Preliminary Engineering Report Pohnpei State Hospital Emergency Generator

June 29, 2010 Pohnpei State submitted the attached pre-Design Planning Document for funding of the replacement of the State Hospitals Emergency Generator. The project was to include: 1. The removal and disposal of the old 600 KW Emergency Generator. 2. The procurement and installation of a new 600 KW Emergency Generator. 3. The procurement and installation of a new Automatic Transfer Switch (ATS). (No allowance was made in their cost estimate to remove and dispose of the old ATS.) 4. The procurement and installation of a 550 gallon fuel storage tank on a new concrete pad. JEMCO approved the project only for a Preliminary Engineering Report to clarify the project scope and cost estimate. The attached PDP indicates that the ATS was inoperable and that the generator had reached its peak usage and required a major overhaul. It was further stated that an overhaul could not be performed because the Hospital did not have parts and service manuals. The emergency generator was inspected in April of 2010 by members of the PMU professional staff. They confirmed that the ATS was inoperable due to a failed actuator. Contacts with the manufacturer revealed that parts were no longer available for the unit. The ATS Is a 1000 Amp switch manufactured by Russelectric of Hingham, Mass, model SRMT-10004CT, Serial No. 8747. A replacement switch is estimated to cost approximately $20,000 (see attached quote), with another $5,000 required for installation of the new ATS and disposal of the old switch. The generator is a 600 kW Caterpillar 3412, Serial Number 81Z03362, Arrangement 2W7900. The unit was found to be fully operational and with the exception of a few minor maintenance problems was in excellent condition. The unit did not have a running hour meter, but from discussions with the maintenance staff, is estimated to have only about 2000 running hours. This model engine requires a top end overhaul at 10,000 hours and a major overhaul at 24,000 hours. An overhaul is not required at this time. The minor maintenance items noted were: 1. The fan drive belts were worn and required replacement. 2. The battery cable terminals had been replaced with automotive units which are undersized. These should be replaced with OEM parts from Caterpillar.

3. One core had been cut out of the radiator to repair a leak. It is estimated that this has reduced the cooling capacity of the radiator by up to 5%. Since the generator is only loaded to about 50% of capacity, this will have no adverse effect on generator operation. No action is recommended at this time. 4. There was a minor oil seepage from the breather in the valve cover. This is normal for an engine without positive crankcase ventilation and no action is recommended at this time. Parts and Service manuals are available from Caterpillar at an estimated cost of $300 (see attached quote). The existing generator is served by 2 existing bulk storage tanks with an estimated capacity of 20,000 gallons each. There was no evidence of leakage or extensive corrosion and the tanks are considered to be in good condition. Both tanks require painting, inside and out and repainting. A large ironwood tree next to the perimeter fence should be removed to avoid future root damage to the foundation. It is recommended that the replacement of the ATS be accomplished by contract funded as an Infrastructure Project. It is recommended that the maintenance problems with the generator and the fuel tanks be accomplished by the Hospital maintenance staff funded as an Infrastructure Maintenance Project.

Prepared by:

Robert A. Westerfield, III, P.E. PMU Resident Engineer, Yap