Maintenance on Catepillar Combined Heat and Power Generator Set

Statement of Work

Combined Heat and Power (CHP) Generator Set Service Contract

Alvin C. York VAMC

Murfreesboro, TN



PART I: GENERAL



A. Introduction

This requirement is to provide full service maintenance and rebuild contract on the Caterpillar G3520C Generator Set and associated radiator system located in Bldg. 16 at the TVHS, Alvin C. York VA Medical Center, 3400 Lebanon Pike Murfreesboro Tennessee, 37129.



B. Background

The Caterpillar G3520C, Serial # GZL00146 Generator set is a natural gas fueled engine that has very strict maintenance requirements for continuous and reliable operation. The intent of the generator set is to provide primary power and steam to the facility and reduce the cost of utilities. The equipment is still under manufacturer's warranty through August of 2017 and requires maintenance at specified intervals to ensure proper operating characteristics as well as continuation of the manufacturer's warranty. Maintenance is of utmost importance for reduced operational cost and to the longevity of the generators life expectancy.



C. Scope of work

The contractor is to provide manufacturer's authorized/certified service technicians, transportation, equipment, maintenance parts, materials, specialty tools and supervision to provide the manufacturer's required maintenance services to ensure proper and continuous operation of the Caterpillar G3520C generator set, radiator system and auxiliary systems connected to the engine. Daily checks will be performed by VA boiler plant employees. This maintenance contract is to include all items required to be checked, inspected, measured, tested or replaced at defined intervals in the manufacturer's service manual, SEBU7681-16 dated November 2010 and will include any manufacturer's updated requirements. This contract will include battery replacement on or before 3 year installation anniversaries, interior and exterior cleaning and servicing of the radiator system to include belt and hose replacement at/or before 5 year recommended intervals, fluid level indicators and fluid replacement as needed at 1000 service hours intervals. The contractor is to provide all parts, materials and labor for 2 (two) standard top end overhauls, 10,000-20,000 service hours and 1(one) in-frame overhaul 22,000-40,000 service hours during the 5 year period of this service contract. Parts found during the overhauls considered to be defective or worn that are not included in the standard overhaul procedures will be covered for under a repair purchase order and are not the contractor's financial responsibility to replace under this agreement. The contractor will provide a list of parts the manufacturer requires to be replaced under the overhauls for clarification of the requirements.



D. Period of Performance

The base year period of performance for this requirement is from November 1 2016 through October 31 2017. Succeeding years will be from November 1 through October 31.



E. Scheduling

The Contractor will perform the generator set maintenance work during normal hours. Hours of work shall be from 8:00 am to 4:30 pm, Monday through Friday, excluding federal holidays. The Contractor is required to schedule the equipment shut down for maintenance with the COR and check in with the COR or alternate COR prior to starting any maintenance on the generator set. This contract does not include any requirements for emergency call backs or overtime hours.





PART II: REQUIREMENTS

" The contractor shall identify which employees will be working under the awarded contract. Contractor personnel shall include employees, sub-contractors, subcontractor employees, suppliers and delivery personnel.

" The contractor will provide proof of manufacturer's authorized service technicians qualifications and certifications to the CO and COR prior to contract award.

" The Contractor will be required to maintain communications at least one time per week with the Boiler Plant Operators, 615-225-3984, to keep track of the generator set operational hours and any changes in operations of the generator set that will affect scheduled maintenance service hours intervals. The VA will inform the contractor when the generator set is placed back into normal operation and the need for maintenance intervals to continue.

" The Contractor is required to check in with the the COR prior to starting any maintenance on the generator set. The Contractor is to provide diagnostic services as needed between services resulting from equipment failures and/or ECM alarms relating to the generator, engine, auxiliary systems associated with the engine and the radiator system. Repair work will be covered under individual purchase orders as needed.

" Parking will be arranged for contractor service vehicles adjacent to the CHP plant.

" The contractor will provide paper or electronic service tickets to the COR, indicating services provided to the generator set as well as any recommended repairs not covered under the service contract or warranty. The contractor is to maintain records of all items replaced, mechanical measurements conducted and fluid test results required by the manufacturer and provide those records to the COR at the end of each contractual period.

" The contractor is responsible for safe and proper handling of all associated parts, materials and fluids, new and replaced. Waste parts, materials and fluids shall be removed from the VA and disposed of in accordance with the appropriate codes and standards.

" The following items are the required service hour intervals and required maintenance as specified in the maintenance manual SEBU7681-16 dated November 2010:









Maintenance Interval Schedule

(G3500C Standard)

SMCS Code: 1000; 4450; 7500

S/N: GZL1-Up

When Required

Battery - Recycle/Replace

Battery or Battery Cable - Disconnect

Cooling System Coolant Sample (Level 2) Obtain and test.

Engine Air Cleaner Element-Replace

Fuel Metering Valve - Check

Generator - Dry

Generator Lead - Check

Generator Set - Test

When Required cont.

Generator Set Alignment - Check

Insulation - Test

Overhaul Considerations

Space Heater - Check

Stator Winding Temperature - Measure/Record

Throttle Control Valve - Check

Radiator Belts and Hoses - Inspect/Replace



Every 250 Service Hours

Battery Electrolyte Level - Check

Cooling System Coolant Sample (Level 1) - Obtain and test

Cooling System Supplemental Coolant Additive (SCA) - TesVAdd

Engine Oil Samples - Obtain and test

Fumes Disposal Filter - Drain



Every 1000 Service Hours

Aftercooler Condensation - Drain

Alternator - inspect

Belts - inspect/adjust/replace

Crankcase Pressure - Measure

Crankshaft Vibration Damper - inspect

Engine Crankcase Breather - Clean

Engine Oil and Oil Filter - Change

Engine Speed/Timing Sensor - Clean/lnspect

Engine Valve Lash and Bridge - Adjust

Flexible Coupling - Inspect

Gas Pressure Regulator Condensation - Drain

Hoses and Clamps - inspect/replace

Inlet Air System - inspect

Radiator - Clean

Radiator Belts and Hoses - Inspect/adjust or replace

Valve Stem Projection - Measure/Record

Water Pump - inspect



Every 2000 Service Hours

Carburetor Air/Fuel Ratio - Check/Adjust

Compressor Bypass - Check

Generator - lnspect

Generator Bearing - Lubricate

Generator Set Vibration - lnspect

Stator Lead - Check



Annually

Cooling System Coolant Sample (Level 2) - Obtain



Every 3000 Service Hours

Ignition System Spark Plugs - Replace

Every 4000 Service Hours

Crankcase Blowby - Measure/Record

Cylinder Pressure - Measure/Record

Engine Mounts - Inspect

Engine Protective Devices - Checks

Ignition System Timing - Check/Adjust

Starting Motor - lnspect



Every 8000 Service Hours

Fumes Disposal Filter Element - Replace

Rotating Rectifier - Check

Turbocharger - Inspect

Varistor - Test

\/\/ater Temperature Regulator - Replace

Winding - Test



Between 10 000 and 20 000 Service Hours

Oil Temperature Regulators - Replace

Overhaul (Top End)



Every 10 000 Service Hours

Generator Bearing - Inspect

Catalytic converter - Remove catalytic module (s), inspect for signs of plugging of the honeycomb or damage to the honeycomb module (s), vacuum module (s) to remove any loose debris/ash. If modules show no sign of plugging or damage reinstall for continued use. If plugging or damage is detected inform the COR replacement units will be required.

Between 22 000 and 40 000 Service Hours

Crankshaft Vibration Damper - lnspect

Overhaul (In-Frame)



Every 24 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change

Between 45 000 and 80 000 Service Hours

Crankshaft Vibration Damper - lnspect

Overhaul (Major) - time frame beyond the scope of this contract



Warranty

All work, materials, and equipment provided with this work shall be warranted against defects in material and workmanship for a period of one (1) year or between service hours intervals from date of acceptance unless otherwise noted.