Annual Preventative Maintenance on Generators

Provide all labor, materials, tools, equipment and supervision required to perform the below scope. Provide all labor, materials, tools, equipment and supervision required to perform the below scope. This request is for a bid for a one (1) year maintenance subcontract with two (2) optional years on the specified equipment. The base year subcontract is to run October 1, 2011 through September 30, 2012. Optional years thereafter will increase the period by one (1) year. Equipment Covered - 1. Caterpillar Diesel Generators # 101 and 102. Model number 3608, serial numbers are 6MC00599 and 6MC0060 respectively. - 2. Caterpillar Generator # 103. Model number 3304, serial number 83Z11315. - 3. Caterpillar Generator # 104. Model number 3306, serial number B8D00791. - 4. Onan - Cummins Generator # Building 695. Model number 125DGEA, serial number L920494413. Scope of Work Subcontractor is to provide preventative maintenance including parts, labor and any other incidental expenses. Perform annual PM on two (2) Caterpillar diesel generators. Both are 3608 models. Serial numbers are 6MC00599 and 6MC0060 respectively. - 1. Perform a visual walk-around inspection of GEN 101/102, with a test run of each engine. - 2. Inspect and replace all filters as required, to include: Engine air cleaner element, engine oil filter, fuel system primary filter / water separator element, fuel system secondary element. - 3. Inspect particle detector; record condition. - 4. Obtain engine oil sample, perform an S-O-S oil analysis and furnish System Engineer and Subcontracts Administrator with test results and recommendations as per Caterpillar 3608 engine requirements. - 5. Clean the crankcase breather elements and replace the o-ring seals. - 6. Dismantle and clean centrifugal oil filers as per Cat service manual. - 7. Perform an S-O-S Level I coolant analysis. Provide System Engineer and Subcontracts Administrator with analysis results and Caterpillar recommendations. If coolant does not meet Caterpillar recommendations, replace existing coolant with Caterpillar Extended Life Coolant. - 8. During the engine test run (Step 1), measure the differential pressure of the air side of the aftercooler. Clean the aftercooler core if differential pressure exceeds Caterpillar requirements. - 9. Check engine mounts. Measure the isolators and make adjustments as per Caterpillar O&M manual. - 10. Perform a calibration check of the engine protective devices. Calibration of the temperature and pressure contactors as per Caterpillar SEHS9828. Inspect the connections of all engine protective devices. - 11. Inspect the engine starting motors system. Inspect the starting motor for proper operation. Inspect the teeth on starting motor pinion and the flywheel ring gear. Replace each if broken or chipped teeth are found. - 12. Check and grease the governor actuator linkage as required. - 13. Inspect components of engine exhaust system for damage, cracks, leaks and loose connections. - 14. Remove, clean and inspect magnetic pickups from the flywheel housing. - 15. Check oil mist detector and replace filters in pressure regulator as required. - 16. Inspect and lubricate the barring device. - 17. Inspect the crankshaft vibration damper and measure temperature of damper (infrared thermometer) during test run. Temperature should be <200 degrees Fahrenheit. - 18. Remove protective screen, pull top off of drive motor, remove plug, and fill with new grease. Replace guard guards and covers. - 19. Westinghouse Operations, Maintenance Technician and Systems Engineer will perform a post maintenance test run of each engine under load. Perform annual PM on (2) Caterpillar diesel generators. Model number for #103 is 3304; model number for #104 is 3306. Serial number for #103 is 83Z11315, serial number for #104 is B8D00791. - 1. Subcontractor's standard annual package. - 2. Conduct a visual inspection. - 3. Cooling system inspection to include fluid sample analysis. - 4. Fuel system inspection. - 5. Inspection and replacement if needed of all filters. - 6. Generator inspection for moisture, oil, dirt. - 7. Generator MegaOhmn test - 8. Generator bearing inspection and lubrication. - 9. Crankcase breather cleaning. - 10. Engine oil check to include oil sample analysis. - 11. Torque check of all power connections >150V. - 12. Battery inspection - replace every other year. - 13. Belt inspection - replace every other year. - 14. Engine protective devices test. - 15. Engine run with check of all gauges and electrical output parameters. - 16. Trip report to include all calibration results, outstanding discrepancies, and outline of work performed to Systems Engineering and Subcontract Administrator. Perform annual PM on (1) Onan - Cummins generator. Model 125DGEA. Serial number L920494413. - 1. Change engine oil and filter. Use 15W-40 multiviscosity CE/SF oil, 243.7 quarts. (Filter vendor provided). - 2. Check fan and fan hub. - 3. Change air intake air filter. (Vendor provided). - 4. Check drive belt tension and tensioner pulley. - 5. Check radiator and inlet duct work. - 6. Change coolant filter. (Vendor provided). - 7. Clean exterior of radiator. - 8. Inspect turbocharger. - 9. Check for obstructions to fuel tank vents and overflow. - 10. Change fuel filter / fuel water separator. (Vendor provided). - 11. Check fuel prefilter. - 12. Check exhaust for restriction. - 13. Exhaust system hangers and supports. - 14. Clean and adjust magnetic pickup. - 15. Clean generator engine, rotor and stator. - 16. Check windings and electrical connections. - 17. Measure insulation resistance with Megger-Record. - 18. Check the power circuit breaker operation. - 19. Perform a post maintenance test run of the generator. - 20. Provide a written report of initial and final adjustments and any work that is recommended to be performed. Subcontractor(s) will participate in the pre-job briefings to ensure that good communications are established with ANCDF Engineering, Operations and Maintenance departments before any work begins. Extreme caution shall be taken to ensure that unplanned outages will not occur. Subcontractor shall provide (1) copy of calibration records for any calibration equipment that is used. Subcontractor shall provide the MSDS sheet for any chemical product(s) brought onsite. Subcontractor shall provide a trip report to include calibration results, outstanding discrepancies, and outline of work performed. All parts and supplies are to be provided by the subcontractor / vendor and be original Caterpillar items unless otherwise approved by WA Engineering.