Statement of Work - Solar Turbine Annual Maintenance.pdf

STATEMENT OF WORK

USDA/ARS/NCAH

2300 Dayton Ave. Ames, Iowa 50010 Turbine Generator Maintenance

1.0 SCOPE OF WORK

The USDA requires a maintenance contract to provide OEM authorized service and maintenance for a Solar brand Taurus 3500 kw natural gas turbine and related equipment located at the USDA Laboratory facility located in Ames, Iowa. The contractor must have at least 10 years’ experience servicing Solar turbine generators and operating the generator via an ISO/PMCS control system. The technicians working on the USDA Solar turbine must have at least 2 years’ experience in the field working on Solar turbines. Only OEM hardware, software, parts, tools, procedures, and methods shall be used in the operation, service and maintenance of this Solar turbine.

2.0 BACKGROUND

The USDA requires a maintenance contract to provide OEM authorized service and maintenance for a Solar brand Taurus 3500 kw natural gas turbine and relate equipment located at the facility in Ames, IA. Proper maintenance utilizing OEM (Original Equipment Manufacturer) parts is critical in ensuring operational and system integrity. It is our understanding that only “authorized dealers” may purchase OEM parts from the Solar Turbine distribution system. The contractor must have at least 10 years’ experience servicing Solar turbine generators and operating the generator via an ISO/PMCS control system. The technicians working on the USDA Solar turbine must have at least 2 years’ experience in the field working on Solar brand turbines.

All work shall be scheduled in advance with management personnel located at the site utility plant. All work shall be completed in the 12-month period of coverage as detailed below.

Contractors shall supply a Quote on their letterhead. Quoted price MUST INCLUDE all Materials, Labor, Equipment, Freight or Shipping, as well as any applicable Duties, Brokerage, or Custom’s fees. It is anticipated that a fixed Price Contract will be awarded.

Award will be made for a 1-year base period with two optional 1-year annual renewal periods. The decision not to renew will be at the sole discretion of the USDA.

Contractor shall be able to respond emergency calls regarding warranty claims for the service work and arrive on-site to an emergency service call within 2 hours (weather and technician availability dependent).

PERIOD OF COVERAGE

Base Year – 12 months Option Year 1 – 12 months following Base Year Option Year 2 – 12 months following Option Year 1

Maintenance shall be performed on the following equipment:

Location PD Package S/N Model Type

NADC 3A801 CG07798 Centaur 40 - 4701S

Generator

3.0 TECHNICAL REQUIREMENTS/TASKS

The following OEM authorized service work shall be performed by OEM trained technicians on the (1) generator listed above as recommended. Technicians must have at least 2 years’ experience in the field working on Solar brand turbines. Only OEM hardware, software, parts, tools, procedures, and methods shall be used in the operation, service, and maintenance of this Solar turbine.

SCOPE OF SERVICE

3.1 Services included in the Monthly Fee

Fleet Manager. Solar shall provide a Fleet Manager to plan and schedule support and troubleshooting maintenance and repair activities.

Scheduled Maintenance Inspections. Solar shall provide consumable maintenance parts except air filters and lubricating liquids, labor and travel for regular maintenance inspections including 4,000 hour and 8,000-hour service and inspections and special tooling. See the services provided later in this document. Solar is required to ship all maintenance and service parts to the USDA facility at least 2 weeks in advance before performing any maintenance work. Turbine shutdowns for maintenance inspections will be required to take place outside of the June 15th to September 15th electrical peak season with at least a 2 week notice.

Condition Assessment Visits. Solar shall provide labor, travel and subsistence to perform at least one onsite assessment per year. Other equipment covered by this agreement may be inspected at this time.

Turbine shutdowns for maintenance inspections will be required to take place outside of the June 15th to September 15th electrical peak season with at least a 2-week notice.

Call Outs for Troubleshooting and Repairs. When the Fleet Manager decides that an unscheduled visit is called for, a Solar technician will be sent out to provide maintenance, troubleshooting or component replacement. This will be provided at no additional cost to the USDA.

Visits will be scheduled to prevent unnecessary travel as long as no events negatively affect turbine performance, safety, or reliability.

3.2 Additional Aftermarket Products and Services.

Parts and service not included in section 3.1 above.

Examples of Products and Works not included.

Package Parts. Solar can provide certified replacement parts as required at a discount.

Generator Inspections, Repairs and Maintenance. Solar can provide generator inspections, planned maintenance and repairs as required.

Turbine Overhaul and/or Engine Exchange. If any repair or engine exchange or overhaul becomes necessary during the Term of this Agreement, such repair or engine exchange or overhaul may be provided by Solar at a discount.

Additional Field Services.

Package System Upgrades.

Engine Upgrades, Conversions or Uprates.

Technical Support.

Technical Training.

Retrofit Kits.

Balance of Plant Equipment Services.

3.3 Scope of Work

3.3.1 Scheduling.

Solar will work with the USDA CO and COR to schedule times for shutdowns to do maintenance and repair. Solar will give at least a 2 week notice to schedule shutdowns for maintenance and repair. This work will be scheduled outside the June 15th to September 15th electrical peak season as much as possible.

3.3.2 Reports.

a. Site Visit Report. Solar will provide a site visit report after each visit.

b. Written Reports. Formal reports of basic services including engine condition, lube oil analysis, vibration analysis and other work will be provided.

3.4 Health, Safety, Security.

a. Solar and the USDA will work to safeguard the lives of people, property and the environment. They will work together to identify and plan for hazards and risks and shall follow all federal and state laws, rules, and regulations.

4.0 Government Furnished: Access to the USDA facility at 1920 Dayton Ave, Ames, Iowa 50010 will be during normal business hours of Monday through Friday, 8am to 4 pm only, excluding nights weekends and government and other holidays. Additional access can be granted on a case-by-case basis with a 2-week notice.

5.0 Deliverables / Schedule:

PLANNED MAINTENANCE DETAILS

The following table lists typical maintenance tasks performed during the Level A (4,000 hours) and Level B (8,000 hours) maintenance visits. All tasks may not be performed if InSight data indicates the device or system is fully functioning correctly and does not require maintenance.

This provides an opportunity to minimize the downtime required to perform the maintenance.

Key Deliverables Item No. Deliverable Objective Due

1. InSight Hardware Initial installation of data collection, controls, network, hosting, customer training.

Within 30 days on contract start

2. InSight Data Collection

Initial set up Within 30 days on contract start

3. InSight reporting Set up of reports, procedures, check sheets, programming, live view screens

Within 30 days on contract start

4. Fleet Manager Review reports and alerts, recommend maintenance and repair, schedule service, phone troubleshooting, resolve technical issues, 24/7 emergency phone support, forecasting and planning engine exchanges, service bulletin implementation.

Upon contract start until contract end.

5. Fleet Manager InSight system use and training Upon contract start until contract end.

6. Fleet Manager Semi-Annual Operation and Maintenance reports

Upon contract start until contract end.

7. Fleet Manager Condition assessment Visit and Equipment Condition Report

Upon contract start until contract end.

8. Fleet Manager Recommended Maintenance Visits Upon contract start until contract end.

9. Fleet Manager Maintenance Consumables and Tooling

Upon contract start until contract end.

10. Fleet Manager Unscheduled Maintenance and Field Service Call Outs

Upon contract start until contract end.

Air Systems Level A 4,000 hours, Leve B 8,000 hours Item No. Deliverable Objective Due

1. Air Systems Inspect enclosure vent fans and filters.

A, B

2. Air Systems Inspect evaporative cooler for proper operation, if equipped.

A, B

3. Air Systems Inspect intake and exhaust systems (debris, leaks, damage).

A, B

4. Air Systems Inspect bleed valve actuator mechanism for proper operation.

A, B

Electric / hydraulic actuators, inspect shafts for cleanliness or scoring.

5. Air Systems Inspect engine compressor variable vane mechanism for wear.

Inspect for bent arms, loose linkage or loose bushings.

A, B

6. Air Systems Inspect inlet guide vanes and position. Inspect linkage and actuation systems. Inspect electric / hydraulic actuators for cleanliness or damage.

A, B

7. Air Systems If self-cleaning air filters used, inspect supply pressure.

Manually cycle through cleaning operation as required.

A, B

8. Air Systems Inspect air inlet housing (obstructions, leaks or contamination). Record differential pressure.

Electrical and

Control Systems Level A 4,000 hours, Leve B 8,000 hours Item No. Deliverable Objective Due

1. Electrical and Control Systems

Visually inspect gages and indicators for proper operation

A, B

2. Electrical and Control Systems

Inspect control console electrical connections for cleanliness and security

A, B

3. Electrical and Control Systems

Verify and record speed magnetic pickup sensor output

A, B

4. Electrical and Control Systems

Inspect condition of thermocouple harnesses and supports

A, B

5. Electrical and Control Systems

Inspect fire detectors for cleanliness and sensitivity.

A, B

6. Electrical and Control Systems

Test fire eyes and thermal devices.

Verify system solenoids for proper operation

A, B

7. Electrical and Control Systems

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

A, B

8. Electrical and Control Systems

Inspect critical gages Calibrate, Fill, or Replace as Required

A, B

9. Electrical and Control Systems

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

A, B

10. Electrical and Control Systems

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

A, B

11. Electrical and Control Systems

Check gas detection devices

12. Electrical and Control Systems

Visually inspect control console A, B

13. Electrical and Control Systems

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

A, B

14. Electrical and Control Systems

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

A, B

15. Electrical and Control Systems

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

A, B

16. Electrical and Control Systems

Perform a battery run down test A, B

17. Electrical and Control Systems

Replace PLC battery

Fuel Systems Level A 4,000 hours, Leve B 8,000 hours Item No. Deliverable Objective Due

1. Fuel Systems Record fuel pressure As required – Customer Adjust regulator (Maybe off Package)

A, B

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

A, B

3. Fuel Systems Inspect fuel control poppet valve Replace as Required (Condition Based)

A, B

4. Fuel Systems Inspect pilot gas filter element

Replace as Required (Condition Based)

A, B

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

A, B

6. Fuel Systems Inspect and lubricate liquid fuel shutoff valves Reassemble with new O-rings

A, B

7. Fuel Systems Inspect and clean fuel strainers A, B

8. Fuel Systems Inspect fuel injectors for cracks, excessive oxidation or damage.

Remove or Replace as Required

A, B

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

10. Fuel Systems Inspect igniter torch housing for cracks and excessive erosion, inspect discharge tube for chaffing wear.

Replace as Required

A, B

11. Fuel Systems Inspect air purge manifolds (discoloration, cracks, overheating)

A, B

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

General Level A 4,000 hours, Leve B 8,000 hours Item No. Deliverable Objective Due

1. General Review Unit Operating Data A, B

2. General Inspect Package lines and hoses (leaks, wear, chaffing) Correct as Required A, B

3. General Inspect mechanical linkages (wear, looseness) Correct as Required

A, B

4. General Visually inspect entire package for fuel, oil, and air leaks

A, B

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

A, B

6. General Inspect package for unusual noise, discoloration, cracks, and chaffing lines

– Correct as Required

A, B

7. General Visually inspect exhaust bellows for cracks or distortion

A, B

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

A, B

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

A, B

10. General Conduct vibration survey. A, B

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

B

12. General Check all safety valves as required A, B

13. General Inspect, clean/replace all package filters

– Condition Based (excludes air inlet filters)

B

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

A, B

15. General Conduct engine performance analysis on As Required – Condition Based

B

Generator (Driven Level A 4,000 hours, Equipment) Leve B 8,000 hours Item No. Deliverable Objective Due

1. Generator (Driven Equipment)

Inspect generator for cleanliness.

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

B

2. Generator (Driven Equipment)

Inspect coupling shear bolts for wear or damage

A, B

3. Generator (Driven Equipment)

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

(New Gaskets)

B

4. Generator (Driven Equipment)

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

B

5. Generator (Driven Equipment)

Resistance check (PI) B

6. Generator (Driven Equipment)

Rectifier assembly, inspection and repair, and diode replacement

As Required

7. Generator (Driven Equipment)

Bearings and oil seal replacement

As Required

8. Generator (Driven Equipment)

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

As Required

Lube Oil and Servo

Oil Systems Level A 4,000 hours, Leve B 8,000 hours

Item No. Deliverable Objective Due

1. Lube Oil and Servo

Oil Systems

Inspect Lube oil tank level Record oil consumption

A, B

2. Lube Oil and Servo Oil Systems

Verify proper operation of oil makeup system, if installed

A, B

3. Lube Oil and Servo Oil Systems

Check oil cooler louver operation, where applicable

A, B

4. Lube Oil and Servo Oil Systems

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

A, B

5. Lube Oil and Servo Oil Systems

Collect oil sample for condition analysis

A, B

6. Lube Oil and Servo Oil Systems

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

A, B

7. Lube Oil and Servo Oil Systems

Inspect Servo oil filter "pop-out" condition indicator Replace filter

(Condition Based) if Required

8. Lube Oil and Servo

Oil Systems Inspect Lube Oil cooler assembly (cleanliness / proper operation)

Start Systems and

Auxiliary Motors Level A 4,000 hours, Leve B 8,000 hours

Item No. Deliverable Objective Due

1. Start Systems and

Auxiliary Motors

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

A, B

2. Start Systems and Auxiliary Motors

Replace starter hydraulic filter (if equipped)

A, B

3. Start Systems and Auxiliary Motors

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

A, B

4. Start Systems and Auxiliary Motors

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

A, B

5. Start Systems and Auxiliary Motors

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

A, B

6. Start Systems and Auxiliary Motors

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

A, B

7. Start Systems and Auxiliary Motors

Inspect VFD's for proper operation and setpoints

A, B

8. Start Systems and Auxiliary Motors

As Required - pneumatic starters: clean, inspect or rebuild shutoff valve (Versa valve, etc.)

Item No. Deliverable Objective Due

1.

Process Conditions Review

Review of external related balance of plant and processes that may impact or has impacted turbine operation

As needed.

2.

Package Air, Fuel and Water Conditions and Impact Review

Assess air filtration and external fuel and water systems service history and condition to determine if any may impact or has impacted turbine operation

3. Operational Practices Review

Review of operations practices, interview operators, review site and event logs

4.

Engine condition review

Conduct annual borescope inspection and vibration survey.

Visually inspect and assess equipment condition

Annually or more often as needed. It is normally done at 4000 and at 8000 hours of run time.

5. Maintenance Review of service tasks and As needed.

Programs and Practices Review intervals, maintenance skills and practices and recommend changes to maintenance practices

6.

Review Service Bulletin Compliance

Review for compliance with Solar-issued service bulletins that are published during the Term of this Agreement

7. Machinery Health Assessment and Recommendations

Report on ability to extend turbine life beyond the TBO while meeting the performance and efficiency requirements of the operation

6.0 Travel: Travel to and from location- N/A

7.0 Contractor’s Key Personnel:

Technicians shall be fully trained and have at least 2 years’ experience in certified Solar turbine operation, maintenance, and service. The technician will be up to date on all safety training such as Lock-Out Tag-Out, risk assessment and common safety hazards and all other common safety protocols.

8.0 Security Requirements: Vendor personnel shall be US Citizens. For all visits, Solar will work with the USDA CO and COR to schedule times for shutdowns to do maintenance and repair at least 2 weeks in advance. All contractors must be escorted when inside buildings (unless they have a contractor Lincpass authorization. Vendors must have proper identification upon entry to facility.

9.0 Data Rights: Vendor shall be able to view and download data when physically visiting in person.

10.0 Section 508 – Electronic and Information Technology Standards:

Vendor shall be able to view and download data when physically visiting in person.

Attachment: N/A