A.02 PWS FY23 OSDP Motor Overhaul.pdf

FY23 OSDP Motor Overhaul Performance Work Statement

01. General

Provide labor, material, and equipment to overhaul one (1) Over Side Dredge Pump (OSDP) electric motor. Overhaul the motor to include rewind of stator and replacement of all bearings and seals.

02. References

Motor Specifications: Manufactured by the Electrovator Corporation, Birmingham Alabama. 1600HP Dredge Pump Motor, 327 SRPM, 60 Hertz, 2300 Volts. Suitable for operation at 42 Hertz, full load amperes 435, continuous rating 80 deg. rise over a 40 deg. C ambient.

Motor drawings and technical manual available upon request.

Bearing Particulars:

Thrust End Radial Bearing Spherical 23048 Split Thrust 29542E Spherical Bearing 23164

03. GFM

None

04. Safety Precautions

Prior to commencing work, follow vessel’s LOTO policy and procedures.

Follow all applicable state local and federal requirements including those specified in EM-385-1-1 latest revision Note the motor has a weight of approximately 37,000 lbs. Lifting and moving equipment shall be rated for safe operation.

05. Specifications

Contractor to arrange delivery of motor from 3556 NW Front Ave, Portland, OR 97209 to Contractor facility. Upon completion of overhaul arrange delivery of motor from Contractor facility to USACE US Moorings 8010 NW St Helens. A crane of sufficient capacity will be required and provided by the Contractor to unload the motor at the US Moorings.

Upon delivery to the motor repair facility the following inspections shall be performed in conjunction with any other inspections deemed prudent by the Contractor.

1. CHECK POINT: Visual inspection of motor for any shipping damages or missing parts. Record any abnormalities on incoming paperwork.

2. Digital photos are to be taken from all sides of the motor.

3. Contractor shall tag the motor and all parts with a related job number as part of the quality assurance program.

4. Check for and record any special instructions.

5. Motor shall be kept inside and under cover at all times.

6. Motor repair shop shall provide proof of insurance to cover liability against loss of damage to motor in the amount of $1,000,000 prior to beginning work.

Recondition the motor to include but not limited to the following:

1. CHECK POINT: Check shaft end play.

2. CHECK POINT: Single-phase rotor test and record findings.

3. Disassemble motor.

a. Visual inspection of all rotating parts for signs of rubbing or other abnormalities.

b. CHECK POINT: All the measurements listed below in c through g

c. All bearing journal fits shall be measured for proper bearing fit and measurements taken and recorded.

d. All shaft seal area fits shall be measured for proper fit or clearance and measurements taken and recorded.

e. All bearing housings shall be measured for proper fit or clearance and measurements taken and recorded.

f. All stationary seal areas shall be measured for proper fit or clearance and measurements taken and recorded.

g. Verify all O’Ring grooves are clean and of correct size and condition.

h. CHECK POINT: Sweep with dial indicator all flange faces, junction box flanges, top flange and end covers to verify flatness in way of sealing surfaces. Provide CFR with condition of these faces.

i. Provide all new 316 Stainless Steel fasteners, lock washers, flat washers for all junction box and cable entry ports. Inspect all threaded connections and repair any that are stripped or damaged.

j. Rotor to be set up in v-blocks or other suitable jig and run out indicator readings (TIR) taken on all areas of the shaft and rotor iron. Measurements shall be taken and recorded.

4. Clean and dry stator and rotor.

5. CHECK POINT: Perform electrical and mechanical inspection and provide Condition Found

Report of findings.

6. CHECK POINT: Perform bearing inspection and record findings.

7. Clean, inspect and prep all parts.

8. Prime, paint, and retreat parts per OEM spec and recommendation for immersion in salt water and/or oil.

9. Provide and install all new bearings, seals and o-rings.

10. Perform Core-Loss test before and after repairs.

11. Clean and prep laminations.

12. Rewind stator.

13. Provide and install slot RTD’s per original.

14. Oven cure.

15. Post winding electrical tests.

16. Perform Vacuum Pressure Impregnation (VPI) to rewound stator.

17. Blast, prime, and paint complete motor.

18. Prep, install and machine bushing as required.

19. Perform a nitrogen or dry air pressure test to prove proper seal integrity.

20. CHECK POINT: Perform two nitrogen or dry air pressure tests to 45psig for 30 minutes to prove proper seal and cable gland integrity. First test shall be on the motor housing with junction box covers removed to verify oil tight motor housing. Second test shall be on the junction boxes with lids installed to prove water tight junction boxes.

21. CHECK POINT: TIR shall be checked after final assembly.

06. Testing

1. Meggar test and record incoming and outgoing reading.

2. Nitrogen or dry air pressure test to prove seals.

3. Final TIR prior to shipping from Contractor’s facility.

07. Inspection / Documentation

Contractor shall advise the COR of progress milestones and appropriate CHECK POINTS. CHECK POINTS shall require the attendance of two (2) USACE personnel on site at the Contractor’s facility to witness all testing, measurements, etc. Efforts by the Contractor to coordinate these CHECK POINTS to occur during a total of six (6) visits would be preferable to USACE.

On satisfactory completion provide three (3) service / repair reports to the COE Representative.