Data Sheets (SDS) shall be provided by the contactor for all HAZMAT materials. Copies will be provided to the COR for approval. No materials will be allowed to be brought on site until they have been submitted and approved by the COR in advance.

7. Preventive maintenance for Standby generator sets to be performed by a technician or mechanic, who is manufacturer certified to work on Caterpillar and Kohler emergency generators as listed above.

8. All off site calibration of generator components to be performed by an authorized Caterpillar repair location, a calibration certificate for each calibrated component must be issued.

9. Perform all annual preventive maintenance procedures prior to beginning out-year cycles.

10. COR must immediately be made aware of any condition discovered that could result in equipment failure.

11. Testing and inspection summary report shall be submitted to the COR within three days of completing all work.

12. If any discrepancies are found with the generator system that are not covered under this scope of work then the contractor must provide the following:

I. Detailed report noting the discrepancy found.

II. Bill of Materials (BOM) to include component name, quantity, part #, and assumption of price for any repair material required and material lead time.

13. All work shall be completed during normal business hours in conjunction with the medical center regularly scheduled monthly generator testing , unless called back for emergency service outside of normal business hours. Emergency call back services shall be assumed to be completed during

WHEN hours.

14. All travel costs associated with performance of this contract are the responsibility of the Contractor and are provided at no additional cost to the government as part of this contract. Travel costs are defined but not limited to time and vehicle costs for personnel in travel to and from job site for all duties outlined in this specification, normal shipping charges on any parts or materials covered by this contract, costs associated with the normal shipping of parts or equipment out for repair that are covered under this contract, etc.

15. The services shall be completed in accordance with the latest National Electrical Code (NEC), and

National Fire Protection Association (NFPA) standard, VA Standards and policies, and local and city codes. In the event there is conflict between any of the standards/codes, the more stringent standard/code shall apply. Clarification for conflicts must be requested in advance of the service rendered.

16. Contractor shall comply in accordance with all OSHA Safety Guidelines.

17. Upon arrival at the medical center, the Contractor shall check in with the maintenance scheduler, COR or designee. Contractor shall sign in and out in engineering during normal business hours.

During WHEN hours the Contractor shall sign in and out at the Boiler Plant. While on property the contractor shall display an appropriate contractor badge at all times.

18. The contractor shall submit technician certification/licensure prior to work start. Copies of these are also to be submitted with the completed checklists.

19. The contractor shall schedule all site visits, to include emergencies, with the COR.

20. All contractor technicians performing work on site must report to Facility Service in Building 6 to the contractor badge check in/out room to sign in on the contractor log and get a “Contractor” badge. Badges must be returned, and log signed out prior to departing the premises. Vendor shall then coordinate with the COR prior to performing their work.

6.0 DELIVERABLES

1. Submittal of proposed maintenance schedule of activities for review and approval by the COR.

2. Submittal of proposed equipment and materials to be used on site for review and approval by the COR.

3. Submittal of Contractor safety plan and lock\out tag\out plan.

4. Submittal of Safety Data Sheets (SDS) shall be provided by the contactor for all chemicals proposed to be brought to the medical center. Chemicals must be approved before they can be located on property.

5. Submittal of all maintenance reports. Must be submitted within 3 days of service completion date.

Reports should include at a minimum:

a. Name and contact information for contractor.

b. Name of employee performing the work.

c. Date of work performed and hours spent.

d. Description of the work performed including PMI’s and equipment worked on. Detailed report noting any deficiencies found.

e. Signature of employee that performed work as well as the COR.

f. Bill of Materials (BOM) to include component name, quantity, part #, and assumption of price for any repair material required and material lead time.

7.0 REFERENCES

• MCP – Medical Center Policy 138-08, Utility Management

• NFPA – National Fire Protection Association 70B, 70E, 99, & 101.

• NEC – National Electrical Code