Attachment 2 SOW.pdf

REVISION No. . CHANGE No. .

STATEMENT OF WORK

COVER SHEET

TITLE

STATEMENT OF WORK FOR VENDOR CONTRACT

TO FACTORY OVERHAUL 140’ WTGB DC MAIN

PROPULSION GENERATOR STATOR

ORIGINATED BY Becky Davis DATE 17 August 2023

ORIGINATOR’S COMMAND SURFACE FORCES LOGISTICS CENTER

DEPARTMENT/DIVISION IBCT PRODUCT LINE

INTERNAL REVIEWER DATE _______

SOWRB APPROVAL _____________________________________ DATE _______

STATEMENT OF WORK FOR VENDOR CONTRACT TO FACTORY OVERHAUL

140’ WTGB DC MAIN PROPULSION GENERATOR ASSEMBLIES

1.0 SCOPE

1.1 General. This Statement of Work (SOW) describes the requirements for factory overhaul of 140’ WTGB main propulsion generator stator. The Vendor will supply technical expertise, facilities, services, labor, materials and any other resources required to return propulsion generator stator to like new conditions.

1.2 Government Furnished Property:

1.2.1 Stator Assembly, Part Number 1578F48G01, NSN 6115-01-359-9187

1.3 Background. These six poles, 1000 kW, 900 VDC machines were originally manufactured by the Heavy Industry Motor Division of Westinghouse Electric Corporation at their Round Rock, Texas factory between 1977 and 1985. Main propulsion generator assemblies, removed from vessels or the Government’s warehouse, may have been modified by third party electrical machinery service shops during their lifetime. The stator will be overhauled to be returned to original design and configuration to ensure compatibility and interchangeability with existing shipboard machinery.

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents – The following documents form a part of this statement of work to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.1.1 USCG Surface Forces Logistics Center (SFLC) Documents

a. Technical Manual TP 1986, SWBS 235, Section A, Cleaning Procedures for Direct Current Propulsion Motors and Generators

b. Technical Manual TP 3475, SWBS Number 235, Section H, Propulsion Electric Equipment – Propulsion Generator

c. Technical Manual TP 3475, SWBS Number 235, Section K, Propulsion Electric Equipment – Maintenance

d. D-084-0481 REV B, Engineering Change Equipment Unit Preservation, Packaging and Marking

e. Standard Specification 2351, 2014, Overhaul DC Generators & Motors

2.1.2 Military Specifications

a. MIL-STD-2073-1E (2011), Standard Practice for Military Packaging http://www.uscg.mil/SFLC/mlclant/vdiv/docs/std_2014/SFLC-Std-Spec-2351.pdf

2.2 Commercial Documents – The following documents form a part of this statement of work to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.2.1 American National Standards Institute (ANSI)

a. ANSI/EASA (Electrical Apparatus Service Association) AR-100 (2020), Recommended Practice for the Repair of Rotating Electrical Apparatus

b. ANSI/NCSL (National Conference of Standards Laboratories) Z540.3-2006 (R2013), Calibration Laboratories, Measuring and Test Equipment – General Requirements

c. ASQ/ANSI/ISO (American Society for Quality) 9001:2015, Quality Management Systems – Requirements

2.2.2 Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE Std 43-2013, Recommended Practice for Testing Insulation Resistance of Rotating Machinery

b. IEEE Std 113-1985, Test Procedures for Direct-Current Machines

c. IEEE Std 432-1992, Guide for Insulation Maintenance for Rotating Electric Machinery (5 HP to less than 10,000 HP)

2.2.3 National Electrical Manufacturers Association

a. NEMA MG-1-2021, Motors and Generators

b. NEMA CB-1-2000 (R2012), Brushes for Electrical Machines

2.2.4 Society of Naval Architects and Marine Engineers (SNAME)

a. SNAME 3-39-2018, Guide for Shop and Installation Tests

2.3 Original Equipment Manufacturer (OEM) Documentation

2.3.1 TECO-Westinghouse Motor Company (TWMC)

a. I.B. 3500-50B-1962, Instructions for Direct Current Generators and Motor Technical Manual (proprietary)

2.4 Specification Order of Precedence – In the event of a conflict between the text of this statement of work and the references cited herein, this document shall take precedence.

3.0 REQUIREMENTS

3.1 General – The Vendor shall overhaul USCG Bay class cutter main propulsion generator assemblies as detailed below. Such work shall be performed in accordance with the policies and procedures described in the references above and this document. Tasks shall include receiving, packaging, shipping, testing, reporting, repairing, and cleaning of one magnet frame (field). The Vendor shall provide all labor, materials and engineering necessary to accomplish the task.

3.2 Vendor Proprietary Specifications and Procedures

3.2.1 Overhaul the generator assemblies in accordance with the generic guidance of SFLC STD Spec 2351, substituting the more current revision of ANSI/EASA AR-100 listed in Section 2.2 above. Section 3.1.3 of SFLC Std Spec 2351 regarding membership in the Electrical Apparatus Service Association (EASA) does not apply to the original equipment manufacturer (TWMC). Because the overhauled generator components will not be assembled to form a working machine, operational test requirements are not applicable.

3.2.2 The Vendor may utilize in house or proprietary specifications or procedures to accomplish work necessary for this task when these documents or procedures are superior to those in the references listed above or described in this document. The Vendor must submit a brief summary highlighting the superiority of their specification or procedure.

The USCG will provide written approval for this deviation.

3.2.3 The Government recognizes that the OEM may have made design improvements to their DC generator product line since the generators were purchased and will entertain recommended improvements. Such could include the following:

a. Temperature class H insulation for class F when components are to be rewound.

b. Vacuum pressure impregnated varnish application in lieu of traditional dip tank methods.

c. Changes in design that minimize the collection of carbon dust and other contaminants in areas which are difficult or impossible to access under normal conditions.

3.3 Contract Line Items – Support provided by the Vendor shall include the following contract line item numbers (CLIN). Detailed descriptions of the contract line items can be found in Appendix A. These CLINs are applicable as noted below in Table 1 to all generator assemblies received by the Vendor. The following are summaries of contract line items:

CLIN 1: Field assembly cleaning, inspection, testing and conditioning

This line item cleans, inspects and tests the field assembly on the magnet frame, including all windings, mountings, bus work, interconnections, and brush riggings. Upon satisfactory testing, the field assembly is reconditioned.

• Clean field assembly

• Inspect magnet frame for flashover damage

• Perform inspections and testing of all windings and brush rigging assemblies

• Clean, test and condition field assembly

CLIN 2: Shunt field assembly rewind

This line item rewinds a main field pole and associated compensating (pole face) winding on the magnet frame if inspection or test results determine that a rewind is necessary. This CLIN may be invoked multiple times in the event that more than one pole requires rewinding. The work excludes tasks performed under CLIN 1 and includes the following:

• Rewind shunt field and compensating windings to original design and current OEM standards

• Shim main pole assembly to original design specifications

CLIN 3a: Commutating (interpole) field assembly replacement

This line item replaces a commutating field pole on the magnet frame if inspection or test results determine it is necessary. At least one interpole is believed to be shorted. This CLIN may be invoked multiple times in the event that more than one interpole requires replacement. The work excludes tasks performed under CLIN 1 and includes the following:

• Replace commutating field pole coil, with one made from new wire, to match original design and current OEM standards

• Shim inter pole assembly to original design specifications

CLIN 3b: Commutating (interpole) field assembly re-insulate.

This line item re-insulates a commutating field pole on the magnet frame if inspection or test results determine it is necessary. At least one interpole is believed to be shorted. This CLIN may be invoked multiple times in the event that more than one interpole requires re-insulation. The work excludes tasks performed under CLIN 1 and includes the following:

• Re-insulate the existing commutating field to original design and current OEM standards

• Shim inter pole assembly to original design specifications

CLIN 4: Package and ship

This line item packages and ships the generator assemblies.

• Package one magnet frame

• Mark all components in accordance with SFLC-D-084-0481

• Ship to destination

3.4 CLIN Applicability – Due to the nature of the work to be performed, not all CLINs will be applicable to each generator assembly. The work performed on each assembly will follow a standard set of CLINs as shown in Table 1 below.

Table 1

CLIN DESCRIPTION APPLICABLILITY CONDITIONAL

1 Field Assembly Clean & Test Magnet frame REQUIRED 2 Main Field Pole Rewind* Magnet frame OPTIONAL 3 Commutating Field Pole Rewind*† Magnet frame OPTIONAL 4 Packaging & Shipping All REQUIRED

* Priced on a per pole basis; may be invoked multiple times † At least one interpole is believed to be shorted ‡ Priced on a per armature rotor basis; may be invoked multiple times

3.5 Place of Performance – The primary place of performance shall be the Vendor’s generator repair facility.

3.6 Reports

For each generator assembly being overhauled the Vendor shall retain records of all tests and submit them to the Contracting Officer. The performance of tests and the preparation of reports shall follow the guidance of SNAME T&R Bulletin 3-39, Guide for Shop and Installation Tests.

3.6.1 Weekly Progress Reports – For each generator being overhauled, the Vendor shall submit weekly progress reports to the USCG summarizing work accomplished in the previous week, work scheduled for the upcoming week, milestones accomplished and internal problems (loss of equipment, employees, etc.) affecting schedule. Weekly reports shall begin when the Vendor takes control of the generator assembly and cease when the Vendor ships the generator assembly back to the USCG facility.

3.6.2 Condition Found Report – Submit a condition found report (CFR) upon completion of each inspection and test, along with a copy of all recorded test data.

Include any corrective action reports in the CFR for any failed tests or inspections.

a. Test Data – Test data shall be generated and submitted for each test conducted.

This shall include a description of the test setup, a description of the procedure, photographs from two adjacent sides, test equipment calibration data, logs of times for start and finish and any measurements taken during the test. Test data shall be generated for both passed and failed tests. All testing shall meet the requirements as identified herein or by section 3.2.

b. Corrective Action Report – If the specified item fails to pass any inspection or test, the Vendor shall provide a corrective action report (CAR) in the CFR. The CAR shall document the failure and the recommended corrective action for the Contracting Officer’s review. The CAR shall include a brief summary of test data, the standards the test data fails, the cause for failure, the recommended method of correction, pictures and a reference to any relevant CFRs. If approved, the corrective measures shall be executed in accordance with this SOW.

3.6.3 Final Report – A final report shall be issued upon completion of each generator assembly overhaul. The final report shall include summaries for each assembly describing its received condition, the tests run, the test equipment used, the QA procedures performed, the personnel conducting the tests, the repairs made, and the final condition.

3.7 Notification of Inspections and Tests – The Coast Guard reserves the right to witness any or all of the tests performed. The Vendor shall notify the Contracting Officer at least fourteen

(14) calendar days prior to the performance of any QA inspections, monitored inspections or testing required herein. The Contracting Officer’s representatives shall have the option to be present to witness the performance of all tests, inspections, and cleaning operations. The Vendor shall request written approval before conducting any potentially destructive tests.

3.8 Material Transportation and Release – The Vendor shall be responsible for transportation of Government Furnished Equipment (GFE), as required herein, from his plant back to the specified Government delivery point after testing and packaging.

3.9 Delivery of Materials – Components shall be preserved, packaged and marked in accordance with SFLC-D-084-0481. The overhauled components shall be packaged in the same shipping containers in which they were received from the Government. Ensure that all previous crate stencils remain legible.

3.10 Material – All material purchased by the Vendor for use in this equipment shall be new and any shelf life must not have expired prior to job completion. The Vendor shall provide the Contracting Officer with a list of all materials to be used for approval, citing the brand names, quantities, and specifications to which they conform. Material containing silicone or mercury shall not be used.

4.0 QUALITY ASSURANCE

4.1 Responsibility for Inspection – The Vendor shall be responsible for the performance of all inspection requirements specified herein. The Vendor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Vendor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth in this scope of work where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2 Responsibility for Compliance – All items shall meet the requirements of sections 3 and 5.

The inspections set forth in this statement of work shall become part of the Vendor’s overall inspection system or quality program. The absence of any inspection requirements in this scope of work shall not relieve the Vendor of the responsibility of assuring that all products or services submitted to the government for acceptance comply with all requirements of the contract.

Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3 Quality System – The Vendor shall maintain a documented Quality System in accordance with ASQ/ANSI/ISO 9001.

4.4 Calibration System – The Vendor, as well as any subcontractors, shall maintain a test equipment calibration program conforming to NCSL Z540.3. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this scope of work.

4.5 Inspections and Tests – The inspections and tests required herein are the minimum required and are not intended to replace any controls, examinations, inspections or tests normally employed by the Vendor to assure the quality of the equipment. See IEEE-STD-113 Section 5 for details of each test.

4.5.1 A Coast Guard Quality Assurance Representative may visit the Vendor’s facility prior to acceptance to witness and/or inspect the following:

a. Final Report – see paragraph 3.6.3.

b. Quality Assurance Plan – see section 4.3

c. Final generator assembly testing – see section 3.7

d. Preservation, Packaging and Marking, see part 5.0

4.6 Failure Responsibility – If a generator assembly fails to pass any inspection or test, the Vendor shall report the failure and their recommendation for corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

4.6.1 The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

4.6.2 The inspection or test shall be discontinued until all corrective action has been taken.

4.6.3 After all corrective action has been taken; the inspection or test shall be continued or repeated, at the option of the Contracting Officer.

4.6.4 Acceptance shall be withheld until re-inspection has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

4.6.5 All corrective actions shall be documented as part of the Vendor’s quality inspection system, and submitted for approval to the Contracting Officer.

4.6.6 Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and steps taken to prevent a recurrence of each defect.

4.7 Reports – One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer for each motor covered herein with the final report.

4.7.1 A copy of any test, inspection, or calibration record for the motor to be tested shall also be turned over to the Quality Assurance representative upon his arrival at the Vendor’s plant.

4.8 Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units.

5.0 PRESERVATION, PACKAGING AND MARKING (PP&M)

5.1 Preservation

5.1.1 Internal and external cleaning shall be in accordance with OEM specifications.

5.1.2 Each motor shall be preserved in accordance with MIL-STD-2073-1E, paragraph 5.2.3.7.1, Method 51 (water vaporproof bag with desiccant, heat sealed).

5.2 Packaging

5.2.1 The stator assembly shall be individually packed in its own reusable wooden crate with a removable cover, constructed as described below and in accordance with ASTM D7478, Type II, Class 1 or 2, Style a.

a. The crate base shall be mounted on solid wood 4” x 4” skids with a metal strip screwed to the front and back of the base to allow the cover to be attached (bolted) to it.

b. The top of the crate shall have eye bolts installed in each corner to allow the cover to be craned off.

c. If more than one crate is required for an assembly, each crate shall be marked “Box 1 of 2” and “Box 2 of 2” or as appropriate.

5.3 Marking – The marking described herein shall be placed on the longest two sides of each box (on opposite ends).

5.3.1 Each container shall be marked in legible 2” (minimum) high black waterproof print on a white contrasting background with the following information:

a. For stator assemblies:

STOCK NUMBER NSN 6115-01-359-9187

ITEM NAME Stator Assembly

PART NUMBER 1578F48G01

CONTRACT NUMBER (See Contract) GROSS WEIGHT (As Determined by Vendor)

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 EA

DATE OF MANUFACTURE (As determined by Vendor)

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT DESTROY

5.4 Bar Coding – Bar code labels shall be supplied on all CLINs except for those that require data submissions only.

5.4.1 All bar coded labels shall be in accordance with SFLC specification D-000-0100.

a. The actual labels shall be Type "V", Grade "A", Style "2", Composition "b" with plastic laminate.

b. Each label shall contain encoded data for the Stock Number.

c. The Bar Code label may be applied separately or as part of the marking required in 5.3 of this scope of work.

6.0 NOTES

6.1 Document Sources

6.1.1 Coast Guard Documents

a. USCG Surface Forces Logistics Center Contracting & Procurement Division (CPD2-IBCT) Coast Guard Island, BLDG 55 Alameda, CA 94501

6.1.2 Other Government Documents

a. Defense Logistics Agency (DLA) ASSIST Quick Search at http://quicksearch.dla.mil

6.1.3 Commercial Documents

a. American Society for Quality (ASQ) 600 North Plankinton Avenue Milwaukee, WI 53203 http://www.asq.org

b. American Society for Testing and Materials (ASTM) 100 Barr Harbor Drive P.O. Box C700 West Conshohocken, PA 19428-2959 http://www.astm.org/

c. National Conference of Standards Laboratories (NCSL) 2569 Park Lane, Suite 204 Lafayette, CO 80026 http://www.ncsli.org

d. Institute of Electrical and Electronic Engineers (IEEE) 445 Hoes Lane http://www.asq.org/ http://www.astm.org/ http://www.ncsli.org/

Piscataway, NJ 08855 http://www.ieee.org

e. National Electrical Manufacturers Association (NEMA) 17th St N, #900 Arlington, VA 22209 http://www.nema.org http://www.ieee.org/ http://www.nema.org/

1.3 Background. These six poles, 1000 kW, 900 VDC machines were originally manufactured by the Heavy Industry Motor Division of Westinghouse Electric Corporation at their Round Rock, Texas factory between 1977 and 1985. Main propulsion generator ass...

2.4 Specification Order of Precedence – In the event of a conflict between the text of this statement of work and the references cited herein, this document shall take precedence.

3.6.3 Final Report – A final report shall be issued upon completion of each generator assembly overhaul. The final report shall include summaries for each assembly describing its received condition, the tests run, the test equipment used, the QA proc...

4.8 Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units.