QASP - Solar Turbine Annual Maintenance.pdf

QUALITY ASSURANCE SURVEILLANCE PLAN (QASP)

FOR

Bldg 154 Taurus Solar Turbine maintenance

1. PURPOSE

This Quality Assurance Surveillance Plan (QASP) is a Government developed and applied document used to make sure that systematic quality assurance methods are used in the administration of the Performance Based Service Contract (PBSC) standards included in this contract. The intent is to ensure that the Contractor performs in accordance with performance metrics set forth in the contract documents, that the Government receives the quality of services called for in the contract and that the Government only pays for the acceptable level of services received.

The QASP has been developed by the requiring activity. It is designed to provide direction to personnel performing contract surveillance activities. Personnel surveying the contract terms and conditions and SOW requirements will periodically review the QASP throughout the life of the contract.

The Contracting Officer’s Representative (COR) will monitor the performance of the Solar Turbines technician in standing by and recovering the turbine from any issues caused by the Caterpillar generator testing.

2. SCOPE

The QASP is put in place to provide Government surveillance oversight of the Contractor’s quality control efforts to ensure the products/results specified in the contract are delivered on time and meet the requirements of the contract. The QASP is not intended to duplicate the Contractor’s Management Plan.

3. GOVERNMENT RESOURCES

The following definitions for Government resources are applicable to this plan:

Contracting Officer - A person duly appointed with the authority to enter into, administer, or terminate contracts and make related determinations and findings on behalf of the Government.

Contracting Officer’s Representative (COR) - An individual designated in writing by the Contracting Officer to act as his authorized representative to assist in administering a contract. The source and authority for a COR is the Contracting Officer. COR limitations are contained in the written letter of appointment.

4. RESPONSIBILITIES:

The Government resources shall have responsibilities for the implementation of this QASP as follows:

Contracting Officer – The Contracting Officer ensures performance of all necessary actions for effective contracting, ensures compliance with the terms of the contract and safeguards the interests of the United States in the contractual relationship. It is the Contracting Officer that ensures the Contractor receives impartial, fair, and equitable treatment under the contract. The Contracting Officer is ultimately responsible for the final determination of the adequacy of the Contractor’s performance.

Contracting Officer’s Representative (COR) - The COR is responsible for technical administration of the project and ensures proper Government surveillance of the Contractor’s performance. The COR is not empowered to make any contractual commitments or to authorize any contractual changes on the Government’s behalf. Any changes that the Contractor deems may affect contract, price, terms, or conditions shall be referred to the Contracting Officer for action.

5. METHODS OF QA SURVEILLANCE

The below listed methods of surveillance shall be used in the administration of this QASP.

Customer Feedback – Customer feedback may be obtained from Utility Plant USDA personnel. Customer complaints, to be considered valid, must set forth clearly and in writing the detailed nature of the complaint, must be signed and must be forwarded to the COR. The COR shall maintain a summary log of all formally received customer complaints as well as a copy of each complaint in a documentation file.

Periodic Inspection – The COR shall monitor the performance of the Solar Turbines Technician as needed. during the standby and recovery period of the contracted period of performance. If there are not issues, then little monitoring is required.

100% Inspection –If issues occur during the period of performance, the COR will monitor the performance of the Solar Turbines technician in the operation, maintenance and repair of the turbine.

6. LEVELS AND STANDARDS OF SERVICE

The standards of services are held to and comply with the standards specified in the PR&C, commercial/industry, and military/government standards.

Location PD Package S/N Model Type

NADC 3A801 CG07798 Centaur 40 - 4701S

Generator

7. IDENTIFIED QA SURVEILLANCE ITEMS

Performance Requirements

Required Services Performance Objective Performance Requirement

Planned Maintenance Visits Scheduled regular visits Scheduled service and maintenance.

Designated Fleet Manager Assistance in monitoring, scheduling, reporting and other services

As needed

InSight Platform Set up hardware and software for monitoring

Monitoring, data collection, transmission.

Semi-Annual and Maintenance Reports

Reporting As scheduled or needed.

Baseline Assessment Visit At beginning of contract Report

Condition Assessment Visit and Equipment Condition Reports

At beginning of contract Report

Covered equipment Gas Turbine Engine (Gas Producer and Power Turbine)

• Gearboxes (Speed Decreasing and Accessory Drives)

• Generator

• Turbine Control System

• Start System

• Fuel System

• Lube Oil System

• Battery Charger

• Ventilation System

• Unit Fire and Gas System

• Vibration System

Service and maintain as scheduled.

Air Systems Level A= 4,000 hours

Level B= 8,000 hours

Inspect air inlet Housing (obstructions, leaks or contamination) Record differential pressure

Level A and B Perform service. Record deficiencies and repair them.

If self-cleaning air filters used, Inspect supply pressure Manually cycle through cleaning operation as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect inlet guide vanes and position. Inspect linkage and actuation systems. Inspect Electric / Hydraulic actuators for cleanliness or damage

Level A and B Perform service. Record deficiencies and repair them.

Inspect engine compressor variable vane mechanism for wear. Inspect for bent arms, loose linkage or loose bushings

Level A and B Perform service. Record deficiencies and repair them.

Inspect bleed valve actuator mechanism for proper operation.

Electric / Hydraulic actuators, inspect shafts for cleanliness or scoring

Level A and B Perform service. Record deficiencies and repair them.

Inspect Intake and Exhaust systems (debris, leaks, damage)

Level A and B Perform service. Record deficiencies and repair them.

Inspect evaporative cooler for proper operation, if equipped.

Level A and B Perform service. Record deficiencies and repair them.

Inspect enclosure vent fans and filters.

Level A and B Perform service. Record deficiencies and repair them.

Electrical and Control Systems

Level A= 4,000 hours

Visually inspect gages and indicators for proper operation

Level A and B Perform service. Record deficiencies and repair them.

Inspect control console electrical connections for cleanliness and security

Level A and B Perform service. Record deficiencies and repair them.

Verify and record speed magnetic pickup sensor output

Level A and B Perform service. Record deficiencies and repair them.

Inspect condition of thermocouple harnesses and supports

Level A and B Perform service. Record deficiencies and repair them.

Inspect fire detectors for cleanliness and sensitivity.

Level A and B Perform service. Record deficiencies and repair them.

Test fire eyes and thermal devices.

Verify system solenoids for proper operation

Level A and B Perform service. Record deficiencies and repair them.

For enclosed units, test Hazardous Package sensors /detector(s) Calibrate as required

Level A and B Perform service. Record deficiencies and repair them.

Inspect critical gages Calibrate, Fill, or Replace as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect speed and temperature control boxes, if equipped Calibrate as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect and Verify back-up over-speed protection monitor Calibrate as Required

Level A and B Perform service. Record deficiencies and repair them.

Check gas detection devices Level A and B Perform service. Record deficiencies and repair them.

Visually inspect control console Level A and B Perform service. Record deficiencies and repair them.

Inspect and Verify safety warning and shutdown devices Calibrate or adjust as Required

Inspect and Verify package vibration monitoring and associated vibration devices (transducers)

Level A and B Perform service. Record deficiencies and repair them.

Inspection of charger (batteries) for condition and proper operation.

Level A and B Perform service. Record deficiencies and repair them.

Perform a battery run down test Level B only Perform service. Record deficiencies and repair them.

Replace PLC battery Level B only Perform service. Record deficiencies and repair them.

Fuel Systems Level A= 4,000 hours

Record fuel pressure As required – Customer Adjust regulator (Maybe off Package)

Level A and B Perform service. Record deficiencies and repair them.

Inspect fuel control system (Integrity, leaks, proper operation) May include fuel System (valves, actuators, linkage & connections)

Level A and B Perform service. Record deficiencies and repair them.

Inspect fuel control poppet valve Replace as Required (Condition Based)

Level A and B Perform service. Record deficiencies and repair them.

Inspect pilot gas filter element Replace as Required (Condition Based)

Level A and B Perform service. Record deficiencies and repair them.

Disassemble, clean, and/or rebuild gas shutoff pilot control valves As Required (Condition Based)

Level A and B Perform service. Record deficiencies and repair them.

Inspect and lubricate liquid fuel shutoff valves Reassemble with new O-rings

Level A and B Perform service. Record deficiencies and repair them.

Inspect and clean fuel strainers Level A and B Perform service. Record deficiencies and repair them.

Inspect fuel injectors for cracks, excessive oxidation or damage.

Remove or Replace as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect, clean, and/or rebuild primary and secondary fuel shutoff valves (Condition Based)

Level A and B Perform service. Record deficiencies and repair them.

Inspect igniter torch housing for cracks and excessive erosion, inspect discharge tube for chaffing wear. Replace as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect air purge manifolds (discoloration, cracks, overheating)

As Required - Liquid / Dual Fuel units, Inspect purge system for proper operation

Level A and B Perform service. Record deficiencies and repair them.

General Level A= 4,000 hours

Review Unit Operating Data Level A and B Perform service. Record deficiencies

Inspect Package lines and hoses (leaks, wear, chaffing) Correct as Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect mechanical linkages (wear, looseness) Correct as Required

Level A and B Perform service. Record deficiencies and repair them.

Visually inspect entire package for fuel, oil, and air leaks

Level A and B Perform service. Record deficiencies and repair them.

Check condition and operation of solenoids and shutoff valves Correct as Required (kits as necessary)

Level A and B Perform service. Record deficiencies and repair them.

Inspect package for unusual noise, discoloration, cracks, and chaffing lines – Correct as Required

Level A and B Perform service. Record deficiencies and repair them.

Visually inspect exhaust bellows for cracks or distortion

Level A and B Perform service. Record deficiencies and repair them.

Perform cleaning of engine per Performance Condition or as Required (Off-line detergent wash)

Level A and B Perform service. Record deficiencies and repair them.

Perform borescope inspection of the compressor, combustion section, and the power turbine

Level A and B Perform service. Record deficiencies and repair them.

Conduct vibration survey. Level A and B Perform service. Record deficiencies and repair them.

Lubricate all electric motors that are equipped with grease fittings Per recommended schedule or as Required

Level B only Perform service. Record deficiencies and repair them.

Check all safety valves as required Level A and B Perform service. Record deficiencies and repair them.

Inspect, clean/replace all package filters – Condition Based (excludes air inlet filters)

Level B only Perform service. Record deficiencies and repair them.

Witness turbine Restart, record acceleration time. Monitor control system for proper sequencing

Level A and B Perform service. Record deficiencies and repair them.

Conduct engine performance analysis on As Required – Condition Based

Level B only Perform service. Record deficiencies

Generator (Driven Equipment)

Inspect generator for cleanliness.

Inspect fan blades, generator rotor and stator for contamination and damage

Level B only Perform service. Record deficiencies and repair them.

Inspect coupling shear bolts for wear or damage

Level A and B Perform service. Record deficiencies and repair them.

If Required – Disassemble, clean, inspect gear engagement wear, repack (Solar coupling grease) Re-assemble

(New Gaskets)

Level B only Perform service. Record deficiencies and repair them.

As required, based on vibration data, check and realign driver/driven equipment

Level B only Perform service. Record deficiencies and repair them.

Resistance check (PI) Level B only Perform service. Record deficiencies and repair them.

Rectifier assembly, inspection and repair, and diode replacement

As required Perform service. Record deficiencies and repair them.

Bearings and oil seal replacement As required Perform service. Record deficiencies and repair them.

Oversee contractor in cleaning the generator utilizing OEM recommendations or Industry Standard Practices

As required Perform service. Record deficiencies and repair them.

Lube Oil and Servo Oil Systems

Inspect Lube oil tank level Record oil consumption

Level A and B Perform service. Record deficiencies and repair them.

Verify proper operation of oil makeup system, if installed

Level A and B Perform service. Record deficiencies and repair them.

Check oil cooler louver operation, where applicable

Level A and B Perform service. Record deficiencies and repair them.

Check lube oil tank vent fan and/or mist eliminator for proper operation

Level A and B Perform service. Record deficiencies and repair them.

Collect oil sample for condition analysis

Level A and B Perform service. Record deficiencies and repair them.

Inspect and record lube oil filter (Delta P). Rotate to Standby filter assembly if equipped (Condition Based). Inspect / Replace filter elements if required.

Inspect Servo oil filter "pop-out" condition indicator Replace filter (Condition Based) if Required

Level A and B Perform service. Record deficiencies and repair them.

Inspect Lube Oil cooler assembly (cleanliness / proper operation)

Level A and B Perform service. Record deficiencies and repair them.

Start Systems and Auxiliary Motors

Inspect Starter reservoir or lubricator oil level. As Required – Fill Reservoir

Level A and B Perform service. Record deficiencies and repair them.

Replace starter hydraulic filter (if equipped)

Level A and B Perform service. Record deficiencies and repair them.

Inspect and Verify pre/post lube oil pump and backup lube oil pump

Level A and B Perform service. Record deficiencies and repair them.

Inspect starter clutch (if applicable) to ensure proper engagement and operation

Level A and B Perform service. Record deficiencies and repair them.

Check pneumatic starter assembly (if applicable) for unusual wear and oil consumption. Verify proper operation of starter when unit is in startup cycle

Level A and B Perform service. Record deficiencies and repair them.

Verify starter gas vent over pressure protection is functional (if applicable).

Level A and B Perform service. Record deficiencies and repair them.

Inspect VFD's for proper operation and setpoints

Level A and B Perform service. Record deficiencies and repair them.

As Required - pneumatic starters:

clean, inspect or rebuild shutoff valve (Versa valve, etc.)

Level B only Perform service. Record deficiencies

Out of Scope

Required Services Performance Objective Performance Requirement

Unscheduled Maintenance / Field Service Call Outs

Complete unscheduled maintenance and repairs

As needed. List price minus 10% at the time of service .

Package Parts Repair or Replacement

Transactional scope.

Provided as required during the contract term.

Per Catalogue price minus 5% at the time of service

Generator Inspections, Repair and Maintenance

Transactional scope.

Provided as required during the contract term.

Per Catalogue price at the time of service

Engine Overhaul Transactional scope.

Provided as required during the contract term.

Per Catalogue price minus 5% at the time of service

Scope of services does not include air filter replacements, consumable/operating liquids, off-skid fuel equipment, cooler assembly, replacement batteries, CO2 bottles and extinguishing media or any balance of plant equipment.

Quote when needed for work outside of this contract

Work completed outside of this contract paid for separately

Engine Overhaul (Exchange Program) or Repair

Quote when needed for work outside of this contract

Work completed outside of this contract paid for separately

Package Parts Repair or Replacement

Quote when needed for work outside of this contract

Work completed outside of this contract paid for separately

Generator Inspections, Repair and Maintenance

Quote when needed for work outside of this contract

Work completed outside of this contract paid for separately

8. DOCUMENTATION

The COR shall, in addition to providing documentation to the Contracting Officer, maintain a complete Quality Assurance file. All such records will be retained for the life of this contract.