DRAFT_PWS_SLD_111220.pdf

Performance Work Statement

DRAFT

1. Title: Code 700 Stiff Leg Derrick (SLD) Motor/Generator Skid Removal, Overhaul and installation.

2. Technical Point of Contact (TPOC): TPOC information will be provided upon award.

3. Period of performance: 09AUG2021 to 15OCT2021 Beginning on 09AUG2021, contractor will commence pre‐inspections, match‐marking and rigging operations in accordance with the requirements as identified in the Scope of Work (Sec

5) to remove the Motor/Generator skid from the SLD Machine House. Rigging, installation, testing and all final inspections are to be completed by 15OCT2021.

4. Background: Portsmouth Naval Shipyard Code 700 requires that the Motor/Generator skid in the SLD Machine house be removed, refurbished and installed to return the equipment to OEM specifications. The need has been established by the annual review of testing of the equipment during preventive maintenance periods.

5. Scope of work:

It is the Government’s expectation that the MOTOR/GENERATOR SKID will meet or exceed OEM Specifications and Naval Ships’ Technical Manual Chapter 300 Electric Plant – General (NSTM 300) requirements once contract is fully executed.

Winning bidder is responsible for all transportation costs of the MOTOR/GENERATOR SKID from Portsmouth Naval Shipyard to contractor’s overhaul facility and back to Portsmouth Naval Shipyard.

CLIN 0001

DISCONNECT AND REMOVE MOTOR / GENERATOR SKID.

Pre‐inspection of GENSET – Electrical/Mechanical

Permanent match mark all footings and record the amount and location of shims, keepers and alignment pins/fasteners during disassembly and assembly.

CDRL A ‐ DUE 20AUG2021 ‐ Pre‐disassembly vibration check of motor‐generator set data shall be provided to the Government.

CDRL A‐ DUE 20AUG2021 ‐ Pre‐disassembly alignment check of each of the GENSET couplings shaft‐to‐shaft shall be provided to the Government.

CDRL A‐ DUE 20AUG2021 ‐ A copy of the existing and final amount and location of footing shims, keepers and alignment pins shall be provided to the Government.

The existing coupling shaft‐to‐shaft angular and parallel alignment shall be measured and recorded before disassembling any couplings. After unbolting the coupling flanges and before coupling removal, measure and record axial coupling hub location on shafts (from shaft end).

CDRL A‐ DUE 20AUG2021 ‐ A copy of the existing coupling shaft‐to‐shaft alignment data and coupling location on the shafts shall be provided to the Government.

Verify and record the amount and thickness of shims and their location under the foundation after foundation removal. See above Match Mark note. Retain the existing foundation fasteners for use during final installation. The contractor shall submit a document outlining the planned procedure for any rigging lift plan to the Government for approval prior to removal or installation of the skid. As Built states a total skid weight of 42,165 lbs. equally split on 8 mounting studs with an unknown Center of Gravity. The Government cannot guarantee that weight is accurate and recommends using 50,000 lbs. as the skid weight for bidding purposes.

CLIN 0002

REMOVE/DISASSEMBLE MOTOR – GENERATORS FROM SKID.

The insulated coupling between the 1000 HP Motor and Main/Aux Generator shall have special attention. The insulated coupling bolts are constructed with an insulating surface on the shank of the bolt. There is a metal washer and an insulating washer for each coupling bolt.

The metal washer goes immediately underneath the coupling bolt head. The insulating washer goes under the metal washer. Turn only the nuts during disassembly / torquing / assembly to avoid damaging the insulating washers. Save these insulated fasteners, metal and insulating washers, and nuts for re‐use.

Verify and record the amount and thickness of shims and their location under the motor – generator feet after motor‐generator removal. See above Match Mark note. Save the existing mounting fasteners.

Clean/Refurbish the following AC motors:

AC Induction motor (GE Model # 8310783801) Type K Frame 8311SU

1000 HP

1228 Amps

AC Blower Motor (GE Model # SKW215BD305A)

5 HP, 60 HZ

3 Phase, 200*‐230/460 Volts

1160 RPM

AC Blower Motor (GE Model # 5K49QG90541) 3 Phase, 200/400 volts 5.74/2.87 Amps

1725 RPM

Use the following Refurbishment guidelines for the AC motors. Note that all Megger values shall be temperature corrected to 25 degrees Celsius:

‐ Incoming electrical inspection:

a. Megger both Stator and Rotor

b. High‐Potential

c. Surge Comparison Test

d. Electrical Balance of Windings

‐ Measure Shaft runout ‐ Dismantle and inspect all parts ‐ Provide a copy of any pictures of the motor internal problem areas.

‐ Inspect/replace wire leads as needed.

‐ Steam clean, bake, insulate (Vacuum Pressure Impregnation (VPI), prime and paint exterior to match existing (presently unpainted items, e.g. machined surfaces, shall remain unpainted), and paint internals with an insulating paint such as Glyptal.

‐ Measure and Record all Mechanical Fits.

‐ Perform Core Loss Test if there is any indication of rotor rubbing on iron core.

‐ Burn out and strip windings, wind and connect.

‐ Dynamically balance rotating parts.

‐ Replace any tywraps with seizing cord.

‐ Replace bearings with sealed bearings (remove and plug grease fittings if present). Bearings must be rated as equal or better. Bearing part numbers and OEM specification/engineering sheets shall be provided to the Government.

‐ Retain all wire numbers/marking along with thermal sleeving and routing during re‐ assembly to facilitate remounting/connection to the crane.

‐ Replace junction box bushed Liquid Tight connector with same size as presently installed, seal to junction box.

‐ Reassemble ‐ Perform post electrical tests:

a. Megger

Stator shall be greater than 1000 MΩ

Rotor shall be greater than 100 MΩ

b. High‐Potential per NSTM 300

c. Surge Comparison per NSTM 300

d. Electrical Balance of Windings

‐ Run motor at rated voltage ‐ Post installation check of correct motor operation during crane operation

CDRL B‐ DUE 08OCT2021 ‐ Supply report with above work/findings (include indicated runout reading, dynamic balancing readings) and part numbers of any replaced parts.

Clean/Refurbish the following DC generators:

DC Flat Comp Wound Generator (GE Model # 5CD203PA947A800)

33 KW

250 Volts Arm. Amps – 132 A FLD Amps – 5.7 A

DC Shunt Wound Generator (GE Model # 5CD463PA825C800)

500 KW

250 Volts Arm. Amps – 2000 A FLD Amps – 5.45 A

DC Shunt Wound Generator (GE Model # 5CD222NA861B800)

60 KW

250 Volts Arm. Amps – 240 A FLD Amps – 2 A

DC Shunt Wound Generator (GE Model # 5CD224TA847B800)

150 KW

250 Volts Arm. Amps – 600 A FLD Amps – 8.2 A

Use the following Refurbishment guidelines for the DC generators. Note that all Megger values shall be temperature corrected to 25 degrees Celsius:

‐ Visually inspect motor before disassemble ‐ Incoming electrical inspection:

a. Megger both Field and Armature

b. High‐Potential

c. Surge Comparison Test

d. Electrical Balance of Windings

‐ Check Brush‐spring tension, check springs for current damage ‐ Dismantle and inspect generator

a. Inspect brush‐holders, verify brush grade and condition

b. Verify brush‐holder spacing around commutator circumference

c. Inspect commutator for evidence of electrical problems

d. Dissect and inspect bearings for circulating currents.

e. Check lead condition (replace if necessary), inspect lugs, connection at fields/ interpoles / brush‐holders.

f. Verify presence/absence of lead jumpers on brush‐holders.

g. Measure all bearing fits, verify compliance with AFBMA specifications.

h. Rewind Armature

i. Rewind / Reinsulate interpoles.

j. Rewind / Reinsulate Shunt and Series Field Poles

k. Turn, undercut and polish commutator; chamfer bar edges for optimal brush performance

l. Steam clean, bake, insulate (Vacuum Pressure Impregnation (VPI), prime and paint exterior to match existing (presently unpainted items, e.g. machined surfaces, shall remain unpainted), and paint internals with an insulating paint such as Glyptal.

m. Dynamically balance armature to ISO 1940 G 2.5 or better.

n. Replace tywraps with seizing cord.

o. Clean brush‐holders assembly

p. Replace bearing with sealed bearings (remove and plug grease fittings if present).

Bearings must be rated as equal or better. Bearing part numbers and OEM specification/engineering sheets shall be provided to the government.

q. Supply, install and seat new brushes (supply new part number)

r. Set electrical neutral, verify correct lead markings (retain all wire numbers/marking to facilitate hooking back up to crane), and verify mechanical end‐play.

s. Replace junction box bushed Liquid Tight connector with same size as presently installed and seal to junction box.

‐ Test‐run unit, verify electrical performance; check and record full‐spectrum vibration analysis. Take readings on all three axes on both ends, with IRD 880 or CSI 2110.

‐ Load test all DC generators.

‐ Install new Plexiglas covers.

‐ Perform post electrical tests:

e. Megger

Shunt Field shall be greater than 1000 MΩ

Complete Armature Circuit shall be greater than 1000 MΩ

f. High‐Potential per NSTM 300

g. Surge Comparison per NSTM 300

h. Electrical Balance of Windings

‐ Post installation check of correct generator operation during crane operation

CDRL B‐ DUE 08OCT2021 ‐ Supply report with above work/findings (include indicated runout reading, dynamic balancing readings) and part numbers of any replaced parts and provide a copy of any motor internal problem areas.

MOUNTING FASTENERS

Component mounting fasteners shall be re‐used. If these mounting fasteners need to be replaced due to damage, they shall be replaced with same grade and length and washer arrangement unless due to final vertical alignment the fastener needs to be longer or shorter to prevent bottoming out of the nut on the shank threads and fastener threads on tapped holes. Threaded connections shall have a hardened steel flat washer under each turned element, either the head or nut. Mounting connections with slotted holes (or holes larger than standard ASTM oversize) in the feet or flanges of housings shall have a 5/16” thick steel cover plate with a drilled hole to match the fastener diameter and overall dimensions to completely cover the slot. Washers shall sit flat. ASTM F436 hardened steel flat washers may be used and clipped per ASTM standard to suit interferences. Hardened steel flat washers shall be used to replace any washers that are damaged and bent. Mounting fasteners shall be torqued to applicable industry standards. A copy of the industry standard used for torquing and the specific torque applied per mounting fastener arrangement shall be provided to the Government. Any changes to mounting fastener arrangement shall be submitted to the Government and must be approved by the Government prior to execution.

COUPLINGS

OEM specifications for fastener torque and lubricant quantities shall be provided to the Government.

New coupling fasteners and gasket and O‐ring seal kits from Amerigear shall be provided for coupling re‐assembly. Only the insulating coupling fasteners shall be reused (new gaskets [qty.

– 2] and an O‐ring seal kit for this coupling will be required). Falk Long Term Grease shall be used as coupling lubricant.

Reassemble the coupling components the way they came off the shafts (see pre‐alignment match‐markings noted above). Use OEM guidelines for re‐assembly. The keys/keyways shall be internally sealed with sealant such as Ultra Blue or The Right Stuff prior to mounting motor‐ generators on the skid. Lubricate coupling internals using OEM guidelines as to lubricant quantity. Torque coupling fasteners per OEM guidelines. See following additional guidelines for the insulated coupling between the 1000 HP Motor and Main/Aux Generator.

Insulated Coupling ‐ Amerigear FI 204½ coupling between 1000 HP Motor and Main/Aux Generator notes.

a. The two coupling halves are separated by a phenolic insulating gasket/spacer. There is a paper gasket on each side of the phenolic insulating gasket/spacer. Since this phenolic insulating gasket/spacer separates the coupling in half, when reassembling the coupling, one‐half of the amount of grease specified by the OEM guidelines shall be in each half of the coupling prior to assembly.

b. The insulated coupling bolts are constructed with an insulating surface on the shank of the bolt. There is a metal washer and an insulating washer for each coupling bolts. The metal washer goes immediately underneath the coupling bolt head. The insulating washer goes under the metal washer. Turn only the nuts during disassembly / torquing / assembly to avoid damaging the insulating washers.

Shipping shall include consideration to protect the new motor‐generator bearings. The method of bearing protection during shipping shall be provided to the Government.

CLIN 0003

RE‐INSTALL AND RE‐CONNECT MOTOR / GENERATOR SKID.

Post alignment check of GENSET after installation.

Post Installation Megger check of each motor/generator circuit. All Megger values shall be temperature corrected to 25 degrees Celsius.

Final alignment of each shaft to shaft coupling shall be within the industry/OEM setup tolerance for the most restrictive coupled component. Alignment pins/fasteners shall be reused or replaced in kind, but due to realignment may be placed in opposite mounting feet.

Shear bars (keepers) if removed shall be replaced in kind with same weld size. Welds between the shear bars and the foundation shall be placed in order for the shear bar to maintain contact with the foundation as the weld cools.

CDRL C– DUE 13OCT2021 ‐ A copy of the industry/OEM setup tolerance used for each of the coupling shaft‐to‐shaft arrangements and final alignment data shall be provided to the Government.

ALIGNMENT SHIMS

(a) Shims, if replaced, shall be corrosion resistant for all applications.

(b) Shim stacks should be limited to four shims.

(c) Commercially available shim kits should be used when practical as they provide a wide assortment of neatly pre‐cut shims slotted for standard fastener sizes.

(d) The equipment shall be installed with shims under each foot and they should be a minimum of 0.100 inch.

(e) Soft foot on the equipment should be limited to 0.001 inch and shall not exceed 0.003 inch.

Soft foot shall be measured and recorded for each mounting foot. A copy of the soft foot data shall be provided to the Government.

Post motor‐generator set vibration check after installation/startup. The final vibration data shall be within the industry standard.

CDRL C‐ DUE 13OCT2021 ‐ A copy of the post motor‐generator set vibration data and the industry standard shall be provided to the Government.

WARRANTY

Offerors shall to offer the Government at least the same warranty terms, including offers of extended warranties, offered to the general public in customary commercial practice. A minimum warranty duration shall be one‐year from the date of acceptance by the Government.

5.1. Should any work performed involve hazardous energy control (HEC) IAW 29 CFR Part

1915.89 and Naval Sea Systems Command (NAVSEA) Occupational Safety, health and Environmental Corporate Manual (OSHECM) Chapter 250 (latest Revision) including Lockout/Tags‐Plus (LOTP, the operator will be required to complete a PNS HEC Contractor Compliance Certification Document (Rev B 8/26/2014)

5.1.1 The text of 29 CFR Part 1915.89 is available at the OSHA Fact Sheet Web Site and the latest revision of OSHECM Chapter 250 is available at:

www.navsea.navy.mil/shipyards/norfolk/Shared%20Documents/Chapter%20250.pdf

6. Security: Contractors shall be registered in the Defense Biometric Identification System (DBIDS) and must attain DBIDS credential for access to Portsmouth Naval Shipyard upon contract award. SLD Machine House is located inside of the Controlled Industrial Area (CIA) of the Portsmouth Naval Shipyard. No person not known to be an American citizen of good standing and repute shall be eligible for access to Portsmouth Naval Shipyard. Proof of citizenship will be required.

The contractor will be required to fill out a Visitors Portable Computer Equipment Registration form if needed. This will be provided to the contractor after award by the TPOC.