Att 1 SOW Mfr Proc QUALI for 22Q7020.doc

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PORTSMOUTH NAVAL SHIPYARD

NEW DESIGN DC ARMATURE COIL MANUFACTURING CONTRACT

STATEMENT OF WORK:

The armature coils are for a General Electric New Design DC armature. Manufacture DC armature coils per the requirements of the Coil Manufacture Procedure. Vendor to manufacture the coils to match the dimensions of Figure 1 of the Coil Manufacture Procedure. Prior to the manufacture of a complete set of coils, the vendor shall provide four each individual sample coils to PNS by way of the Request for Technical Evaluation (RTE) process within 15 working days of contract award. PNS will test fit the sample coils in an armature and will forward comments and findings to the vendor by replying to the RTE. Vendor shall manufacture subsequent sample coils as required per the comments from PNS and forward to PNS, by way of the RTE process, for test fit in a rotor. When all deficiencies are resolved, the vendor will then manufacture complete sets, each set consisting of 157 complete coils. Vendor to ship each requested set of coils to PNS within 15 working days of request. All materials shall be as specified. Equivalent materials may be used if preapproved by PNS by way of a RTE. The coil manufacturer is responsible to provide a Final Certification Package, which is comprised of:

Notes:

The manufacture of the DC armature coils called for in this procedure shall be formed to match the dimensions of Figure 1 of the Coil Manufacture Procedure.

The manufacture of the DC armature coils called for in this procedure shall be completed as follows:

The vendor to provide four each sample coils to PNS within 15 working days of contract award by way of the RTE process. PNS will test fit the sample coils in an armature. PNS will forward comments and findings to the vendor by replying to the RTE following test fit-up.

The coil sets to be manufactured shall be completed as follows:

The coil sets are to be completed within 15 working days after requisition in writing from Portsmouth Naval Shipyard. Multiple sets requisitioned concurrently will have ship dates as follows:

The vendor providing services must have extensive experience with the processes involved in the manufacture of armature coils.

The contractor awarded the contract shall notify PNS prior to subcontracting any of the coil forming and/or coil taping to a different contractor. PNS reserves the right to verify the subcontractor has extensive experience in the field. In the event that PNS deems the subcontractor unqualified, the subcontractor shall not be used.

Dimensional tolerances unless otherwise specified in the contract shall be the same as standards used for high quality coil manufacture and/or the "Twenty Eighth Edition of Machinery's Handbook".

All measuring instruments used for certification of data shall meet the requirements of MIL-STD-45662A "Calibration Systems Requirements", and/or ISO-9002.

Coils shall be packaged for shipping in a method that will prevent damage.

Shipping sample coils and completed coil sets to PNS shall be at the vendor's expense.

The coil vendor shall contact Portsmouth Naval Shipyard and the local DCMA representative 10 days prior to shipment of each coil set so that an on site representative can review the manufacturing data before shipment. Portsmouth Naval Shipyard and the local DCMA representative shall also be allowed access to the vendor's facilities to do spot checks during manufacturing of the coils to ensure that the requirements of the contract are being followed.

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COIL MANUFACTURE PROCEDURE

NEW DESIGN

The coils shall be manufactured in accordance with the following instructions. Vendor to manufacture the coils to match the dimensions of Figure 1. All materials shall be as specified. Equivalent materials may be used only if preapproved by Portsmouth Naval Shipyard (PNS) by way of the Request for Technical Evaluation (RTE) process. The coil manufacturer is responsible to provide a Final Certification Package, which is comprised of:

This Final Certification Package shall be shipped with each set of coils manufactured. Subsequent sets of coils shall be certified on photocopied sheets of this instruction. Failure to meet any requirements shall be cause for rejection of coils.

DATA FOR MANUFACTURE OF COILS

Armature conductor: 4ea.(0.080" X 0.300") Weight of armature coils: 300 lbs.

I (approx.)

Conductor Insulation for Magnet Wire

Magnet wire consists of copper conductor insulated with a heavy build of polyesterimide enamel plus a double wrap of glass fiber (see note below) covering bonded with polyester varnish thermal class 180 per ANSI/NEMA MW-1000/MW 52-C.

NEMA P/N MW052Cha080300N.

Note: The NEMA MW Product Identification Number (PIN) Table does not provide an option for double wrap of glass fiber at PIN position 8. The "a" in the above P/N (position 8) denotes a single wrap of fiberglass fiber. However, this magnet wire is required to have a double wrap of glass fiber.

INSTRUCTIONS:

NO SILICONE OR SILICONE CONTAINING PRODUCTS SHALL BE USED IN THE MANUFACTURE OF THE COILS INCLUDING BINDER TAPE.

Cut and shape magnet wire for the coils per Figure 1

Signature/Date:

Magnet wire formed per Figure 1

Strip the insulation from both ends of the coil per Figure 1. Do not tin the stripped areas. The connections will be welded by GTAW method at PNS.

Magnet wire stripped per Figure 1

Assemble the coil bundles and insulate as follows.

Note: Do not use adhesive film tape to hold the insulation tape near the ends of the conductors, as this will burn when the conductors are welded to the commutator. Adhesive tape use shall be kept to a minimum on the entire coil.

Apply two layers half lapped .005"TK x 3/4"W mica mat tape (VonRoll Mica Mat 77944 or preauthorized equivalent) to the entire coil stopping ¼-½" from the stripped portion on each end. Start with tuck under method and terminate with a small amount of adhesive (Sterling T- 723 or preauthorized equivalent).

Apply one layer .004"TK x 3/4"W caramelized glass tape (Breyden Products Inc. GT475MW or preauthorized equivalent) to the same portion of coil as listed in 4.1. Extend slightly beyond the mica mat tape to seal over end of mica mat tape. The glass tape is to be butt lapped in the slot portion and 1/2 lapped on the end-turns. Start with tuck under method and terminate with a small amount of adhesive (Sterling T-723 or preauthorized equivalent).

Coils formed and taped per Figure 1 and paragraph 4 above

The required number of armature coils in each set is 157 coils.

DCMA Pre-Manufacture Inspection Criteria- New Design Magnet Wire and Secondary Insulation System The New Design DC armature coils shall be manufactured with magnet wire meeting the requirements of the standard defined below. It is common practice for magnet wire manufacturers to use internal part number codes. The part number codes may differ from the National Electrical Manufacturer's Association (NEMA) Magnet Wire (MW) standards. The definitions of these internal part number codes must be verified as meeting the required NEMA MW52-C standard.

NEMA MW-52C standard is defined as (see "Coil Manufacture Procedure, New Design- Table on Page 1):

"Glass fiber covered high-temperature organic varnish treated, bare or heavy film-insulated, rectangular and square copper magnet wire. Thermal class 180°C."

The NEMA Standards Publication ANSI/NEMA MW 1000-2018 part number for the required MW-52C magnet wire is:

Part number code definition:

MW52CHa080300N

NOTE: The New Design coil requires a double wrap of glass fiber. The NEMA MW Product Identification (PIN) Table does not provide an option for a double wrap of glass fiber in this PIN position. See the New Design Coil Manufacture Procedure "Data for Manufacture of Coils" table.

1.3.5. 080300- 0.080" x 0.300" (size of wire)

1.3.6. N- none (type of lubricant)

Prior to the manufacture of the coils, DCMA shall review the magnet wire manufacturer's documentation to verify the wire meets the MW-52C standard defined above.

DCMA shall verify the spools of magnet wire to be used for coil manufacture have part numbers, or other verifiable information, that matches the magnet wire manufacturer's documentation.

DCMA shall verify that the secondary insulation to be applied to the magnet wire matches the manufacturer's part number referenced in the Coil Manufacture Procedure, paragraphs 4.1 and 4.2, or that PNS has authorized an equivalent material by way of a Request for Technical Evaluation (RTE).

DCMA Inspector, verify below that the magnet wire to be used for coil manufacture meets NEMA MW52-C standard and that the secondary insulation is in accordance with paragraph 4 above.

Signature/Date Magnet wire to be used meets the requirements of NEMA MW52-C standard and the secondary insulation is suitable for use:

DCMA Post-Manufacture Inspection Criteria- New Design Coils

Administrative Inspection

Signature/Date Additional layers of insulation are satisfactory. Final Certification Package is complete and included in shipping box.