ag034 overhaul description.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME GENERATOR,ALTERNATING CURRENT

STOCK NUMBER 6115-01-121-8046

PART NUMBER AA20241000

USED ON 270 WMEC SSDG (STBD)

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul each designated Ship Service Diesel Generator ashore in a suitable repair facility.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 2703-311-H, K & 2820A-311-I, 2820B- 311-A Manufacturer's Instruction Books - SWBS Group(s) 311 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

SSPC SP6/NACE NO.3 Joint Surface Preparation Standard Commercial Blast Cleaning - Item 21067; SSPC-SP6 MIL-STD-2073-1E W/Change 1, Standard Practice for Military Packaging, 1/7/2011

3. REQUIREMENTS

3.1 General. Overhaul Ship Service Diesel Generators ashore in a suitable repair facility in accordance with SFLC Std Spec 3101. Generator data is shown below.

Characteristics: 475 kW, 450 VAC, 60 Hz, 3 phase, 1200 RPM, 0.8 power factor Kato Engineering Model 475-6770361114, Type 20241, Single Bearing Generator- Sleeve Exciter-Brushless.

3.2 Initial inspection. Perform the initial inspection and tests of section

3.3 of SFLC Std Spec 3101.

3.3 Shop work. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

3.3.1 Reconditioning. Recondition each generator per Appendix B. Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.2 Rewinding. Rewinding per Appendix C is not expected to be necessary, but may become the subject of a change order if reconditioning efforts are unsuccessful. The insulation between the laminates and the core shall not be damaged during the removal process of the old windings. Varnish shall be applied to new windings using the vacuum pressure impregnation (VPI) method.

Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.3 Miscellaneous repairs. Renew the space heater and internal wiring. If the generator requires a rewind, all of the temperature sensors shall be renewed. None of the other miscellaneous repairs of Appendix D are expected to be needed, but may become the subject of a change order if deficiencies are found during the initial inspection. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.4 Balancing. Dynamically balance each rotor assembly per Section 3.4.4 of SFLC Std Spec 3101.

3.5 Reassembly. Reassemble each machine per Section 3.4.5 of SFLC Std Spec 3101.

3.6 Shop acceptance testing. Accomplish the shop acceptance tests of Section

3.5 of SFLC Std Spec 3101.

3.7 Final assembly. Complete reassembly work per Section 3.6 of SFLC Std Spec 3101.

3.8 Clean and Paint. The equipment shall be prepared to commercial blast cleaning (SSPC-SP6/NACE3) standards, cleaned, and the paint renewed to OEM specifications. *** DO NOT PAINT DATA PLATES OR TAGS ***

3.9 Preservation, packing and marking. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.9.1 Preservation. Surfaces dependent on lubricant for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to three years; lubricant shall not be detrimental to the equipment operation. The generator shall be packed with desiccant and heat shrink-wrap with heavy plastic film.

3.9.2 Packing. Material shall he packed in containers meeting MIL-STD-2073-1E and shall be suitable for shipment by rail or motor freight. The Contractor shall package items in such a manner as to prevent damage to the equipment during shipment. The equipment shall be packaged in skid mounted shipping containers, suitable for handling with a forklift. The containers shall be suitable for long term inside storage in a warehouse. Containers shall be assembled with screws to permit ease of removal of the cover or lid from the base. The generator shall he bolted to the framing system. Suitable cribbing shall be provided to prevent damage during shipment. Protrusions, projections, corners, sharp edges and fragile areas shall he cushioned as required to protect the equipment and to prevent rupture of shrink-wrap materials. The generator hub coupling on the rotor shall be supported to prevent movement of the rotor during transit. Fiber boards shall be inserted between the rotor and the stator with yellow tag visible on the coupling end saying to remove at installation.

SHELF LIFE CD 0

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul each designated Ship Service Diesel Generator ashore in a suitable repair facility.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 2703-311-H, K & 2820A-311-I, 2820B- 311-A Manufacturer's Instruction Books - SWBS Group(s) 311 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

SSPC SP6/NACE NO.3 Joint Surface Preparation Standard Commercial Blast Cleaning - Item 21067; SSPC-SP6 MIL-STD-2073-1E W/Change 1, Standard Practice for Military Packaging, 1/7/2011

3. REQUIREMENTS

3.1 General. Overhaul Ship Service Diesel Generators ashore in a suitable repair facility in accordance with SFLC Std Spec 3101. Generator data is shown below.

Characteristics: 475 kW, 450 VAC, 60 Hz, 3 phase, 1200 RPM, 0.8 power factor Kato Engineering Model 475-6770361114, Type 20241, Single Bearing Generator- Sleeve Exciter-Brushless.

3.2 Initial inspection. Perform the initial inspection and tests of section

3.3 of SFLC Std Spec 3101.

3.3 Shop work. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

3.3.1 Reconditioning. Recondition each generator per Appendix B. Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.2 Rewinding. Rewinding per Appendix C is not expected to be necessary, but may become the subject of a change order if reconditioning efforts are unsuccessful. The insulation between the laminates and the core shall not be damaged during the removal process of the old windings. Varnish shall be applied to new windings using the vacuum pressure impregnation (VPI) method.

Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.3 Miscellaneous repairs. Renew the space heater and internal wiring. If the generator requires a rewind, all of the temperature sensors shall be renewed. None of the other miscellaneous repairs of Appendix D are expected to be needed, but may become the subject of a change order if deficiencies are found during the initial inspection. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.4 Balancing. Dynamically balance each rotor assembly per Section 3.4.4 of SFLC Std Spec 3101.

3.5 Reassembly. Reassemble each machine per Section 3.4.5 of SFLC Std Spec 3101.

3.6 Shop acceptance testing. Accomplish the shop acceptance tests of Section

3.5 of SFLC Std Spec 3101.

3.7 Final assembly. Complete reassembly work per Section 3.6 of SFLC Std Spec 3101.

3.8 Clean and Paint. The equipment shall be prepared to commercial blast cleaning (SSPC-SP6/NACE3) standards, cleaned, and the paint renewed to OEM specifications. *** DO NOT PAINT DATA PLATES OR TAGS ***

3.9 Preservation, packing and marking. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.9.1 Preservation. Surfaces dependent on lubricant for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to three years; lubricant shall not be detrimental to the equipment operation. The generator shall be packed with desiccant and heat shrink-wrap with heavy plastic film.

3.9.2 Packing. Material shall he packed in containers meeting MIL-STD-2073-1E and shall be suitable for shipment by rail or motor freight. The Contractor shall package items in such a manner as to prevent damage to the equipment during shipment. The equipment shall be packaged in skid mounted shipping containers, suitable for handling with a forklift. The containers shall be suitable for long term inside storage in a warehouse. Containers shall be assembled with screws to permit ease of removal of the cover or lid from the base. The generator shall he bolted to the framing system. Suitable cribbing shall be provided to prevent damage during shipment. Protrusions, projections, corners, sharp edges and fragile areas shall he cushioned as required to protect the equipment and to prevent rupture of shrink-wrap materials. The generator hub coupling on the rotor shall be supported to prevent movement of the rotor during transit. Fiber boards shall be inserted between the rotor and the stator with yellow tag visible on the coupling end saying to remove at installation.

The generator shall be packaged in accordance with ASTM D7478/D7478M Heavy Duty Sheathed Wood Crates. The crate shall be Type II, Class 2, Style A construction, (preservation code method 54). The crate cover shall be bolted to the base with hex head lag bolts. The crate cover shall be provided with lifting attachments and an inspection port to view generator condition. The top, side and one end of the crate shall be marked ?Re-usable Container ? use for return or NRFI Assembly? with black letters a minimum of 2? high.

3.9.3 Marking. Each package shall be marked. Shipping container shall be stenciled with black enamel paint with the information as laid out below.

Stencil shall be applied to the container on two opposite sides in upper left corner. Markings shall be 3/4 inch minimum height black characters on a white painted background. All previous markings and /or quality assurance decals shall be removed from the reusable shipping container prior to the application of any new markings. Marking shall consist of the National Stock Number (NSN), Item Name, Part Number, Contract Number and Delivery Order Number, Shipping Weight, Quantity and unit of issue, and the words "U.S.

Coast Guard SFLC Material, "Condition-A". The following is an example:

NSN: 6115-01-121-8046

Item Name: Generator, Alternating

P/N: AA20241001

Shipping Weight: xxxx Lbs (including crate) Government Contract No.: XXZXXXXXPXXXXXB00 (per contract).

Words: Coast Guard SFLC Material Condition A, 1 ea."

4. NOTES

4.1 Conditional performance. This work item is performed only when warranted by the condition of the generator windings. Rewinding would typically be performed no more than once during the lifetime of the vessel.

WARRANTY:

A. Standard Manufacturer's Warranty

X B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for

90 days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

6115-01-121-8046

GENERATOR,ALTERNATING CURRENT

AA20241000

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

KATO ENGINEERING INC.

DBA KATO ENGINEERING

2075 HOWARD DRIVE

NORTH MANKATO, MINNESOTA 56003-1525

JAMES METTLER BEST POC AS OF 5/25/22

SCHULZ ELECTRIC

30 GANDO DRIVE

NEW HAVEN, CT. 06513

203-562-5811

WARD LEONARD ELECTRIC CO.

401 WATERTOWN RD

THOMASTON, CT 06787-1922

PHONE 203-283-5801

WRITTEN BY:

DATE :

MARK LOVINGOOD

06 DEC 22

Cost Estimate for Overhaul NOT TO EXCEED: $84,988.8