PWS - Generator Maintenance Service.pdf

GENERATOR SET MAINTENANCE

BACKGROUND INFORMATION: The United States Department of Agriculture, National Center for Cool and Cold Water Aquaculture (USDA-NCCCWA) located at 11861 Leetown Road, Kearneysville, WV requires routine maintenance service on three generator sets and emergency service with a mandatory response time of two hours. Routine Service includes both minor and major service/inspections with all tasks/frequencies identified in work statement.

Emergency service includes services required to remedy unscheduled equipment failures. All work shall be performed by trained certified personnel and shall adhere with all local, state, federal codes. Work shall be in accordance with manufacturer specifications and accepted commercial practices. Service Contract Act applies in accordance with attached Wage Determination No.

DESCRIPTION/SPECIFICATIONS/AND WORK STATEMENT: The contractor shall provide all services including labor, materials, supplies, supervision, tools, equipment, insurance, and transportation necessary to provide minor and major routine preventative maintenance and unscheduled emergency service for each of the following three generator sets:

1) 750 kW Caterpillar Diesel Generator, Model SR4B Serial 7aJ02135, 480volt 3ph 60Hz Engine Model CAT 3412, Serial 2WJ06063 Oil filter # CAT 1R-0716 (2 filters), Fuel filter # CAT 1R-0749 (2 filters) Frequency: Quarterly – Three Minor and one Major Service.

2) 200 kW Katolight Diesel Generator, Model D200FPJ4 Serial LM240590 83260-0902, 480volt 3ph 60Hz Engine Model John Deere RG6081A155061 Baldwin oil filter BT486 Frequency: Quarterly - Three Minor and one Major Service.

3) 150 kW Kohler Generator; DEC-3500 Controller Model: 150REOZJ4, S/N 3377GMFP0001 Engine Model: John Deere PE6068U065007 / 6068HFG08 Air Filter: Donaldson Inner: P533781 Outer: P532966 Oil filter: John Deere: RE539279 Fuel Filter: John Deere: Primary: RE 551507 Secondary: RE560681 Coolant Filter: John Deere: DZ106083 (201806) Frequency: Quarterly - Three Minor and one Major Service.

Minor Preventative Maintenance and Service/Inspection/Operation Report Cooling System:

1. Visually check for damage and leaks in radiator and obstruction that would prevent air flow;

2. Check coolant level, add as needed;

3. Test coolant for proper antifreeze percentage and record;

4. Check water jacket heater for proper temp and operation, adjust as necessary;

5. Inspect radiator cap and sealing gaskets;

6. Check water pump for leaks;

7. Check all flexible hoses for leaks and signs of dry rot;

8. Check v-belt condition and tension;

9. Inspect pulleys and lubricate hub bearings.

Fuel and oil system:

1. Check oil level add as needed;

2. Check for oil leaks;

3. Inspect all oil hoses for cracking and leaks;

4. Inspect flexible fuel lines for cracking;

5. Check day tank level;

6. Drain water from water separator;

7. Inspect steel fuel lines.

Batteries:

1. Check batteries for proper charge;

2. Check for proper electrolyte level;

3. Top off fluid level in cell (distilled water);

4. Check for any damage to batteries;

5. Check battery charger for proper operation;

6. Check all battery connections;

7. Inspect starter motor.

Exhaust System:

1. Inspect exhaust system for leaks;

2. Inspect exhaust manifolds for oil / fuel slobbering;

3. Drain water in exhaust moisture trap.

4. Check DEF level.

Air Intake:

1. Inspect air filter for plugging or deterioration, clean as required;

2. Check all air plumbing for leaks, loose connections;

3. Inspect air filter seal;

4. Inspect turbo charger for proper operation and seal leakage.

Installation:

1. Perform 360 walk around, observe;

2. Check seismic isolators;

3. Check for abnormal noise or vibration;

4. Check for oil and coolant leaks while running;

5. Check for proper operation of fan motors, thermostats, circulation pumps, and solenoid valves.

Control Panel:

1. Check all bulbs, lights and safety lamps for proper operation;

2. Check control panels for faults;

3. Check for proper operation of generator instrument displays;

4. Adjust governor control as needed;

5. Check voltage regulator;

6. Test Emergency stop.

Power Generation:

1. Check that generator excitation circuitry is working properly;

2. Check that proper 480 voltage is being generated across all three legs.

Completion:

1. Put all generator controls back in auto;

2. Check that battery charger is on;

3. Ensure that day tank controls are on;

4. Re-install all guards and covers;

5. Provide Service/Inspection/Operation Report noting service provided and deficiencies.

Major Preventative Maintenance and Service/Inspection/Operation Report Perform all Minor Preventative Maintenance tasks AND:

1. Change oil and oil filters;

2. Change fuel and fuel filters;

3. Replace coolant filter;

4. Dispose of waste oil and filters;

5. Lubricate fan drive;

6. Lubricate all bearings;

7. Lubricate governor linkage;

8. Replace inlet filter in day tank;

9. Replace fan/serpentine belt(s);

10. Replace air filter(s);

11. Clean battery terminals.

12. Ensure proper operation of DEF system, where applicable.

Emergency Service: Contractor must be capable of responding to emergency service calls and be on site within 2 hours of a service call in the event of an unscheduled equipment failure.

MANAGEMENT/QUALITY CONTROL: The Contractor shall manage the total work effort associated with the services provided to assure fully adequate and timely completion of these services. Contractor shall provide trained and certified technicians with the expertise to assure the performance of the work in accordance with sound and efficient commercial business practices.

WORK SCHEDULE: Hours of operation are 7:00 am to 4:00 pm Monday through Friday with the exception of official federal holidays.

CONTRACTING OFFICER'S TECHNICAL REPRESENTATIVE:

Technical Points of Contact:

Nick Esprecion: T: 304-724-8340 x2110, C: 681-247-9213, E: nick.esprecion@usda.gov Address: USDA-ARS-NCCCWA, 11861 Leetown Road, Kearneysville, WV 25430