Attachment 1_Statement of Work.pdf

STATEMENT OF WORK

1. SCOPE

1.1. Title: Statement of Work for the repair of the AC Motor identified in section 1.3.

1.2. Location of Work: Work to be performed at Contractor’s facility.

1.3. Identification: A.C. MOTOR, 3 speed, 200/25/3.1 HP, 440V, 3 phase, 60HZ, Frame size 586 WVY, insulation class F, Nameplate AMP rating 247/40/14, Squirrel cage rotor, vertically mounted, continuous duty, manufactured by General Dynamics, Electro Dynamics Division.

1.4. Security Classification: Unclassified, CUI

2. REFERENCES

2.1 A.C. MOTOR; DWG No. 3586-3, REV A5

2.2 Electric Plant General, NSTM Chapter 300; NAVSEA S9086-KC-STM-010/CH-

2.3 Electrical Machinery Repair Technical Manual; NAVSEA S6260-BJ-GTP-010

3. REQUIREMENTS

CAUTION - NOISE QUIET EQUIPMENT:

Ensure AC Motor assembly is transported/moved on a shock mounted skid that the government will provide, when assembled. Component parts may be transported throughout the repair facility during the repair process without a shock-mounted platform but must be handled with extreme care.

WARNING:

COLLECTION/RECORDING OF VIBRATION DATA BY CONTRACTOR DURING

OPERATIONAL TESTING IS EXPLICITLY FORBIDDEN.

NOTE:

Appendix A is provided to capture electrical, mechanical and visual inspections.

Appendix B is provided to assist with Insulation Resistance correction, Winding

Resistance correction and torque specs.

3.1.1. The contractor shall perform an as-arrived visual inspection, as-arrived electrical tests and mechanical checks of the AC Motor assembly in accordance with references 2.1, 2.2 and 2.3. The contractor shall record this data on Tables 1 through 3 in Appendix A. The contractor shall report these results to PNSDETSD Code 270, via email:

3.1.2. The contractor shall then disassemble the AC Motor guided by references 2.1 and

2.3. The contractor shall clean all component parts and clean and dry the stator windings in accordance with references 2.1 and 2.3. The contractor shall perform visual inspections and electrical testing of the stator windings in accordance with References 2.1, 2.2 and 2.3. The contractor shall record this data on Tables 4 through 8 in Appendix A. The contractor shall report these results to PNSDETSD Code 270, via email:

NOTE: Prior to determining whether rewind/replacement is required, the stator may be cleaned and dried 2 additional times and insulation resistance re-measured.

3.1.3. The contractor shall stop work and Notify PNSDETSD TPOC immediately shall the Stator winding, Insulation Resistance fails after the 3rd attempt at Cleaning & Drying.

3.1.4. The contractor shall allow PNSDET Code 270 to visually evaluate the winding insulation after Cleaning & Drying (at the contractor’s facility) to determine whether varnish treatment is warranted. If 270 authorizes Varnish Dip by checking “YES” in Table 8, The contractor shall proceed to Requirement 3.1.5. If PNSDET Code 270 checks “NO” for Varnish Dip in Table 8, The contractor shall proceed to Requirement 3.1.6.

3.1.5. The contractor shall Varnish Dip & Bake Stator Windings (If authorized in Table 8), using References (a), (b) & (c) as a guide. The contractor shall perform After Varnish Dip & Bake Electrical tests, visual inspection and record data on Tables 9 through 13 of Appendix A.

3.1.6. The contractor shall Re-assemble motor using References (a) & (c) as a guide and perform After Re-assembly Electrical and Mechanical checks. The contractor shall record this data in Tables 14 through 17 of Appendix A and table 21 in Appendix B.

3.1.7. The contractor shall perform an operational (No Load) test of the re-assembled motor and allow PNSDET Code 270 to obtain vibration data during the test (at the contractor’s facility). The contractor shall record this data in Tables 18 through 20 in Appendix A.

4. RESPONSIBILITITES

4.1. The Government will remove the AC motor and ship to the contractor’s facility.

4.2. The Contractor shall perform all work and obey Notes, Cautions and Warnings as described in Section 3 Requirements.

4.3. The Government will provide the contractor, engineering evaluations and vibration data collection as described in Section 3 Requirements.

4.4. The Government will provide any or all applicable references from Section 2 References.

4.5. The Government will ship the AC Motor assembly to Naval Base Point Loma.

5. DELIVERY / RETURN

5.1. The Government will transport the motor to and from the contractor’s facility at the governments expense.

5.2. The Contractor is responsible for Loading and Unloading the motor to and from the Government owned truck at the Contractor’s facility.

6. General

6.1. Contractor shall provide all completed Tables in Appendix A & B to PNSDETSD TPOC within two business days once work is completed. TPOC EMAIL:

Appendix A - Page 1 of 10

Table 1:

As-arrived Insulation Resistance Tests (pre-disassembly)

Temperature-corrected to 25°C (77°F)

Insulation Resistance Measurement (high speed): ____________________MΩ Insulation Resistance Measurement (medium speed): ____________________MΩ Insulation Resistance Measurement (low speed): ____________________MΩ

Signature/ Print Name/ Date:

Table 2:

As-arrived Winding Resistance (pre-disassembly)

Measured Winding Resistance (ohms)

Corrected Winding Resistance (ohms)

T1-T2 (low speed)

T2-T3 (low speed)

T1-T3 (low speed)

T4-T5 (medium speed)

T5-T6 (medium speed)

T4-T6 (medium speed)

T11-T12 (high speed)

T12-T13 (high speed)

T11-T13 (high speed)

Appendix A - Page 1 of 10

- “Expected”: each phase is expected to be 2.3866 to 2.6378 ohms (for low speed)

- “Expected”: each phase is expected to be 0.5966 to 0.6594 ohms (for medium speed)

- “Expected”: each phase is expected to be 0.0313 to 0.0347 ohms (for high speed) Required: Each phase must be within ±3 percent of the average of the 3 phases.

Appendix A - Page 2 of 10

Table 3:

As-arrived visual inspection and shaft radial runout (pre-disassembly)

Visual inspection comments:

F.E & B.E shaft radial runout readings for informational purposes only

Expected: Not to exceed 0.001” tir.

F.E. Shaft Radial Runout: ____________ in.

B.E. Shaft Radial Runout: ____________ in.

Table 4:

After disassembly & cleaning Insulation Resistance Tests

Temperature-corrected to 25°C (77°F)

Insulation Resistance Measurement (high speed): ____________________MΩ Insulation Resistance Measurement (medium speed): ____________________MΩ

Appendix A - Page 3 of 10

Table 5:

After disassembly & cleaning Winding Resistance Tests

Measured Winding Resistance (ohms)

Corrected Winding Resistance (ohms)

T1-T2 (low speed)

T2-T3 (low speed)

T1-T3 (low speed)

T4-T5 (medium speed)

T5-T6 (medium speed)

T4-T6 (medium speed)

T11-T12 (high speed)

- “Expected”: each phase is expected to be 0.0313 to 0.0347 ohms (for high speed)

Table 6:

After disassembly & cleaning Surge Comparison Tests

Surge Comparison Test: SAT ______ UNSAT ______

Appendix A - Page 4 of 10

Table 7:

After disassembly & cleaning DC HiPot test

DC HiPot Test: SAT ______ UNSAT ______

Table 8:

After disassembly & cleaning Visual inspection of the winding insulation system

Comments:

PNSDET CODE 270 EVALUATION:

Varnish Dip Stator Windings: YES ______ NO ______

Signature/ Badge/ Date:

Appendix A - Page 5 of 10

Table 9:

After Vanish Dip & Bake Insulation Resistance Tests

Temperature-corrected to 25°C (77°F)

Insulation Resistance Measurement (high speed): ____________________MΩ Insulation Resistance Measurement (medium speed): ____________________MΩ

Table 10:

After Vanish Dip & Bake Winding Resistance Tests

Measured Winding Resistance (ohms)

Corrected Winding Resistance (ohms)

T1-T2 (low speed)

T2-T3 (low speed)

T1-T3 (low speed)

T4-T5 (medium speed)

T5-T6 (medium speed)

T4-T6 (medium speed)

T11-T12 (high speed)

- “Expected”: each phase is expected to be 0.0313 to 0.0347 ohms (for high speed)

Appendix A - Page 6 of 10

Table 11:

After Vanish Dip & Bake Surge Comparison Tests

Surge Comparison Test: SAT ______ UNSAT ______

Table 12:

After Vanish Dip & Bake DC HiPot test

DC HiPot Test: SAT ______ UNSAT ______

Table 13:

After Vanish Dip & Bake Visual inspection of the insulation system

Comments:

Appendix A - Page 7 of 10

Table 14:

After Re-assembly Insulation Resistance Tests

Temperature-corrected to 25°C (77°F)

Insulation Resistance Measurement (high speed): ____________________MΩ Insulation Resistance Measurement (medium speed): ____________________MΩ

Table 15:

After Re-assembly Winding Resistance Tests

Measured Winding Resistance (ohms)

Corrected Winding Resistance (ohms)

T1-T2 (low speed)

T2-T3 (low speed)

T1-T3 (low speed)

T4-T5 (medium speed)

T5-T6 (medium speed)

T4-T6 (medium speed)

T11-T12 (high speed)

- “Expected”: each phase is expected to be 0.0313 to 0.0347 ohms (for high speed)

Appendix A - Page 8 of 10

Table 16:

After Re-assembly visual inspection and shaft radial runout

Visual inspection comments:

F.E & B.E shaft radial runout readings

Required: Not to exceed 0.001” tir.

F.E. Shaft Radial Runout: ____________ in.

B.E. Shaft Radial Runout: ____________ in.

Table 17:

After Re-assembly axial end play measurement.

Axial End Play: _____________ in.

SAT/UNSAT ____________

Required:

- Force must be less than 1455 lbs (150 percent of the rotating assembly weight.)

- Total axial end play must be greater than 0.003” but not exceed 0.005”.

Appendix A - Page 9 of 10

Table 18:

After Re-assembly operational test (test data)

Motor Speed:

(low speed): ___________ RPM

(medium speed): ___________ RPM

(high speed): ___________ RPM

Input Wattage:

(wattage measured must not exceed the following values:

300 RPM: 1208 Watts 600 RPM: 1438 Watts 1200 RPM: 3335 Watts

(low speed): ___________ watts

(medium speed): ___________ watts

(high speed): ___________ watts

Input Current:

(low speed): ___________ amps

(medium speed): ___________ amps

(high speed): ___________ amps

Voltage:

(low speed): ___________ volts

(medium speed): ___________ volts

(high speed): ___________ volts

Power Factor (if instrumentation is not available, write in “N/A”) (low speed): ___________ (medium speed): ___________ (high speed): ___________

Appendix A - Page 10 of 10

Table 19:

After Re-assembly operational test (temperature rise)

Permissible temperature rises (above ambient):

- 60°C (108°F) for frame

- 40°C (72°F) for bearings (measured at end bracket)

Record Temperatures: Low Speed Medium Speed High Speed

Ambient: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

Frame - Start: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

- End: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

F.E. Bearing - Start: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

- End: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

B.E. Bearing - Start: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

- End: ___________ (°C/°F) ___________ (°C/°F) ___________ (°C/°F)

SAT/UNSAT: ___________

Table 20:

After Operational test Insulation Resistance

Temperature-corrected to 25°C (77°F)

Insulation Resistance Measurement (high speed): ____________________MΩ Insulation Resistance Measurement (medium speed): ____________________MΩ

Appendix B - Page 1 of 3

Temperature Correction Factor for Insulation Resistance (IAW NSTM Ch. 300)

Component Temp

Correction Factor to

25°C

Component Temp Correction Factor to

25°C

Component Temp Correction Factor to

25°C °C °F °C °F °C °F 10 50 0.35 44 111.2 3.73 78 172.4 39.40 11 51.8 0.38 45 113 4.00 79 174.2 42.22 12 53.6 0.41 46 114.8 4.29 80 176 45.25 13 55.4 0.44 47 116.6 4.59 81 177.8 48.50 14 57.2 0.47 48 118.4 4.92 82 179.6 51.98 15 59 0.50 49 120.2 5.28 83 181.4 55.72 16 60.8 0.54 50 122 5.66 84 183.2 59.71 17 62.6 0.57 51 123.8 6.06 85 185 64.00 18 64.4 0.62 52 125.6 6.50 86 186.8 68.59 19 66.2 0.66 53 127.4 6.96 87 188.6 73.52 20 68 0.71 54 129.2 7.46 88 190.4 78.79 21 69.8 0.76 55 131 8.00 89 192.2 84.45 22 71.6 0.81 56 132.8 8.57 90 194 90.51 23 73.4 0.87 57 134.6 9.19 91 195.8 97.01 24 75.2 0.93 58 136.4 9.85 92 197.6 103.97 25 77 1.00 59 138.2 10.56 93 199.4 111.43 26 78.8 1.07 60 140 11.31 94 201.2 119.43 27 80.6 1.15 61 141.8 12.13 95 203 128.00 28 82.4 1.23 62 143.6 13.00 96 204.8 137.19 29 84.2 1.32 63 145.4 13.93 97 206.6 147.03 30 86 1.41 64 147.2 14.93 98 208.4 157.59 31 87.8 1.52 65 149 16.00 99 210.2 168.90 32 89.6 1.62 66 150.8 17.15 100 212 181.02 33 91.4 1.74 67 152.6 18.38 101 213.8 194.01 34 93.2 1.87 68 154.4 19.70 102 215.6 207.94 35 95 2.00 69 156.2 21.11 103 217.4 222.86 36 96.8 2.14 70 158 22.63 104 219.2 238.86 37 98.6 2.30 71 159.8 24.25 105 221 256.00 38 100.4 2.46 72 161.6 25.99 106 222.8 274.37 39 102.2 2.64 73 163.4 27.86 107 224.6 294.07 40 104 2.83 74 165.2 29.86 108 226.4 315.17 41 105.8 3.03 75 167 32.00 109 228.2 337.79 42 107.6 3.25 76 168.8 34.30 110 230 362.04 43 109.4 3.48 77 170.6 36.76

NOTES:

(1) The measured value of insulation resistance does not require correction to 25°C if either of the following conditions is satisfied:

a. The measured value is equal to or greater than the minimum value specified in the test document and the temperature at the time of measurement is 25°C (77°F) or higher.

b. The measured value is equal to or greater than twice the minimum value specified in the test document and the temperature at the time of measurement is 15°C (59°F) or higher.

(2) If the insulation resistance was not corrected to 25°C, write N/A in the IR correction block.

(3) To obtain corrected insulation resistance, multiply the measured insulation resistance by the correction factor in the table at the measured component temperature.

(4) Beyond the table range consult Code 270.

(5) The Correction Factor is based upon a two-fold increase of insulation resistance for every 10 °C decrease in temperature, given by the following formula:

(6) Fahrenheit/Centigrade conversion formulas are °F = [(9/5 x °C) + 32] and °C = [5/9 x (°F - 32)].

Appendix B - Page 2 of 3

Temperature Correction Factor for Copper Winding Resistance

Component Temp Correction

Factor to 25°C

Component Temp Correction

Factor to 25°C °C °F °C °F

0 32 1.1065 31 87.8 0.9974

5 41 1.0834 32 89.6 0.9738

10 50 1.0613 33 91.4 0.9701

11 51.8 1.0570 34 93.2 0.9665

12 53.6 1.0527 35 95.0 0.9629

13 55.4 1.0484 36 96.8 0.9594

14 57.2 1.0442 37 98.6 0.9558

15 59.0 1.0400 38 100.4 0.9523

16 60.8 1.0359 39 102.2 0.9489

17 62.6 1.0318 40 104.0 0.9454

18 64.4 1.0277 45 113.0 0.9285

19 66.2 1.0236 50 122.0 0.9122

20 68.0 1.0196 55 131.0 0.8965

21 69.8 1.0156 60 140.0 0.8813

22 71.6 1.0117 65 149.0 0.8666

23 73.4 1.0078 70 158.0 0.8523

24 75.2 1.0039 75 167.0 0.8386

25 77.0 1.0000 80 176.0 0.8253

26 78.8 0.9962 85 185.0 0.8123

27 80.6 0.9924 90 194.0 0.7998

28 82.4 0.9886 95 203.0 0.7877

29 84.2 0.9848 100 212.0 0.7759

30 86.0 0.9811 105 0.7645

To convert resistance readings at any given temp to 25°C, multiply by the factor.

To convert resistance at 25°C to any other temp, divide by the factor.

Appendix B - Page 3 of 3

BOLT

NUT

STUD

SIZE

(INCH)

HEXAGON

HEAD BOLT

GRADE 1 & 2

HEXAGON

HEAD BOLT

GRADE 5

HEXAGON

HEAD BOLT

GRADE 8

NO MARKING 3 RADIAL LINES 6 RADIAL LINES

CARBON STEEL

CORROSION

CARBON STEEL ALLOY

STEEL

CARBON ALLOY STEEL

1/4 2-4 6-8 9-12 5/16 4-8 13-17 18-25 3/8 6-12 23-30 35-45 7/16 10-20 35-50 55-70 1/2 15-30 55-75 80-110 9/16 23-45 80-110 110-150 5/8 30-60 110-150 170-220 3/4 50-100 200-260 280-380 7/8 80-160 300-400 460-600 1 123-245 440-580 680-900 1-1/8 195-390 600-800 960-1280 1-1/4 273-545 840-1120 1360-1820 1-3/8 365-730 1100-1460 1780-2380 1-1/2 437-875 1460-1940 2360-3160

Applicable to UNC, NC, UNF and NF threads, Class 2 and 3 fits.

Stud grade marking identical to that for hexagon head bolts. Symbols appear on nut end of stud.

Nut grade marking is applied to the top face of nut. Grades 1 and 2, no marking; grade

5, three raised dashes; grade 8, six raised dashes.

Applicable to plated and non-plated fasteners with no lubrication applied to threads.

Multiply by 12 to convert to inch pounds.

Values obtained from (NSTM CH 244).

Table 21:

Torque specs requiring documentation (write in actual torque value applied)

F E. Bearing Locknut Torque: ____________ ft-lbs Required: 220 to 440 ft-lbs

B.E. Bearing Locknut Torque: ____________ ft-lbs Required: 220 to 440 ft-lbs

F.E. Balance Disk Locknut Torque: ____________ ft-lbs Required: 165 to 248 ft-lbs