(A1) Draft Statement Of Work_SiemensMajorMaint_Sept 2025.pdf

This information is controlled by the U.S. Department of Commerce Export Administration Regulations, 15 C.F.R Parts 730-774 as EAR99 Technology.

September 2025 Statement of Work 1

Statement of Work Title Siemens motor generator set major maintenance

Lead PI & contact info SOW Version

Richard Porqueddu Porqueddu@bnl.gov 631-344-7443 A

Project Objective

The purpose of this Statement of Work (SOW) is to describe the major maintenance required for a 13.8 kV motor driving a 7.5 kV salient-pole generator, subsequently referred to as the Siemens Motor Generator set (MG set). In this major maintenance, a full disassembly is required, including removing both rotors and setting them up for detailed inspection, testing, cleaning, and refurbishment of both rotors and stators. The motor and generator rotor slip ring systems shall be evaluated in detail and shall require major on-site refurbishment. After an initial inspection, a report shall be issued to BSA describing the MG set condition. Any scope of work outside of the SOW deemed necessary in this report will be evaluated. As an option, it shall be considered to remove the motor rotor to the vendor's site for slip ring refurbishment and/or total replacement.

Additionally, the vendor may consider shipping the generator rotor to their facility for evaluation. After all remediation, the MG set shall be reassembled and returned to service under the oversight of the vendor.

The vendor shall make any recommendations for testing, examination, or remediation that may not be specifically mentioned in this SOW and include them in their proposal to BSA. Before any offsite work commences, the vendor shall host BSA personnel at their facility, and BSA approval is required on all recommended work. The vendor shall supply any documentation created for replacement parts. Finally, the vendor shall examine motor input current variation during initial run-up and provide a solution.

Project Scope

1. A major maintenance is required for the Siemens Motor / Generator set.

a. See Appendix 1 for equipment details.

b. Motor is 13.8 KV, 410A and 9000 KW

c. Generator is 7,500 V, 3850A and 50,000 KVA

i. It is a salient pole generator (6 poles)

d. Motor and Generator were commissioned in 1969

e. All inspections below require the vendor to make a recommendation for remediation of any indications found to be included in a separate scope of work.

2. Vendor shall prepare for onsite work by performing at a minimum:

a. On site Contractor Vendor Orientation (2.5 hours classroom).

b. Electrical Lockout Tagout (LOTO) training:

i. 2 hours online class may be done offsite in advance.

ii. Must pass the online exam.

mailto:Porqueddu@bnl.gov

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iii. Must take and pass an onsite job performance measure (1 hour)

iv. Attend an electrical LOTO briefing and apply a BSA supplied lock to job lock box and maintain custody of vendors’ key.

c. Provide a Job Hazard assessment report typically 10 pages long:

i. List all job hazards, administrative and remedial measures to address them. It must include:

1. Fall protection training, OSHA or equivalent training with certificate and vendors organizational written policy.

2. Full face respirator training and medical surveillance including a fit test report and vendors organizational written policy.

3. Oxygen deficiency training and medical surveillance.

ii. Rigging/heavy equipment operators and any associated certifications.

d. Provide a rigging plan that may require an onsite pre visit and scale dimensional layout drawings starting from BSA documentation.

i. Rigging plan must include step by step plans to dissemble the machine and drawings and diagrams to illustrate.

ii. Vendor shall plan to spend several days assisting the cognizant engineer in completing a critical lift evaluation form (CLEF).

iii. Vendor shall plan to come onsite to complete and sign off on the critical lift prior to commencing work.

e. Must be a US citizen with appropriate documentation, or an on-site pass must be requested at least 6 weeks prior to work commencement.

3. Dynamic testing:

a. Prior to disassembly the vendor shall provide PDMA style dynamic motor testing while motor is running to include but not limited to:

i. Power quality

ii. Current levels and imbalances

iii. Motor Circuit analysis

iv. Vibration analysis

v. Oil sample analysis

4. Rigging:

a. Vendor is responsible for providing all rigging to disassemble and reassemble the MG set.

i. All rigging equipment and material brought on site shall comply with

OSHA and ASME standards and be checked for counterfeit hardware.

b. The vendor shall remove the motor rotor and place it on its work stand and subsequently reinstall it when maintenance is complete.

c. In the optional case where the vendor shall remove the motor rotor and transport it to his factory – these shipping instructions apply for both directions.

i. The vendor shall provide and use a heavy grade plastic bag to insert the rotor into and seal it airtight.

ii. The vendor shall insert desiccant absorption packs into airtight shipping bag.

iii. The vendor shall insert humidity monitors in the bag.

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iv. An external shrink wrap, tarp or covered transport shall be used for shipping the rotor.

v. Impact monitors shall be installed on the motor shipping cradle, cradle is supplied by BSA.

d. The vendor shall remove the Generator rotor and place it on its work stand and subsequently reinstall it when maintenance is complete.

e. In the optional case the vendor shall remove the Generator rotor and transport it to his factory – these shipping instructions apply for both directions.

i. The vendor shall design a steel I-beam style shipping cradle with hardwood inserts where it contacts the rotor.

ii. The shipping cradle shall have a Professional Engineer (P.E.) stamp.

iii. The vendor shall provide and use a heavy grade plastic bag to insert the rotor into and seal it airtight.

iv. The vendor shall insert desiccant absorption packs into airtight shipping bag.

v. The vendor shall insert humidity monitors in the bag.

vi. An external shrink wrap, tarp or covered transport shall be used for shipping the rotor.

vii. Impact monitors shall be installed on the motor shipping cradle, cradle is supplied by BSA.

f. The MG set is mounted on a foundation isolated from the building. The floor adjacent to the MG set is not rated to hold the weight of the rotors so they cannot be placed there or rigging equipment supported there. All load bearing equipment must rest on the MG set Foundation or extended to the sill plates of the building.

g. A rigging gantry is required, it must rest on the MG set foundation in the middle of the room and extend to the building edge. Openings are provided in the walls so any gantry railway can extend through it. See Appendix 2.

h. BSA will provide work stands on which the rotors can be placed observing the loading restrictions mentioned above. See Appendix 2

i. Vendor shall supply the following:

i. Rigging team to perform the operation.

ii. Mobile powered track gantry with at least three load picking points.

iii. Powered phenolic turning wheels for the motor and generator rotors to mount on existing work stands.

iv. A 35-ton swivel to spin the motor rotor 90 degrees.

v. Any heavy equipment needed to offload equipment and / or manage the machine rigging inside the high bay.

vi. All required straps, D rings and rigging hardware.

j. BSA shall provide the following:

i. 8-Ton overhead crane for ancillary support.

ii. Work stands to support the rotors.

iii. Motor shaft extensions and hardware to extract it.

iv. Generator shaft extensions and hardware to extract it.

v. Motor Rotor shipping cradle P.E. stamped.

5. Motor Rotor:

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a. Vendor shall perform the following static electrical tests:

i. Measure Resistance, Inductance and capacitance/impedance.

ii. DC Megohm and Polarization Index (PI)

b. Vendor shall visually inspect all rotor bar end connections:

i. Checking for decolorization due to overheating

ii. Presence of solder ejection

iii. Checking for other indications of impending failure.

c. Vendor shall inspect existing cracking on rotor structural welds and compare to previous years documentation.

d. Vendor shall perform a nondestructive examination of the coupling flange and adjacent radius area.

e. Vendor shall perform an inspection of the retaining rings (rings are bare

Stainless Steel for this purpose):

i. Visually inspect surface for indications.

ii. Use a phased array ultrasound to inspect it for defects.

f. Vendor shall perform an inspection of the motor Journal bearings (2) and bearing surfaces:

i. Lead crush clearance test prior to removal.

ii. Measurement of journal diameter with micrometer.

iii. Assemble bearings and measure ID with ID micrometer and report journal clearance.

iv. Blue bearing parting faces and remediate with a stone if required.

v. Blue shaft and examine contact area with bearing face.

vi. Measure thrust bearing width on the motor drive end bearing and shaft.

vii. Measure concentricity and runout of journal bearing surfaces.

viii. Visually inspect babbitt on bearing surfaces.

ix. Measure babbitt bond with ultrasound and determine that the adhesion is more than 95%.

x. Measure ball face OD with OD micrometer.

g. Vendor shall evaluate the inner bearing zinc oil control rings.

i. Take reversed engineered spare parts created by BNL and determine their usability considering dimensions, materials and fabrication methods.

ii. Replace the zinc rings with spares if appropriate or refurbish existing ones if replacements are not suitable.

h. Vendor shall refurbish the motor sealing rings (4):

i. Using oversized brass caulking remove and replace all seals (4 to 5 per) with material and geometry approved by BSA cognizant Engineer.

ii. Machine parting line surfaces on seals flat.

iii. Machine seal mounting holes open to a diameter provided by the BSA

Cognizant Engineer to allow for seal adjustment during installation.

iv. Modify the oil drainage slot to increase performance.

v. Machine ID of sealing rings to the ID provided by the BSA Cognizant

Engineer.

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vi. Sharpen sealing rings to a point without removing any material from the ID.

vii. place rotor in a lathe on machine centers machine sealing surfaces until they clean up and polish hone to proper surface finish.

i. Vendor shall refurbish the motor slip ring assembly:

i. Measure diameter, concentricity, runout, flatness and surface finish of ring assembly and verify it is within industry standards and approved of by the BSA Cognizant Engineer.

ii. Measure cooling groove dimensions and evaluate for effectiveness.

iii. Place the rotor in a lathe on machine centers machine collector rings and cooling grooves to specification.

iv. Perform the static electrical tests through the collector rings and confirm performance is better than or equal to prior measurements.

j. Perform optional collector ring replacement if necessary.

i. Remove all buss bars and connections up to the rotor distribution ring.

ii. Fabricate a new collector ring assembly, insulating mounting sleeves, all new buss connections and buss bars and bus insulating sleeves.

iii. Provide documentation (part drawings) so rings can be serviced again in the future.

iv. Install new collector ring assembly and turn brush contact surface on centers in a lathe.

v. Solder/braze all buss connection joints.

vi. Reinsulate all buss connections and joints.

k. Dry Ice blast entire rotor clean, remove as much paint as possible aggressively from steel rotor structure. Clean up lamination, bar and retaining ring areas gently.

l. Refinish (VPI) with insulating varnish leaving retaining rings bare and bake dry in oven.

m. Repeat Resistance, Inductance and Capacitance/impedance measurements.

Repeat DC Megohm and PI measurements, verify improvement based on corrective actions taken.

n. Vendor shall provide the best service available to them for rebalancing the rotor.

o. Vendor shall remove and deliver motor pedestals (2) to their factory:

i. Increase seal oil drainage slots to increase performance.

ii. Perform bluing check between parting line faces between pedestal and cap and remediate with a flat stone if required.

iii. Polish ball face bearing seats with tools provided by BSA.

iv. Measure ball face ID and calculate bearing / pedestal clearance.

v. Use lead crush or plastic gauge to confirm clearance calculation.

vi. Perform bluing check between bearing OD and Pedestal ID.

vii. Aggressively bead blast outside of pedestals clean of any loose paint and feather broken paint edges.

viii. Repair or replace weld-on high pressure oil line instrumentation fittings on pedestal #2.

ix. Thoroughly clean inside of pedestals with solvent.

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x. Paint inside of pedestals with Glyptal 1202 red alkyd enamel or equivalent.

xi. Paint outside of pedestal with Benjamin Moore Aliphatic Acrylic urethane gloss deep base V500-87 or equivalent.

xii. Replace all drain valves, plugs and associated hardware with stainless steel fittings.

6. Generator rotor:

a. Vendor shall perform the following static electrical tests:

i. Measure Resistance, Inductance and capacitance/impedance.

ii. DC Megohm and Polarization Index (PI)

iii. Impedance per coil,

1. Apply AC voltage to coil in steps from 10-120 VAC.

2. Measure the current draw for the entire rotor and for each pole individually.

3. Plot the results for the final report.

b. Vendor shall inspect rotor:

i. Check amortisseur bars and connections for cracks, shifting or signs of impending failures.

ii. Check all pole wedges are secure. Any loose wedges must be addressed:

1. Check visual indicators and knock over tabs on all pole bolts for movement.

2. Check that torque on each wedge bolt meets specifications supplied by BSA by loosening and retorquing.

3. Check each pole wedge is secure in its spot.

4. Check each pole wedge bearing plate is secure against the adjacent pole.

5. Check each bolt and wedge with nondestructive in place examination. e.g. using ultrasound from the bolt head down to observe for cracks.

iii. Inspect repair and refurbish insulation system between the rotor core and the pole windings.

1. Any delamination found shall be cleaned and filled with an appropriate insulation system for a rotating mass.

iv. Inspect cooling fans on the Non-Drive and Drive side of the rotor.

1. Devise a way to measure the OD of the fan blades that has a nominal diameter of 2000 mm.

2. Compare this measurement to the fiberglass covers to determine clearance.

c. Vendor shall evaluate the rotor and identify actions that may increase the PI readings.

d. Vendor shall perform a nondestructive examination of the coupling flange and radius area.

e. Vendor shall perform an inspection of the retaining rings (rings are bare

Stainless Steel for this purpose) (There are two rings per side):

i. Visually inspect surface for indications.

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ii. Use a phased array ultrasound to inspect for defects.

f. Vendor shall perform a low speed balance after all repairs.

g. Vendor shall perform an inspection of the generator Journal bearing (1) and bearing surfaces:

i. Lead crush clearance test prior to removal.

ii. Measurement of journal diameter with micrometer.

iii. Assemble bearings and measure ID with ID micrometer and calculate journal clearance.

iv. Measure ball face OD with OD micrometer.

v. Blue bearing parting faces and remediate with a stone if required.

vi. Blue shaft and examine contact area with bearing face.

vii. Measure concentricity and runout of journal bearing surfaces.

viii. Visually inspect babbitt on bearing surfaces.

ix. Measure babbitt bond with ultrasound and determine that the adhesion is more than 95%.

h. Vendor shall evaluate the inner bearing zinc oil control rings.

i. Take reversed engineered spare parts created by BNL and determine their usability considering dimensions, materials and fabrication methods.

ii. Replace the zinc rings with spares if appropriate or refurbish existing ones if replacements are not suitable.

i. Vendor shall refurbish the generator sealing rings (2):

i. Using oversized brass caulking remove and replace all seals with material and geometry approved by BSA cognizant Engineer.

ii. Machine parting line surfaces on seals flat.

iii. Machine seal mounting holes open to a diameter provided by the BSA Cognizant Engineer to allow for seal adjustment during installation.

iv. Modify the oil drainage slot to increase performance.

v. Machine ID of sealing rings to the ID provided by the BSA Cognizant

Engineer.

vi. Sharpen sealing rings to a point without removing any material from the ID.

j. Vendor shall remove and deliver generator pedestal (1) to their factory:

i. Increase seal oil drainage slots to increase performance.

ii. Perform bluing check between parting line faces between pedestal and cap and remediate with a flat stone if required.

iii. Polish ball face bearing seats with tools provided by BSA.

iv. Measure ball face ID and calculate clearance.

v. Perform lead crush or plastic gauge clearance check of ball face fit.

vi. Perform bluing check between bearing OD and Pedestal ID.

vii. Aggressively bead blast outside of pedestals clean of any loose paint and feather broken paint edges.

viii. Thoroughly clean inside of pedestals with solvent.

ix. Paint inside of pedestals with Glyptal 1202 red alkyd enamel or equivalent.

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x. Paint outside of pedestal with Benjamin Moore Aliphatic Acrylic urethane gloss deep base V500-87 or equivalent.

xi. Replace all drain valves, plugs and associated hardware with stainless steel fittings.

k. Vendor shall gently clean entire rotor by dry ice blasting touching up insulating varnish where required.

l. Vendor shall inspect collector rings:

i. Measure diameter, concentricity, runout, flatness and surface finish of ring assembly and verify it is within industry standards and approved of by the BSA Cognizant Engineer.

ii. Measure cooling groove dimensions and evaluate for effectiveness.

iii. Place the rotor in a lathe on machine centers machine collector rings and cooling grooves to specification.

iv. Perform the static electrical tests through the collector rings and confirm performance is better than or equal to prior measurements.

7. Motor and Generator stators:

a. Vendor shall perform the following static electrical tests separating each Y connection and testing each coil individually as well as connected.

i. Measure Resistance, Inductance and capacitance/impedance.

ii. DC Megohm and Polarization Index (PI).

iii. Electromagnetic Core Imperfection Detection (ELCID)

b. Vendor shall visually inspect both stators for any signs of impending failures.

c. Vendor shall clean both stators:

i. Gently with dry ice blasting.

ii. Verify all cooling slots are open and clean using compressed air and pipe brushes.

iii. Enter pits below and vacuum / clean all debris and dust.

iv. Blow out and clean all air to water heat exchangers in basement.

v. Check stators hold down hardware and tapered pins are secure.

d. Vendor shall verify integrity of wedging blocks by applying a tapping method.

e. Vendor shall refurbish all RTD’s in both stators.

i. Vendor shall test each RTD individually and for any that have failed abandon in place and identify accordingly.

ii. Vendor shall install all new exterior RTD’s on both stators, in the same quantity as internal RTD’s.

iii. For any internal RTD’s identified as failed an extra backup external

RTD shall be installed.

iv. For any internal RTD’s that have failed wire up the appropriate new external RTD in it’s place.

v. For any unused external RTD’s secure wires in place and label as backup RTD’s.

vi. Vendor shall include a system to connect the RTD’s to existing equipment that also allows it to be quickly grounded for high potential testing safety.

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f. Paint outside of stators with Benjamin Moore Aliphatic Acrylic urethane gloss deep base V500-87 or equivalent (to match covers).

i. Vendor shall also evaluate the insulation system on the end windings.

ii. Vendor shall redress end windings before painting with an appropriate insulation system as required as this area has taken a lot of abuse historically in an effort to add a layer of protection to it.

8. Brush Rigging (Motor and Generator):

a. Vendor shall determine if the following work is best performed at his facility or on site here.

b. Disassemble entire stands and clean all carbon dust - bead blasting entire assembly as required.

c. If any insulator parts are compromised fabricate replacement parts and reinstall.

d. Reassemble and paint with Astro 6922 buff epoxy paint system or equivalent.

e. Clean all brush holders using a non-abrasive means.

9. MG set Covers

a. Vendor shall deliver all 12 metal covers to his facility.

i. All weld nuts shall be replaced

ii. Covers shall be aggressively bead blasted and cleaned.

iii. Paint covers with primer.

iv. Paint covers with Benjamin Moore Aliphatic Acrylic urethane gloss deep base V500-87 or equivalent.

10. Vendor shall reassemble MG set:

a. Install all pedestals and bearings, check insulation to ground.

b. Install generator and motor rotors, check insulation to ground during each step.

c. Check Shaft inclination at all three bearings.

d. Check and adjust coupling alignment prior to closing, check shaft insulation.

e. Install all bearing seals as per directions provided by BSA cognizant engineer, check shaft insulation.

f. Measure and record air gap of Motor and Generator to verify rotors are centrally mounted in the stators.

g. Install all covers on motor and generator.

h. Install brush rigging on motor:

i. Verify brush rigging is diametrically and laterally centrally located as directed by the BSA cognizant engineer.

ii. Make any changes necessary to achieve proper mounting location modifying brush rigging and installing tapered pins as required.

iii. Prepare new brushes by sanding a radius on the contact end using tooling provided by BSA.

iv. Lap brushes to new collector rings by installing them in place and using a proper garnet abrasive sheet pulled between the brush and ring.

v. Measure and document brush spring pressure replacing springs as necessary.

i. Install Generator brush rigging.

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i. Prepare new brushes by sanding a radius on the contact end using tooling provided by BSA.

ii. Lap brushes to new collector rings by installing them in place and using a proper garnet abrasive sheet pulled between the brush and ring.

iii. Measure and document brush spring pressure replacing springs as necessary.

11. Vendor shall install all ancillary MG set equipment including but not limited to:

a. Motor Damper and accessory stand.

b. Shaft pump, piping and stand.

c. Pedestal piping and insulating pads

d. Optical tachometer and associated coupling

e. Brush rigging covers, ventilation fans and ducting.

12. The vendor shall perform prior to commissioning:

a. Motor Rotor static electrical tests.

b. Generator Rotor static electrical tests.

c. Shaft ground isolation check.

d. Motor Stator static electrical tests (Y disconnected).

e. Generator Rotor static electrical tests (Y disconnected)

f. AC voltage drop test.

g. Measure and record shaft resistance to ground.

h. Measure shaft lift under lift pump pressure.

i. Ensure rotor spins freely by hand, take corrective actions if it does not.

13. The vendor shall oversee the initial startup of the machine:

a. Concur that machine is ready to start.

i. Vendor shall provide his best assurance that machine is OK to turn on.

ii. Vendor shall provide interim test reports to demonstrate this to the cognizant engineer and receive his approval.

b. Start machine, run up to 700 RPM and test brake.

c. Restart the machine and remain present for 24 hours of running time.

d. vendor shall provide dynamic motor testing while motor is running to include but not limited to:

i. Power quality

ii. Current levels and imbalances

iii. Motor Circuit analysis

iv. Vibration analysis

v. Oil sample analysis

e. Oversee coast down period and perform post run inspection and checks.

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Deliverables Deliverable Description Due Date (in # of days or weeks after contract award)

Input current variation solution

Vendor shall evaluate our MG set and the existing input current variation problem and propose a solution.

6 weeks ARO

Operational MG set A running Motor Generator set prepared for a full 22 week run at rated power outputs.

21 weeks ARO

Documentation Drawings of Motor slip rings and associated hardware for future servicing.

3 weeks after Operational MG set.

Report

A report on all measurements taken, visual impressions observed, operations performed and recommendations for future service

3 weeks after Operational MG set.

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Schedule

Task or Milestone Milestone Duration (weeks)

Vendor shall arrive on site No 2

MG set minor disassembly No 2

Rigging equipment set up No 1

Rigging removal of both rotors and installed in inspection stands No 1 Machine inspection No 2

Shipment of motor rotor to vendors site No 1

In person review of motor rotor status at vendor facility No 1 Motor rotor refurbishment on vendors site No 4

Any additional corrective actions discovered by inspection No 2

Motor Rotor return and installation on inspection stand No 1 *If optional collector ring replacement is exercised No 6

Rigging installation of both rotors No 1

Removal of rigging equipment No 1 MG set minor assembly No 2

Verification run of MG set No 1

Submit inspection report No 3

Assumptions This Statement of Work is based on the following assumptions.

• Vendor shall provide onsite project management personnel and technicians to perform work.

• Vendor shall use BSA personnel (2 mechanical technicians a cognizant Mechanical and Electrical engineer during the minor disassembly / reassembly process).

• Vendor may use local BSA rigging to stage equipment on site including the rigging hardware specific to this machine stored at BSA.

• Vendor shall inspect motor running prior to work commencing.

• Vendor shall contract with an outside rigging contractor to provide rigging support.

• Vendor shall cover shipping costs for the Motor and or Generator rotor to their site and back to BNL.

• Vendor shall cover shipping costs for the MG set covers to their site and back to BNL.

• Any additional scope of work discovered during inspection shall be quoted as a separate scope of work and remediation provided within the project schedule listed.

• Vendor shall remain on site or return to oversee recommissioning of the MG set and perform post maintenance inspections while running.

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• Vendor shall participate in a daily pre job briefing with the Cognizant Mechanical and Electrical engineer, discuss any prior test data or evaluation and agree on future tasks and actions.

• Vendor shall participate in the after run verification check out as mentioned within, but this is to include energizing the generator. That may require BSA to check out other equipment (the load) and prepare it to receive power from the generator. This process has to plan around several other demands on our main control room and may cause delay or additional time in the after run process.

Reporting

The BSA technical representative shall always retain operational control over the project.

Title, signature and date of Tech Rep or Dept Chair

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Appendix 1: MG set data

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Appendix 2 – Rigging

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