140R3026Q0048_Attachment_01_PWS.pdf

A. PERFORMANCE WORK STATEMENT (PWS).

The Bureau of Reclamation’s (Reclamation) Hoover Dam generators use static voltage regulators with rotating exciters (Armatures) to inject DC voltage onto main generator field windings.

Hoover Dam’s Armatures require cleaning, weighing, measuring, inspection, testing, repair and rewind. Reclamation needs a qualified Electrical Apparatus Service Association (EASA) Contractor to perform these services and certify work is completed in accordance with the EASA Standard

(AR100-2015).

Upon completion of repair, to simplify the organization of Armatures at Hoover Dam, an engraving will be etched on the PMG mount. A number 1-19 with a circle around the digit will be etched. Depending on availability of numbers, the first Armature to be completed will be etched/engraved “1” with a circle around and so forth. If an Armature already has a number 1-19 with a circle around the digit already etched, then no new etching will be required. The digit and the circle around it will be colored in bright red paint (or another color if bright red is not discernible) that is high-temperature resistant, non-conductive, long lasting, and appropriate for its utilization.

After the services required above have been completed, the Contractor shall perform testing on each generator Armature to determine accurate, up-to-date nameplate values including rated Armature voltage, rated current (amperes), and insulation class. Testing shall be conducted using proven, industry-accepted methods, and in accordance with applicable standards.

Armatures that have already been permanently engraved with a unique identification number enclosed within a circle and generator unit(s) compatibility shall only be tested to ensure they meet their nameplate values upon completion of work.

HOWEVER, if the COR deems the test results of the nameplate tests as unsatisfactory, the Contractor must work with the COR to reach acceptable nameplate test results. The costs from additional work/repair will be borne by the Contractor.

If the Armature has not already been engraved permanently with a generator unit(s) compatibility and the COR deems the results of the nameplate tests as acceptable, the COR will then instruct the Contractor to complete additional engraving/etching that designates which generator unit(s) is/are compatible with the Armature on the PMG mount. Etching/engraving will be in the same size and specifications as the digits; however, there will be no need to circle around it.

NO additional serial numbers, engravings/etchings, or markings will be inscribed by the Contractor on the Armatures apart from what has been established by this statement of work.

Etchings/engravings on Armatures that have been inscribed through this performance statement shall not be erased unless instructed by the COR.

The final report shall reference each Armature by its designated number and make note in the report(s) the generator unit(s) it is compatible with. The report(s) will NOT refer to the Armatures by generator unit.

140R3026Q0048 Attachment 01

This will be an Indefinite Delivery/Indefinite Quantity contract, Armatures requiring maintenance will be sent out to be serviced as needed.

B. BACKGROUND.

Generator excitation systems consist of main rotating exciter (Armatures), static pilot exciters, voltage regulators and certain excitation control features. The Armatures are designed and equipped to be direct-connected, direct current, vertical shaft, shunt-wound-type main rotating exciters mounted on top of a generator. Reclamation will not provide any additional drawings or information.

The continuous capacity of these rotating exciters (Armatures) is sufficient to carry the current supplied by the generator’s static pilot exciter and regulator. The continuous capacity of the excitation system is ten percent in excess of the actual capacity (in amperes) required to supply the field excitation current of the generator when operating at 100 percent uprated kilowatt output, rated power factor, and rated voltage. These Armatures are stored inside wood crates ready to load and ship to the repair facility. Pickup and delivery shall be at the Hoover Dam Central Warehouse. The Hoover Dam Central Warehouse is located on Nevada State Route 172 about eight miles East of Boulder City, Nevada. Take Exit 2 (SR-172) past the Hoover Dam Lodge & Casino and follow the signs.

C. PERFORMANCE REQUIREMENTS.

1. The Contractor shall furnish the tools, equipment, materials, cranes, rigging, and incidental items necessary to safely transport, unload, open, photograph, clean, measure, diagnostic test; repair, replace the commutator and rewind; final test, photograph, build return shipping crates, and safely reload (onto the return transport vehicle) Armatures at the Contractor’s facility.

2. The Contractor shall transport the Armatures from Hoover Dam to the

Contractor’s facility and return from the Contractor’s facility to Hoover Dam. Contractor will have a place to work at the Hoover Dam Central Warehouse to load the vehicle transporting the Armatures out for repair and unloading them upon their return. Reclamation will have available a forklift and a qualified forklift operator to load and unload the Contractor’s transport vehicles. Reclamation will also provide an escort for the Contractor’s transport vehicle’s driver while loading or unloading the Armatures.

3. The Contractor shall provide all the necessary tools, equipment, accessories, etc., to safely secure the Armatures placed on the transport vehicle at the Hoover Dam Central Warehouse and at the Contractor’s Facility.

3-1. Armature weight is approximately 11,000 to 13,000 pounds each.

3-2. Armatures are installed inside crates to minimize damage during shipping. Approximate crate dimensions are 6 feet (length) x 6 feet (width) x 5 feet (height).

4. The Contractor’s facility shall be Electrical Apparatus Service

Association (EASA) certified to repair and rewind rotating exciter Armatures.

5. The Contractor’s facility shall provide documentation to certify

Armature repair work complies with ANSI/EASA Standard (AR100- 2015) per Deliverable 3.

6. The Contractor shall provide documentation to certify testing was performed following the repair as specified by EASA Standard (AR100- 2015). Contractor shall submit the certified test results to the Contracting Officer’s Representative (COR) and to:

ibr3lcddworkcontrol@usbr.gov per Deliverable 5.

7. The Contracting Officer (CO) will provide the Approval or Disapproval of Deliverable within 5 days of receipt by the COR.

8. The Contractor shall allow the Contracting Officer’s Representative (COR), or designated Hoover Dam personnel, access to the Contractor’s facility during normal working hours to inspect the facility, equipment, processes, and work being performed under this contract. Inspections may be conducted with or without prior notice and shall not interfere unreasonably with the Contractor’s operations. The purpose of these inspections is to verify compliance with contract requirements, including but not limited to quality assurance, EASA AR100-2015 compliance, documentation, testing, and safety practices.

8-1. The Contractor shall accommodate inspection requests within 24 hours' notice and provide access to all areas relevant to the scope of this contract, including in-process Armature repair work, testing stations, documentation, and quality control areas.

D. SCOPE.

1. The Contractor shall perform all work in compliance with Electrical

Apparatus Service Association (EASA) Standard AR100-2015.

Contractor shall not deviate from the EASA Standard (AR100-2015) without written permission from the CO.

1-1. AR100-2015 lists recommended practices for the repair of rotating electrical apparatus.

1-2. A copy of the standard is available FREE from EASA website at:

www.easa.com.

1-3. A repair record of the procedures followed to refurbish Armature windings and other components (including its commutator) must be made and certified in accordance with the Standard.

1-4. A copy of the certified repair record is required under Deliverable 6 to be sent to the COR.

1-5. All parts shall be made accurate to standard gauge to facilitate replacement and repair.

2. The Contractor shall arrange for transportation to pick up the crated Armatures at the Hoover Dam Central Warehouse and deliver them to the Contractor’s facility. The Hoover Dam Central Warehouse is open for pick-up and deliveries from 7:30 a.m. to 3:30 p.m. (Pacific Time Zone), Tuesday through Thursday. Pick up or delivery outside the aforementioned hours shall be done only after approval from the COR.

2-1. The Contractor shall provide a secure, weatherproof cover over the crated Armatures.

3. The Contractor shall notify the COR of the arrival and departure times at least 5 business days in advance. Advance notice is required to allow Warehouse staff to be available for escort, review of the Job Hazard Analysis (JHA) and for issue and release of the Reclamation provided Special Work Permit (SWP); and Warehousemen and Mechanical Craftsmen are available to operate the forklift and perform any rigging duties that may be needed to load or unload the transport vehicle.

4. A Reclamation escort or inspector will be available on the days and hours approved for work.

5. The Contractor shall inspect, photograph, weigh, measure, and document

Armature condition upon arrival.

5-1. The Contractor shall provide the following information to the COR before beginning repair on each Armature per Deliverable 5 and 6.

a. Photograph the Armature (from at least three positions) upon removal from the crate.

b. Record the name plate data and all marks stamped into the metal for each Armature.

c. Record each Armature’s weight and dimensions in inches & millimeters before repair.

(1) Measure and record core shaft outside diameter.

(2) Measure and record core shaft thickness.

(3) Measure and record core shaft height.

(4) Measure and record the commutator outside diameter.

(5) Measure and record commutator thickness.

(6) Measure and record commutator height.

(7) Measure and record the windings’ outside diameter.

(8) Measure and record the windings’ thickness.

(9) Measure and record the windings’ height.

(10) Measure and record the height of the windings and commutator.

(11) Measure and record the height of the shaft.

(12) Measure and record other dimensions the vendor deems necessary.

(13) Weigh and record Armature weight in pounds.

5-2. Record Armature dimensions on paper in Microsoft Word format.

5-3. Place all measurements on a CAD-generated drawing of the Armature.

6. The Contractor shall clean, inspect, test, repair, rewind, and certify the work was completed as instructed in the EASA Standard (AR100-2015).

7. Core, Commutator or both Core and Commutator Replacement (OPTIONAL LINE ITEM 00020, 00030, or 00020 and 00030, Clause 52.217-7, Option for Increased Quantity—Separately Priced Line Item). If the test and assessments result in conditions which require the core, commutator or both core and commutator to be replaced, the Contractor shall immediately stop work and submit to the CO and COR the diagnostic test reports indicating the hot spots on the commutator. If any Optional Line is exercised (authorized), the CO will issue a modification to exercise the respective Optional Line Item. The exercise of this Optional Line Item will include a time extension of 30 work days or other agreeable timeframe but not to exceed 50 work days. Contractor may not proceed without the authorization from the CO; performance of work without the authorization is at the Contractor’s own expense.

7-1. Inspection, assessment and additional repair recommendations must be completed using the practices and procedures stated in Sections One (General) and Two (Mechanical Repair) of the ANSI/EASA AR100-2015 Recommended Practice Standard.

8. The Contractor shall compare commutator diameter to the minimum acceptable diameter to determine whether the commutator can be reused or must be replaced.

8-1. Undercut and chamfer commutator segments, turn and polish the surface

(if needed).

8-2. Balance the Armature to the ANSI/EASA Standard (AR100-2015) tolerance.

9. A written repair plan for this Armature shall be sent to the COR before work begins per Deliverable 3.

9-1. Contractor shall provide a CAD-generated drawing, a brief description of the repair plan, a material list, a schedule to complete the work, and an estimated date to deliver each individual Armature per Deliverable 5.

9-2. Written approval to proceed with the repair plan will come from the CO.

10. The Contractor shall resurface each Armature’s commutator following practices and procedures stated in Section Two (Mechanical Repair), paragraph 2.8 (Commutators) of the ANSI/EASA AR1002015 Recommended Practice Standard.

11. The Contractor must test and record the results following repair to document the Armature’s upgraded condition.

12. The Contractor shall run all tests on the Armature in accordance with the practices and procedures stated in Section Four (Testing) of the ANSI/EASA AR100-2015 Recommended Practice Standard.

13. The Contractor shall certify Armature tests were performed using calibrated test equipment per Deliverable 6.

14. The Contractor shall perform all tests listed in Section 4.3 Recommended Winding Tests of Standard AR100-2015, including tests on each Armature to ensure there are no grounds, short circuits, open circuits, incorrect connections or high resistance connections.

15. The Contractor shall certify the rewound Armature meets the ANSI/EASA standard and include the items listed below, per Deliverable 6.

15-1. Briefly describe the work completed.

15-2. Briefly describe the commutator’s resurface procedure.

15-3. Briefly describe the test procedure and results.

15-4. Certify the tests comply with EASA Standard AR100-2015.

16. The Contractor shall document each Armature is ready for return shipping by completing the following tasks.

16-1. Photograph each Armature following repair from three different views

(side, top and bottom) to document each Armature’s upgraded and undamaged condition.

16-2. Document in writing and CAD-generated drawing each rewound

Armature’s dimensions and weight as instructed in 5-3 and 9-1.

16-3. Certify each Armature’s dimensions and weight do not exceed those taken on arrival before repairs began.

16-4. Ensure all certifications, records, reports, and tests are completed for each Armature.

16-5. Coordinate with the COR before returning each Armature to Hoover Dam.

16-6. Return of Armature does not relieve the Contractor of the responsibility to conform to all requirements in this statement of work.

17. The Contractor must dispose of all items removed from the Armature in an environmentally friendly manner and in compliance with all laws, rules and regulations.

18. Work shall be performed and completed in a neat, thorough and workmanlike manner following the best modern practices in the manufacture of high-grade machinery.

19. Each Armature shall be permanently marked with a unique identification number ranging from 1 to 19 enclosed within a circle, engraved/etched directly onto the Permanent Magnet Generator (PMG) mount and painted bright red (or another color if bright red is not clearly discernible). The Contractor shall submit photographs to the Contracting Officer’s Representative (COR) to verify the visual clarity of the engraving or etching. The Contractor shall coordinate with the COR and make any necessary adjustments until the markings are deemed acceptable by the

COR.

19-1. The first Armature to be completed under this contract shall be assigned the number 1, and subsequent units shall be numbered sequentially, subject to availability of unused numbers.

19-2. If an Armature already bears an existing circled number (1–19) from previous repair, no additional etching shall be performed.

19-3. All etchings shall be filled in with bright red paint (or another color if bright red is not clearly discernible) that is:

High-temperature resistant Non-conductive Durable and appropriate for industrial application

19-4. The Contractor shall reference each Armature by its designated number in all related documentation and reports.

20. Upon completion of Requirements D.1-D.19, the Contractor shall perform testing on each generator Armature to determine accurate, up-to-date nameplate values, including:

Rated voltage Rated current (amperes) Insulation class

20-1. Testing shall be conducted using proven, industry-accepted methods, and in accordance with applicable standards (but not limited to) such as those published by IEEE, NETA, or the original equipment manufacturer (OEM).

20-2. The Contractor shall clearly document the procedures, instruments, and standards used for testing nameplate values and certify testing equipment were properly calibrated.

21. The Contractor shall send the results of the nameplate tests to the COR. If the COR deems the test results satisfactory, the COR will then instruct the Contractor to complete additional engraving/etching that designates which generator unit(s) is/are compatible with the Armature on the PMG mount.

21-1. The additional engraving/etching will be engraved/etched directly onto the

Permanent Magnet Generator (PMG) mount and painted bright red (or another color if bright red is not clearly discernible). It shall be in the same size and specifications as the digits; however, there will be no need to circle around it. See Exhibit 3 for image reference. The Contractor shall submit photographs to the Contracting Officer’s Representative (COR) to verify the visual clarity of the engraving or etching. The Contractor shall coordinate with the COR and make any necessary adjustments until the markings are deemed acceptable by the COR.

21-2. All etchings shall be filled in with bright red paint (or another color if bright red is not clearly discernible) that is:

High-temperature resistant Non-conductive Durable and appropriate for industrial application

22. IF the COR deems the test results of the nameplate tests as unsatisfactory, the Contractor must work with the COR to reach acceptable nameplate test results. The costs from additional work/repair will be borne by the Contractor.

23. NO additional serial numbers, engravings/etchings, or markings will be inscribed by the Contractor on the Armatures apart from what has been established by this statement of work. Etchings/engravings on Armatures that have been inscribed through this statement of work shall not be erased unless instructed by the COR.

24. If modifications in the engraving(s)/etching(s) is/are requested by the COR, the Contractor shall make the modifications requested without damaging and/or affecting the Armature negatively. The Contractor shall bear full responsibility for any damages incurred and shall work with the COR to ensure timely resolution and full restoration of affected conditions to an acceptable standard, as determined by the COR.

25. If the COR deems pre-existing markings on the PMG mount hinder visibility of the engravings established through Requirements D.19 and D.21, the Contractor shall work with the COR to remove it without damaging and/or affecting the Armature negatively. The Contractor shall bear full responsibility for any damages incurred and shall work with the COR to ensure timely resolution and full restoration of affected conditions to an acceptable standard, as determined by the COR.

26. Upon completion of requirements D.1-D.25 and before shipment of the

Armature(s) to the Hoover Dam Central Warehouse, the Contractor must create a final post-repair report compiling all required deliverables (see G.

DELIVERABLES and J. PERFORMANCE REQUIREMENT SUMMARY TABLE). The final report shall reference each Armature by its designated number and make note in the report(s) the generator unit(s) it is compatible with. The report(s) will NOT refer to the Armatures by generator unit.

27. Upon receipt and approval of final post-repair report from the COR, the

Contractor shall coordinate the shipment of each Armature in a new heavy-duty wood crate to ensure it is secure, supported, and covered in weatherproof protective covering for the return shipping to Hoover Dam.

The Hoover Dam Central Warehouse is open for pick-up and deliveries from 7:30 a.m. to 3:30 p.m. (Pacific Time Zone), Tuesday through Thursday. Delivery outside the aforementioned hours shall be done only after approval from the COR.

E. REFERENCE DOCUMENTS.

The Contractor’s shall refer to the Exhibits 1 through 3 in performance of the work; copies of these exhibits are attached.

1. Exhibit 1. The Electrical Apparatus Service Association Standard (AR100- 2015).

2. Exhibit 2. Unit A7 Westinghouse Test and Inspection Data

3. Exhibit 3. Sample Engraving on PMG mount of Armature

F. SPECIAL REQUIREMENTS.

1. Contractor’s transport drivers shall follow Reclamation Safety Standards while working on-site at the Hoover Dam Central Warehouse.

1-1. Transport drivers shall comply with all federal, state and local laws and standards as well as the Reclamation manual Reclamation Safety and Health Standards (RSHS), 2014 Edition. The Contractor may order the RSHS manual (Stock item GPO-024-003-00178-3) from:

The Government Printing Office Superintendent of Documents North Capitol and H St. N.W.

MS-SSMC - Room 566 Washington, D.C. 20401

The Contractor may also download or view the electronic version of the RSHS manual at no charge from Reclamation web site:

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

1-2. The Contractor’s transport driver must review, discuss and sign a Job Hazard Analysis (JHA) before beginning loading or unloading the Armatures at the Hoover Dam Central Warehouse.

G. DELIVERABLES.

1. The Contractor shall provide the items Table 1, List of Deliverables to the

COR.

2. Reports shall be compatible with Microsoft Office Suite (Word, etc.) or Adobe (pdf).

3. Attach a cover sheet with the job name and Contract Number to each Deliverable.

TABLE 1 - LIST OF DELIVERABLES

No. Deliverable Item Due date

Three (3) digital photographs in PDF format of each Armature upon arrival at Contractor’s facility

Within seven (7) days after arrival at the repair facility

CAD-generated drawing of each Armature with dimensions, measurements, weight shown in Word format (1 set per page); upon arrival at Contractor’s facility prior to repairs

Within seven (7) days after arrival at the repair facility.

3 Written repair plan to complete each Armature repair and rewind

Within seven (7) days after arrival at the repair facility.

4 Three (3) digital photographs in PDF format of each Armature after repair and rewind

Before shipping an Armature back to Hoover Dam

CAD-generated drawing of each Armature with dimensions, measurements, weight shown in Word Format (1 set per page); after repair, rewind, and tests are complete

Before shipping an Armature back to Hoover Dam.

Certified copy of repairs and test results for each Armature to include the repair, rewind, resurface, insulation, vibration, balance and other winding test results.

Before shipping an Armature back to Hoover Dam.

7 Digital photographs of etching/engraving (see D.19) on PMG mount

Upon completion of requirement.

8 Digital photographs of etching/engraving (see D.21-1) on PMG mount

Upon completion of requirement.

9 Certified copy of test results from Armature nameplate testing (D.20).

Upon completion of testing.

10 Final report (D.26). Before shipping an Armature back to Hoover Dam.

H. PERIOD OF PERFORMANCE.

1. The Contractor may request from the COR early site access to review the Hoover Dam Central Warehouse area used for loading and unloading tractor-trailers.

2. The Contractor shall ship back each Armature as soon as work is completed; at minimum, one Armature every 15 weeks.

I. SPECIAL REQUIREMENTS – SECURITY.

The Contractor is responsible for employee compliance with Hoover Dam Security rules. Contractor employees must comply with the following:

1. The operation of Hoover Dam and Power-plant requires continuous and effective security measures. Security is carried out by a Federal guard system whose regulations provide for controlled access to all areas of the Facility. Additional restrictions apply to switch yards, power-plants, remote sites, and other critical areas.

2. Construction Work Areas - All areas where work is required under this contract are designated as construction work areas. Reclamation will designate suitable access ways to construction work areas for use by Contractor Employees. Unless specifically authorized, Contractor Employees are restricted to these areas. It is the Contractor’s responsibility to ensure Employees work only in areas designated.

3. Restricted Areas – Contractor Employees are not permitted to enter restricted areas unless authorized. Restricted area entry must comply with security provisions established for that area. The Contractor must ensure his Employees enter only those areas they are authorized to enter.

4. Contractor’s Tractor-Trailer Truck Parking and Entry Procedure.

4-1. Truck drivers approaching the Hoover Dam Central Warehouse must observe all traffic rules and park only in designated areas.

4-2. Arriving Truckers must ring the buzzer on the South office wall to alert Warehousemen of their arrival, to show their transport documents and to gain entry into the yard of the Hoover Dam Central Warehouse.

4-3. After review of transport documents, Warehousemen will open the yard’s roll gate and direct the trucker to the designated loading and unloading area.

J. PERFORMANCE REQUIREMENT SUMMARY TABLE.

Performance Task Paragraph No.

Acceptable Quality Level

Method of Surveillance

Incentive/Disincentive

Three (3) digital photographs in PDF format of each Armature upon arrival at Contractor’s facility

C.1, D.5 Contractor submits required photographs within the 7 days as required by the

PWS

COR receives and reviews in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

CAD-generated drawing of each Armature with dimensions, measurements, weight shown in Word format (1 set per page); upon arrival at Contractor’s facility prior to repairs

D.5 Contractor submits required certified copy of repair record and test results within the 7 days as required by the

PWS.

COR receives and reviews in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Written repair plan to complete each Armature repair and rewind

D.9 Contractor submits required CAD-generated drawing before repair and rewind;

and after repair and rewind.

COR receives and reviews in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Three (3) digital photographs in PDF format of each Armature after repair and rewind

D.16 Contractor submits required 3 digital photographs before shipping each Armature.

COR receives and reviews in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

CAD-generated drawing of each Armature with dimensions, measurements, weight shown in Word Format (1 set per page); after repair, rewind, and tests are complete

D.16 Contractor submits required CAD-generated drawing before shipping each Armature.

COR receives and reviews in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Certified copy of repairs and test results for each Armature to include the repair, rewind, resurface, insulation, vibration, balance and other winding test results.

C.7, D.6, D.13, D.15

Contractor submits required certified copy of test results before shipping each Armature.

COR receives repair record and test results in accordance with the PWS.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Results of nameplate rating tests and methods of testing

D.20, D.20- 1-2

Contractor submits report upon completion of nameplate value testing

COR receives report in a timely manner and report is well-documented

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Photographs of Armature engraving/etching.

D.19, D.19- 1-4

Contractor submits pictures of engraving/etching in a timely manner that allows for modifications if needed.

COR receives pictures in a timely manner that allows for input on modifications if not acceptable.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Photographs of additional Armature engraving/etching.

D.21, D.21- 1-2

Contractor submits pictures of additional engraving/etching in a timely manner that allows for modifications if needed.

COR receives pictures in a timely manner that allows for input on modifications if not acceptable.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

Final report compiling all the deliverables and details work covered in the Scope.

D.26 Contractor submits final report upon completion of all work covered in Scope.

COR receives final report and deems it acceptable.

Incentive: Positive Past Performance evaluation Disincentive: Negative Past Performance evaluation

EASA Standard AR100-2015

R E C O M M E N D E D P R A C T I C E

FOR THE REPAIR OF ROTATING

ELECTRICAL APPARATUS

Recognized as an American National Standard (ANSI)

A N S I / E A S A A R 10 0 - 2 015

EASA AR100-2015 Recommended Practice - Rev. August 2015

EASA AR100-2015

RECOMMENDED

PRACTICE

FOR THE REPAIR OF ROTATING

ELECTRICAL APPARATUS

Copyright © 2015. All rights reserved.

Electrical Apparatus Service Association, Inc.

1331 Baur Blvd. • St. Louis, MO 63132 USA

314-993-2220 • Fax: 314-993-1269 www.easa.com • easainfo@easa.com ii

TABLE OF CONTENTS

1.4 CONDITION ASSESSMENT AND

FAILURE INVESTIGATION

Eccentricity and Face Runout

2.5 LAMINATED CORES

TABLES

2-1 Shaft Extension Diameter Tolerances–

NEMA Machines 2-2 Shaft Extension Diameter Tolerances–IEC

Machines 2-3 Permissible Shaft Extension Runout–

NEMA Machines 2-4 Permissible Shaft Extension Runout–IEC

Machines 2-5 Shaft Extension Keyseat Width

Tolerances–NEMA Machines 2-6 Shaft Extension Keyseat (Keyway) Width

Tolerances–IEC Machines

and Face Runout–NEMA Type C Face- Mounting Motors and Type D Flange- Mounting Motors

2-9 Mounting Surface Tolerances, Eccentricity, and Face Runout–NEMA Type P Flange- Mounting Motors

2-10 Mounting Rabbet (Spigot) Diameter Tolerances–IEC Flange-Mounted Machines

2-11 Mounting Surface Eccentricity and Face Runout–IEC Flange-Mounted Machines

COILS

Table of Contents, Page 1 iii

WINDINGS

WINDINGS

3.11 COIL CONNECTIONS

AND TESTS

Compensating and Synchronous Rotor Windings

Reconditioned

4.4.2 Accessories

Reconditioned Windings

4.4.2.3 Accessories of Machines with

Windings Not Reconditioned

4.5 NO-LOAD TESTS

TABLES

4-1 High-Potential Test Using AC–New

Windings 4-2 High-Potential Test Using DC–New

Windings 4-3 High-Potential Test Using AC–New

Accessories 4-4 High-Potential Test Using DC–New

Accessories 4-5 Unfiltered Vibration Limits–Resiliently

Mounted Machines

APPENDIX: ELECTRICAL TESTING

SAFETY CONSIDERATIONS

TEST

BIBLIOGRAPHY

STANDARDS ORGANIZATIONS &

OTHER RESOURCES

Table of Contents, Page 2 iv

Section 1 General and a new nameplate mounted adjacent to it with the word “redesigned” and the new rating and date of redesign shown. The original nameplate may be reversed (blank side out) to prevent misinterpreta-tion, but it should remain with the frame.

1.4 CONDITION ASSESSMENT AND

FAILURE INVESTIGATION

The service center should inspect and test the ap-paratus when received to confirm its condition and obtain data for any failure investigation. Initial data collection should proceed before any work is carried out. Inspect all parts for defects before and after cleaning. Document any evidence of distress, such as physical damage, overheating, tampering, inap-propriate lubrication, electrical tracking, or foreign object damage. If possible, obtain information about operating conditions at the time of failure. Collect and carefully examine any debris from any fault.

The primary cause of failure should be determined, if practical, and documented in the repair record.

If required clean the external surfaces of the equip-ment to avoid contaminating internal components during disassembly. Disassembly should be done methodically. Record the condition of all components, take dimensions necessary for reassembly, condition assessment and fault diagnosis. Each component should be clearly and indelibly marked so that it can be placed in the correct location upon re-assembly.

It is important to preserve and carefully inspect any material or component that may have been involved in a failure. Inspect all parts for wear and damage before final cleaning.

Insulation should be examined for evidence of degradation or damage, such as:

(1) Puffiness, cracking, separation or discolor-ation as indication of thermal aging.

rings.

(6) Fretting at supports, bracing or crossings (an indication of looseness or movement).

(Reference: IEEE Stds. 432, Sec. 5.)

Bars and end rings for amortisseur and squirrel cage windings should be examined for evidence of defects. Testing may be needed (see Paragraph 4.3.2).

1.1 PURPOSE

The purpose of this document is to establish recommended practices in each step of the rotat-ing electrical apparatus rewinding and rebuilding processes.

1.2 SCOPE

This document describes record keeping, tests, analysis, and general guidelines for the repair of induction, synchronous and direct current rotat-ing electrical apparatus. It is not intended to take the place of the customer’s or the machine manu-facturer’s specific instructions or specifications or specific accepted and applicable industry standards or recommended practices.

This document should be supplemented by ad-ditional requirements applicable to specialized rotating electrical apparatus including, but not lim-ited to, listed explosion proof, dust-ignition proof, and other listed machines for hazardous locations; and specific or additional requirements for hermetic mo-tors, hydrogen-cooled machines, submersible motors, traction motors, or Class 1E nuclear service motors.

Machines or standalone components received for repair should have the repair company’s name or identifying logo and shop order number permanently affixed to machine or standalone components for future reference. This shop order number should be listed on the repair invoice.

1.3.2 Records

A record of each machine received for repair should be established at the time of receipt and kept on file for at least 3 years. The record should include the nameplate data, electrical test data (both before and after repair), mechanical measurements (both before and after repair), original winding data, final wind-ing data, and details of replaced parts. This record should be made available to the customer for review if requested. The primary cause of failure should be determined, if possible, and should be recorded on the apparatus repair record.

1.3.3 Nameplate

An electrical machine should have a permanent nameplate containing the principal information needed to put the machine into service. The original nameplate is preferred. If a machine is redesigned, the original nameplate should remain on the unit

Section 1, Page 1

1.5.2 Cleaning

All windings and parts should be cleaned. Dirt, grit, grease, oil, and cleaning agent residue should be removed. The parts that do not require immedi-ate work should then be clearly labeled to identify the customer or job number and stored to prevent damage, contamination or corrosion.

1.6 TERMINAL LEADS

All apparatus equipped with lead wire should have insulated lead wire that meets or exceeds machine rated current, temperature class and voltage. The temperature rating should be appropriate for the duty and any oven curing process, and allow for the effect of heat transfer to the terminals.

All leads should be suitably marked or colored where necessary to indicate correct connection. Lead markings should conform to original manufacturer markings, NEMA Stds. MG 1 or IEC Stds. 60034-8, whichever is applicable.

Leads and markings should be of sufficient du-rability to withstand the environment involved and be of sufficient length for ease of connecting to power supply at the terminal box or to terminal blocks. Leads on totally enclosed apparatus should be properly sealed to meet environmental operating conditions.

A print or plate should be furnished, where neces-sary, indicating correct connections.

1.7 TERMINAL CONNECTORS

The recommended method of attaching terminal connectors (lugs) to lead wire is by crimping or pressure indenting the lug barrel, using a lug sized to suit the particular cable stranding provided, in accordance with recommendations of the lug manu-facturer.

Damaged or missing lugs should be repaired or replaced.

1.8 TERMINAL BOXES

Missing terminal boxes should be replaced, and damaged terminal boxes should be repaired or re-placed. See NEMA Stds. MG 1, 4.19 for guidance on replacement terminal boxes. Gaskets and seals that are removed should be replaced.

1.9 COOLING SYSTEM

The fans and cooling ducts should be clean and operational. Cover plates and air baffles should be clean and in place. Damaged or missing parts of the cooling system should be repaired or replaced.

1.10 EXTERIOR FINISH

Apparatus should be externally cleaned and painted, unless the customer requests otherwise.

1.11 PACKAGING AND

TRANSPORTATION

After completion of the repair and testing, the ma-chine should be packed in a manner suitable for the form of transport to be used. Packing and transport should be as arranged with the customer. Blocking of the shaft is recommended, depending on the type of machine, mode of transport and the distance to be traveled. Where blocking is used, it should be clearly identified. Oil-lubricated machines should be shipped without oil, and the need for lubricant clearly identified.

1.12 AUTHORIZATION TO SHIP

Repaired machines that have passed all required repair related tests and inspections should have the indication of acceptability, for example, “OK to ship” entered in the repair record. The service cen-ter should identify those authorized to make this determination.

Section 1, Page 2

Section 2 Mechanical Repair manufacturer’s specifications if available. Other-wise, the values in Table 2-7 are provided as a guide.

Measure the final seal dimensions.

If bearings require grease lubrication, grease in-lets should be equipped with fittings and the inlet passages and tubes cleaned and filled with appropri-ate grease. Lubricant should be compatible with the customer’s lubricant. Open bearings should be filled with grease during assembly.

In the absence of the machine manufacturer’s lubrication instructions, the grease reservoir should be filled to approximately 1/3 capacity.

2.3.2 Oil

Lubricant, including oil for test operation, should be compatible with the customer’s lubricant. There should be a means to indicate proper oil level, such as an oil sight gauge. Evidence of oil leaks should be investigated and the cause corrected.

Frame and bearing housings should be examined for defects. Cracks and breaks should be repaired and fits restored to manufacturer’s specifications.

2.4.2 Mounting Surface Tolerances, Eccentricity and Face Runout

• NEMA Type C face-mounting motors and Type D flange-mounting motors: See Table 2-8.

• NEMA Type P flange-mounting motors: See Table 2-9.

• IEC flange-mounted machines: See Table 2-10 and Table 2-11.

2.5 LAMINATED CORES

Examine stator and rotating element laminations for evidence of hot spots, physical damage or miss-ing components.

2.5.1 Rotating Elements

Inspect rotating element core for evidence of loose fit on the shaft, sleeve or spider on which the lamination stack is assembled. The outer diameter of the rotating element laminations should be true and concentric with the bearing journals.

2.5.2 Stators

The stator laminations should not be loose in the frame. If applicable, the bore of the stator lamina-tions should be true and concentric with the rabbet

2.1 SHAFTS

Shafts should be checked for wear, cracks, scoring and straightness. Shaft extension dimensions should be checked as follows.

2.1.3 Keyseat (Keyway) Width

Tolerances

Keyseats should be true and accommodate keys to a tap fit.

2.2 BEARINGS

Bearings should be inspected for failure modes such as spalling, contamination, fretting, fluting, and scoring. Bearings and bearing arrangements should be identified and documented. Insulated bearings should be tested (see 4.2.7).

2.2.1 Ball or Roller Bearings

Bearing housing and shaft bearing fits should be measured and compared to design specifications (Reference: ANSI/ABMA Stds. 7 as a guide). Any fits that are not within tolerance should be restored.

See Tables 2-13 and 2-14. Replacement bearings should be equivalent to the original manufacturer’s specifications unless redesigned by agreement with, or at the instruction of the customer.

2.2.2 Sleeve Bearings

The sleeve bearing fit in the housing and the diametral clearance should be measured and set to original equipment manufacturer’s specifications if available. Note: Not all sleeve bearing bores are cylindrical.

2.2.2.1 Sleeve Bearing End-Thrust

Bearings of horizontal machines should be posi-tioned on the shaft to eliminate end-thrust against either bearing.

2.2.2.2 Oil Rings

Oil rings should be true and rotate freely. Retain-ers, when provided, should be inspected and replaced if necessary.

2.2.2.3 Seals

Seal clearance should be set to original equipment

Section 2, Page 1

(spigot) diameter of the frame.

2.6 BALANCING

Dynamic balancing of the rotating element should be to the level specified by the customer. In the absence of a requested level, dynamic balancing to balance quality grade G2.5 (ISO 1940/1) for ma-chines rated 2500 rpm or slower, and to the level of grade G1.0 for machines rated above 2500 rpm should enable the machine to meet final vibration limits as defined in Paragraph 4.5.6.

Note: Locate balance weights so that they do not interfere with other components.

2.7 SLIP RINGS

The slip rings should be turned to concentricity with the shaft bearing seats.

The surface finish should be between 40 and 60 micro-inches (1.02 and 1.52 microns). For those de-signs where the slip rings are equipped with a spiral groove to reduce brush operating temperature, both edges of the groove should be lightly chamfered.

Slip rings should have sufficient stock to ensure proper brush performance. Manufacturer’s limits should apply.

The commutator should be turned to concentricity with the shaft bearing seats.

The surface finish should be between 40 and 60 micro-inches (1.02 and 1.52 microns). No flat spots or high, low or loose segments should exist.

Commutators should have sufficient stock to ensure proper brush performance. Manufacturer’s limits should apply.

2.8.2 Undercutting and Beveling

The mica should be undercut, or left flush, as re-quired by the application. When undercut, the mica should be removed along the sides of the bar for at least the complete length up to the riser or dust groove and to a depth of approximately the width of the slot. Undercut areas should be free of foreign material and high mica.

Beveling may be required for those commutators that have rough segment edges resulting from work-hardening of the copper during the undercutting process.

2.9 BRUSHHOLDERS

Brushholders should be clean and free of any de-bris, oil, or dirt. Movable brushholder parts should be free working. The brush fit in the brushholder box should be inspected for excessive clearance, and worn brushholders should be replaced. Clearances should be as specified in Table 2-12.

Brush stud insulation should be free of cracks and should not be charred or have missing components.

In the final assembly of the machine, brushhold ers should be adjusted for clearance to the commuta-tor or slip rings of 0.060 inch (1.5 mm) to 0.125 inch (3 mm), depending on the size of the unit. Manufac-turer’s specifications should apply.

For commutator machines, it should be verified that the brushholders align the brushes with the commutator bars and maintain equal circumferen-tial spacing between brushes.

Spring pressure should be measured and adjusted to a range recommended by the original equipment manufacturer or the brush manufacturer for the specific application and brush type.

Brushholders and jumpers should be high-poten-tial tested to the machine frame at the test voltage specified for the corresponding winding circuit (see Subsection 4.4).

2.10 BRUSHES

Brush shunts should be tight in the brush and connections to the holder should be clean and tight and maintain clearance to other components.

The face of the brush should be seated, or con-toured, to make full contact with the commutator surface or slip rings. The brush fit in the brushholder box should be inspected for side clearance (see Table 2-12) and for excessively worn brushes. Brushes worn beyond useful length should be replaced.

Brushes in the same circuit of a machine should be of the same grade unless otherwise specified by the original equipment manufacturer. For DC ma-chines, brushes should be the size and grade to give successful commutation in normal service.

2.11 BRUSH SETTING FOR DC

MACHINES

In the final assembly, the brush rigging should be positioned so that the brushes are set for brush neu-tral, with brush position clearly marked. Accepted methods of determining this position vary widely, and no single standard procedure applies.

Note: In an assembled DC machine, each brush must contact at least two commutator bars at a time. Then, the brush short-circuits the armature coil connected to these bars. The brushes are consid-ered to be set for brush neutral when the armature coils shorted by the brushes are midway between main poles.

2.12 AIR GAP OF MACHINES

The air gap of the machine should be uniform

(within plus or minus 10% of the average), or to original manufacturer’s specifications.

In a DC machine, the air gaps of the main poles should be uniform, and the air gaps of the interpoles should be uniform.

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Section 2, Page 3

Capacitors should be tested for rated capacitance and subjected to a high-potential test…