14566-18-002_Rewind_of_Stators_Rotors_DRAFT.pdf

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Attached to: Rewind Stators Rotors Tunnel 9 Motors
Solicitation number: FA9101-19-Q-0004
Issued by: Department of the Air Force Materiel Command Test Center

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Distribution A Approved for Public Release. Distribution is unlimited.

(AEDC PA # AEDC2018-032 & IRA-3622)

SOW NO. 14566-18-002

11 October 2018

STATEMENT OF WORK

FOR

REWIND OF STATORS AND ROTORS OF FOUR (4) TUNNEL 9 MOTORS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

TUNNEL 9 – WHITE OAK, MARYLAND 20903

Distribution Statement A – Approved for Public Release

Distribution Unlimited

IRA-3622

DRAFT

14566-18-002

(AEDC PA # AEDC2018-032 & IRA-3622) Page 2

TABLE OF CONTENTS

1. SCOPE

1.1 General Statement

1.2 Background

2. APPLICABLE DOCUMENTS

2.1 Drawings

2.2 Referenced Standards

3. REQUIREMENTS

3.1 Base Bid: Disassembly, Transportation, and Reassembly of All Four Motors

3.2 Base Bid 1: Motor I SN 1S4OP262 – Stator/Rotor Rewind

3.3 Option 1: Motor I – Blast Clean Rotor

3.4 Base Bid 2: Motor II – Stator/Rotor Rewind

3.5 Option 2: Motor II – Blast Clean Rotor

3.6 Base Bid 3: Motor III – Stator/Rotor Rewind

3.7 Option 3: Motor III – Blast Clean Rotor

3.8 Base Bid 4: Motor IV – Stator/Rotor Rewind

3.9 Option 4: Motor IV – Blast Clean Rotor

4. WARRANTY

5. SUBMITTALS

Appendix A – Submittal Procedures

Appendix B – Sample Test Forms

Appendix C – Tunnel 9 Vacuum Compressor Plant Motor Layout Drawings

Appendix D – Tunnel 9 Vacuum Compressor Plant Motor Name Plate Data

(AEDC PA # AEDC2018-032 & IRA-3622) Page 3

Appendix E – Core Loop Test Coil Calculations Instructions

Appendix F – Machine Alignment Tolerances

(AEDC PA # AEDC2018-032 & IRA-3622) Page 4

1. SCOPE

1.1 This Statement of Work (SOW) describes the requirements for the inspection, rewinding, and repairs of stators, rotors, and generator sets of four Westinghouse motors. The work includes transportation of the motor to and from the Contractor’s facility and Tunnel 9 Arnold Engineering Development Complex-White Oak, Maryland, testing, and installation. All four motors are to be removed, rewound, and returned at the same time in one continuous block of time not to exceed 8 weeks.

1.2 Background:

A. Motors I and II are wound rotor induction motors and consist of across the line stator with liquid rheostat in series with rotor.

B. Motors III and IV are salient pole synchronous motors employing a motor generator set for DC excitation.

C. All motors are operated as frequently cycled units. Motors are typically brought from dead stop, to full load, and shut down again multiple times per day.

D. All motors are original Westinghouse equipment manufactured ~1953 and have been rewound and re-insulated since their manufacture.

E. The existing cable insulation may contain asbestos. Contractor shall exercise appropriate precautions and asbestos testing of cable. Contractor will dispose of such material in accordance with all federal and local regulations.

2. APPLICABLE DOCUMENTS

2.1 Drawings:

A. Motor I Assembly Outline 22-B-8163

B. Motor II Assembly Outline 22-B-8164

C. Motor III Assembly Outline 22-B-8439

D. Motor IV Assembly Outline 22-B-8451

2.2 Referenced Standards:

A. IEEE 1068 Standard for the Repair and Rewinding of AC Electric Motors in the Petroleum, Chemical,and

Process Industries

(AEDC PA # AEDC2018-032 & IRA-3622) Page 5

B. IEEE 62.2-04 Guide for Diagnostic Field Testing of Electric Power Apparatus Electrical Machinery.

C. IEEE 43-13 Recommend Practice for Testing Insulation

Resistance of Rotating Machinery.

D. IEEE 112-17 Standard Test Procedure for Polyphase Induction

Motors and Generators.

E. IEEE 522-09 Guide for Testing Turn Insulation of Form-Wound

Stator Coils for Alternating Current Electric Machines.

F. IEEE 432 Guide or Insulation Maintenance for Rotating

Electric Machinery (5hp to less than 10000hp).

G. IEEE 95 Recommend Practice for Insulation Testing of

AC Electric Machinery (2300V and Above) With High Direct Voltage.

H. ANSI/EASA AR100-2010 Recommended Practice for the Repair of Rotating

Electrical Apparatus.

I. ISO 1940-1 Mechanical vibration – Balance quality requirements for rotors in a constant (rigid) state.

J. EPRI 1000897 Repair and Reconditioning Specification for AC

Squirrel-Cage Motors with Voltage Ratings of 2.3 to 13.2 kV.

K. https://www.ieee.org/

L. https://www.easa.com/

M. https://www.iso.org/home.html

N. https://www.epri.com/

3. REQUIREMENTS

3.1 Disassembly, Transportation, and Reassembly of All Four Motors:

3.1.1 Motors Identification: Motor I, SN 1S4OP262

Motor II, SN 1S4OP263 Motor III, SN 1S4OP264 Motor IV, SN 1S4OP265

(AEDC PA # AEDC2018-032 & IRA-3622) Page 6

3.1.2 Contractor shall electrically and physically disconnect the motors for transport. A 20 ton overhead crane is available for use; to be operated by the government.

3.1.3 Contractor shall provide transportation for motors from 10905 New Hampshire

Ave. Silver Spring, MD 20903 Tunnel 9 Arnold Engineering Development Complex-White Oak, Maryland to the Contractor’s facility.

3.1.4 Motor and Rotor Shaft shall have alignment laser recorded before removal from

Tunnel 9.

3.1.5 All four motors shall be picked up and transported to the contractor shop in one continuous block of time not to exceed three working days on site at Tunnel 9.

3.1.6 Contractor shall provide transportation for motors from their facility back to

10905 New Hampshire Ave. Silver Spring, MD 20903 Tunnel 9 Arnold Engineering Development Complex-White Oak, Maryland after the completion of repairs and testing.

3.1.7 Contractor shall electrically and physically reconnect the motors for transport. A

20 ton overhead crane is available for use; to be operated by the government.

3.1.8 All four motors shall be returned and reconnected at Tunnel 9 in one continuous block of time not to exceed three working days on site at Tunnel 9.

A. Electrically reconnect motors for correct direction of rotation as dictated by AEDC.

3.1.9 Motor and Rotor Shaft shall be laser aligned once in place at Tunnel 9. Alignment shall meet the appropriate tolerance called out in Appendix F.

3.1.10 The motors shall be placed on the contractor’s truck and contractor shall secure motors for transport such that they will not move or become damaged in transit.

3.1.11 The contractor shall provide a list of additional recommended repairs that are not covered by this scope of work before reinstallation at Tunnel 9.

3.2 CLIN 0001: Motor I SN 1S4OP262 – Stator/Rotor Rewind:

3.2.1 Motor I SN IS4OP262 shall be disconnected, transported and returned as described in section 3.1.

3.2.2 Motor I SN 1S4OP262 Stator Documentation:

A. Contractor shall document motor stator and rotor winding configuration (wye or delta) and shall be rewound in the same configuration as they

(AEDC PA # AEDC2018-032 & IRA-3622) Page 7 were when supplied (picked up from Tunnel 9). This information shall be submitted to the contracting officer.

B. Existing Resistance Temperature Detector (RTD) locations and terminal identification shall be documented.

C. BOM for new materials shall be submitted to the contracting officer before installation in the motor.

D. The Contractor shall inform the Contracting Officer a minimum of 3 calendar days prior to acceptance testing. The Government reserves the right to witness each test. Upon failure to notify the Government of testing at least 3 calendar days prior to any planned tests the Government reserves the right to require the Contractor to conduct the tests again at no additional cost to the Government.

3.2.3 Motor I SN 1S4OP262 Stator Inspection:

A. Remove rotor from stator.

B. Clean and bake stator dry before testing.

C. Visually inspect the stator per IEEE 62.2 section 8.

D. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Test each phase and record winding temperature during the test and polarization index value.

3. Perform the test in accordance with the latest revision of IEEE 43.

E. DC Low Ohm Resistance

1. DC low ohm resistance reading of winding conductors to 4 significant digits. There shall be three resistance test results, one result for each phase, as well as, one %imbalance calculated test result.

%𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 =

𝐴𝐴𝐼𝐼𝐴𝐴𝐴𝐴𝐼𝐼𝐴𝐴𝐴𝐴𝐼𝐼 𝑉𝑉𝐼𝐼𝐼𝐼𝐴𝐴𝐼𝐼 𝐴𝐴𝑜𝑜 𝐿𝐿𝐼𝐼𝐿𝐿𝐿𝐿𝐼𝐼𝐴𝐴𝐴𝐴 𝐷𝐷𝐼𝐼𝐷𝐷𝐷𝐷𝐼𝐼𝐴𝐴𝐷𝐷𝐴𝐴𝐼𝐼 𝐹𝐹𝐿𝐿𝐴𝐴𝐼𝐼 𝐴𝐴𝐷𝐷𝐼𝐼𝐿𝐿𝐼𝐼𝐿𝐿𝐼𝐼 𝑅𝑅𝐼𝐼𝐴𝐴𝐷𝐷𝐴𝐴𝐴𝐴𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼

𝐴𝐴𝐷𝐷𝐼𝐼𝐿𝐿𝐼𝐼𝐿𝐿𝐼𝐼 𝑅𝑅𝐼𝐼𝐴𝐴𝐷𝐷𝐴𝐴𝐴𝐴𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 × 100

(AEDC PA # AEDC2018-032 & IRA-3622) Page 8

2. The contractor shall record the DC low ohm resistance for each phase conductor and the percent imbalance of the test results.

F. Perform a core loop test of the stator core prior to the removal of any stator material. Core Loop test is described in IEEE 432 section 9.1.

Follow the instructions in Appendix D on the calculations for the correct current and coils turns to perform this test. Contractor shall analyze for hot spots with thermal imaging systems for a minimum of 20 minutes and calculate core losses in Watts/LB provide results to the contracting officer.

G. Fully inspect the core laminations and winding support structures in accordance with IEEE 62.2, 7.1.1.

H. Record the number of winding slots, core length, core depth, stator core bore diameter, and slot depth. Submit this information to the contracting officer.

I. Submit results of these tests and inspections to the contracting officer for approval before proceeding to remove stator windings.

3.2.4 Motor I SN 1S4OP262 Stator Winding Removal:

A. Remove stator windings including coils and end connections. Completely strip stator windings in a manner to protect the core laminations and prevent damage to the magnetic characteristics of the motor. Accomplish coil and wedge removal so as not to damage the stator iron core. The coil stripping process shall follow one of the three methods listed in IEEE 1068 section 8 and all additional requirements listed here in.

B. Use of a burnout oven is permitted only after end turns have been removed End turns shall be removed manually without use of heat. Burnout oven shall be temperature controlled and shall use the lowest temperature deemed sufficient for successful burnout. Burnout temperature shall not exceed 680⁰F as measured in the stator core. Temperature log of burnout oven shall be made available to the contracting officer upon request. Use of open flame is not permitted.

C. Contractor will strip out the coils from the stator taking care to remove all copper and any sharp burs while preserving the laminations.

D. Contractor shall blast clean remaining core and steam clean and dry the core prior to new winding insertion.

1. Blast clean using appropriate material from the list in section

9.9.2.4 of EPRI report 1000987. Sand or coal slag abrasives are not allowed.

(AEDC PA # AEDC2018-032 & IRA-3622) Page 9

E. The Contractor shall coordinate the removal and disposal of all removed stator winding material and is responsible for its removal and disposal or recycle. The Government will make no claim on recycle value.

F. Inspect the stator slots and other portions of the stator frames in accordance with IEEE 62.2, 7.2.4 Check core iron for looseness or other conditions which could lead to local heating of the core iron.

G. Perform a core loop test of the stator core as described in IEEE 432 section 9.1. Follow the instructions in Appendix D on the calculations for the correct current and coils turns to perform this test. Contractor shall analyze for hot spots with thermal imaging systems for at least 20 minutes and provide results to the contracting officer. Acceptance criteria shall be based on EPRI 1000897:

1. No core hotspots higher than 50F above ambient temperature.

2. Maximum core loss of 4.0 watts/lb.

3. No more than 5.0% increase in watts/lb loss after removal of the stator windings for replacement.

H. If stator core fails core loop test after burnout and winding removal (after passing the initial loop test, the core shall be repaired or replaced to match the core as it was delivered. At no additional cost to the government.

3.2.5 Motor I SN 1S4OP262 Stator Rewind:

A. Winding and connection data shall be collected to ensure that the replacement windings will replicate the physical, mechanical, and electrical characteristics of the existing windings. Such data shall include, but not be limited to type of winding (lap or concentric, balanced or unbalanced), insulated and uninsulated wire size, number of strands, turns per coil, mean turn length, coil pitch, end-turn length, end-turn fit to end-shield, and lead cable size. Effort shall be made to determine the configuration and materials used in the existing winding system. This information shall be used to demonstrate that the replacement insulation system is equivalent or superior to the existing system. Photographs sufficient to document the incoming motor condition and construction, shall be taken.

B. Stator shall be rewound to match the winding as it was when Picked up from Tunnel 9 with no loss in conductor and winding coil cross sectional area. Conductor cross section shall be measured to match the winding cross sectional area as it was received by the contractor. Connect in the same manner it was supplied (wye or delta).

(AEDC PA # AEDC2018-032 & IRA-3622) Page 10

C. Stator shall be cleaned and baked dry prior to installation of insulation materials and windings.

D. Contractor shall at a minimum follow all requirements listed in EPRI Report 1000897 (Ref J) Section 9.2 in rewinding the stator more stringent requirements are stated in this contract in some cases. This includes but is not limited to documentation, coil construction, strand insulation, ground wall insulation, turn insulation, wedges, surge rings, support systems, and testing.

1. A detailed list of all materials and their application shall be submitted for approval to the Government.

2. All materials shall be compatible with VPI.

3. As stated in EPRI Report 1000897 section 9.9.9.8, all coils shall have dedicated mica tape turn insulation consisting of at a minimum one ½ lap layer of tape. If slot spacing allows (without reducing coil conductor cross sectional area) use two or three ½ lap layers of mica tape. Entire form coil shall be taped, ensure reinforced coil end-turn insulation.

E. The winding conductors shall be a “pure” ETP copper (greater than 99.9% copper content).The exact winding conductor’s copper grade and specification shall be submitted to the Government for approval.

F. Individual Wire strands shall have Class H enamel coating and Dacron wrap as specified in EPRI 1000897.

G. Utilize DMD or similar slot strips to provide sufficient ground wall insulation per EPRI Report 1000897.

H. Each coil shall be turn to turn surge tested per IEEE 522 section 5.1.a before insertion in the stator slots.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

I. Two (2) sample coils for testing will be provided by the contractor following the same construction and VPI process as described in EPRI report 1000897 section 9.2.2.12.

1. After VPI sample coils shall be Surge tested to destruction or Hi- Pot to failure if surge does not cause failure.

2. Sample coils shall be cut and examined to ensure full resin

(AEDC PA # AEDC2018-032 & IRA-3622) Page 11 impregnation per EPRI 1000897. Void spaces shall not exceed EPRI standards.

3. Provide results and pictures to the contracting officer.

J. New RTDs shall be installed in the same location as they were originally provided. New RTDs shall 100Ω @ 25⁰C platinum 3-wire Resistance Temperature Detectors.

K. Installation of New Stator Winding shall be accordance with EPRI 1000897 section 9.2:

1. Install and connect the new coil windings to the stator. Install coils so they are wedged in place in a manner that will not damage the insulation system during installation or while in service.

2. Install coils in a manner to ensure that air passages are not blocked, and such that the end turns protrude evenly from the stator iron.

L. Stator Winding Bracing shall be accordance with EPRI 1000897 section

9.2 specifically sections 9.2.2.13 – 9.2.2.16:

1. Insulated Surge Rings

2. Blocking and Tying

3. Fillers and Packing

4. Wedges

5. All materials shall be suitable for VPI Flammable materials such as wood shall not be allowed. Submit materials descriptions before beginning work. Submit any alternate materials for approval.

M. Individual Stator Coil Testing:

1. Perform testing on coils inserted and wedged in slots as described in EPRI report 1000897 section 9.2.2.17 following IEEE procedure 522 section 5.1.d for conducting a surge test.

2. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

N. Coil connections shall be performed in a manner consistent with

EPRI report 1000897 section 9.2.2.18.

O. Global VPI is required on the stator. Contractor shall only use Class H

(AEDC PA # AEDC2018-032 & IRA-3622) Page 12

Epoxy resin. Polyester resins are not permitted.

P. Stator shall have two VPI treatments with epoxy resin system.

Q. Motor Lead Connections:

1. Contractor will install new stator leads to the connection box in the same configuration with a spare cable length of at least 4’.

2. Vendor shall match the size and insulation rating of the lead connection cables to cables the motor had when removed from

AEDC.

3. Vendor shall use two hole, long barrel compression lugs on all motor leads.

R. The Contractor shall repaint the exterior of the stator frame assembly in gray. Take care to protect the stator core and windings from paint contamination and debris during the surface preparation and paint applications.

3.2.6 Motor I SN 1S4OP262 Post Rewind Acceptance Testing:

A. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Perform this test before and after the High Potential test and surge test.

3. The minimum acceptable test value for these motor stators shall be 1000 megohms when corrected to a 40°C temperature.

4. Test each phase and record winding temperature during the test and polarization index value.

5. Perform the test in accordance with the latest revision of IEEE 43.

B. Perform a high potential withstand test, 60 hertz AC for a period of one minute. The test voltage shall be 9320 rms volts or equivalent DC test at 15844 volts (AC twice rated voltage plus 5,000 volts AC to DC factor 1.7). Perform the test in accordance with the latest revision of IEEE 112.

Submit test results to the Contracting Officer for approval.

C. Perform Surge test on motor connections following standard IEEE 522 listed in section 5.1.e.

(AEDC PA # AEDC2018-032 & IRA-3622) Page 13

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

2. Carefully select impulse voltage levels to avoid over stressing ground insulation per IEEE 522.

D. DC Low Ohm Resistance

2. There shall not be more than a 0.5% imbalance between test results.

3. The contractor shall record the DC low ohm resistance for each phase conductor and the percent imbalance of the test results.

E. Successful operation of the repaired motor place at Tunnel 9.

F. If the rewound stator fails to pass any test, the stator shall be rejected. The Contractor shall rebuild and retest until all tests are approved by the Contracting Officer at no expense to the Government.

3.2.7 Motor I SN 1S4OP262 Rotor Inspection:

A. Remove rotor from stator and visually examine rotor and rotor windings.

Inspect the rotor per all requirements listed in IEEE 1068 section 6.2 as applicable specifically section 6.2.e.

1. Visually inspect and take TIR readings of the slip rings.

B. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Test each phase and record winding temperature during the test and polarization index value.

3. Perform the test in accordance with the latest revision of IEEE 43.

C. DC Low Ohm Resistance

(AEDC PA # AEDC2018-032 & IRA-3622) Page 14

1. DC low ohm resistance reading of winding conductors to 4 significant digits. There shall be three resistance test results, one

D. Perform an Induced Current and Loop Test on the rotor laminations as described in EPRI 1000897 (Ref J) Section 10.2.3.1 to check for local hot spots or bar damage. Submit all hot spot with thermal pictures results to the contracting officer.

E. Observe and notify the Government of any other damage not specifically covered in this Statement of Work. Submit all inspections and test results to the contracting officer.

F. The Contractor shall inform the Contracting Officer a minimum of 3 right to witness each test. Upon failure to notify the Government of testing at least 3 calendar days prior to any planned tests the Government

3.2.8 Motor I SN 1S4OP262 Remove Rotor Windings

A. Remove rotor windings in a manner to protect the core laminations and prevent damage to the magnetic characteristics of the motor. Ensure that all repair operations do not damage or distort the shaft in any way.

B. Use only non-flame winding removal methods on rotor; Use of a burnout oven is NOT permitted on the rotor. Contractor shall inform the contracting office of recommended winding removal method for approval before proceeding with removing any rotor windings.

C. The contractor shall coordinate the removal and disposal of all removed rotor winding material and is responsible for its removal and disposal or recycle. The Government will make no claim on recycle value.

D. Perform an Induced Current and Loop Test on the rotor laminations as described in EPRI 1000897 (Ref J) Section 10.2.3.1 to check for local hot spots. Submit all hot spots with thermal picture results to the contracting

(AEDC PA # AEDC2018-032 & IRA-3622) Page 15 officer.

3.2.9 Motor I SN 1S4OP262 Rewind Rotor

B. Rotor shall be rewound to match the winding as it was when picked up from Tunnel 9 with no loss in conductor and winding coil cross sectional area. Conductor cross section shall be measured to match the winding cross sectional area as it was received by the contractor. Connect

C. Rotor shall be cleaned and baked dry prior to installation of insulation

D. Contractor shall at a minimum follow all requirements listed in EPRI Report 1000897 (Ref J) Section 9.2 in rewinding the rotor coils more stringent requirements are stated in this contract in some cases. This includes but is not limited to documentation, coil construction, strand insulation, ground wall insulation, turn insulation, wedges, surge rings, support systems, and testing.

1. A detailed list of all materials and their application shall be submitted for approval to the contracting officer.

2. All materials shall be compatible with VPI.

3. As stated in EPRI Report 1000897 section 9.9.9.8 All coils shall have dedicated mica tape turn insulation consisting of at a minimum one ½ lap layer of tape. If slot spacing allows (without reducing coil conductor cross sectional area) use two or three ½ lap layers of mica tape. Entire form coil shall be taped, ensure reinforced coil end-turn insulation.

E. The winding conductors shall be a “pure” ETP copper (greater than 99.9% copper content).The exact winding conductor’s copper grade and

(AEDC PA # AEDC2018-032 & IRA-3622) Page 16 specification shall be submitted to the Government for approval.

F. Individual Wire strands shall have Class H enamel coating and Dacron wrap as specified in EPRI 1000897.

G. Each coil shall be turn to turn surge tested per IEEE 522 section 5.1.a before insertion in the stator slots.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

H. Two (2) sample coils for testing will be provided by the contractor

Pot to failure is surge does not cause failure.

2. Sample coils shall be cut and examined to ensure full resin impregnation per EPRI 1000897. Void spaces shall not exceed EPRI standards.

I. Contractor shall include rotor end winding to retaining ring insulation.

J. Installation of New rotor Winding shall be accordance with EPRI 1000897 section 9.2:

1. Install and connect the new coil windings to the rotor. Install coils so they are wedged in place in a manner that will not damage the insulation system during installation or while in service.

2. Install coils in a manner to ensure that air passages are not blocked, and such that the end turns protrude evenly from the rotor iron.

K. Rotor Winding Bracing shall be accordance with EPRI 1000897 section

9.2 specifically sections 9.2.2.13 – 9.2.2.16:

1. Blocking and Tying

2. Fillers and Packing

3. Wedges

4. All materials shall be suitable for VPI Flammable materials such as wood shall not be allowed. Submit materials descriptions before beginning work. Submit any alternate materials for approval.

(AEDC PA # AEDC2018-032 & IRA-3622) Page 17

L. Individual Coil Testing:

1. Perform testing on coils inserted and wedged in slots as described in EPRI report 1000897 section 9.2.2.17 following IEEE procedure 522 section 5.1.d for conducting a surge test.

2. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

M. Coil connections shall be performed in a manner consistent with EPRI report 1000897 section 9.2.2.18.

N. Conduct a phase to phase surge comparison test of all coils in the rotor following IEEE 522. This test must be passed before proceeding to VPI the stator.

O. Global VPI is required on the rotor. Contractor shall only use Class H Epoxy resin. Polyester resins are not permitted.

1. Rotor shall have two VPI treatments with epoxy resin system.

P. Brush Rig Lead Connections:

1. Contractor will install new stator leads to the connection box in the same configuration with a spare cable length of at least 4’.

2. Vendor shall match the size and insulation rating of the lead connection cables to cables the motor had when removed from

AEDC.

3. Vendor shall use two hole, long barrel compression lugs on all motor leads.

3.2.10 Motor I SN 1S4OP262 Rotor Shop Acceptance Testing

A. Balance rotor per ISO 1940-1 standard before insertion into the stator.

Balance grade quality must meet G2.5. Balancing shall be achieved using standard half key seat.

B. Take a megger reading at a minimum of 1,000 volts for thirty seconds, one minute, and ten minutes before and after the high potential test and surge tests. The minimum acceptable test value for these motor rotors shall be 1000 megohms when corrected to a 40⁰C temperature. Perform the test in accordance with the latest revision of IEEE 43. Submit results to the Contracting Officer for approval.

C. Contractor shall perform a high potential withstand test, for a period of

(AEDC PA # AEDC2018-032 & IRA-3622) Page 18 one minute.

1. Contractor shall perform a High Potential withstand test on new rotor windings with the based on ANSI/EASA AR100-2010 6460VAC or 10982 VDC.

D. Perform Surge test on motor connections following standard IEEE 522 listed in section 5.1.e.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

2. Carefully select impulse voltage levels to avoid over stressing ground insulation per IEEE 522.

E. Low Ohm Resistance

F. Measure rotor shaft runout per IEEE 1068. Final results shall meet the acceptance criterial specified in EASA AR100-2015.

G. Motors are installed and operated atTunnel 9 to pull vacuum on the sphere down to at least 8.6 mmHg as read in the 403 control room.

H. Test results shall be submitted to the Contracting officer for approval before reassembly. If the upgraded rotor fails to pass any test, the rotor shall be rejected. The contractor shall rebuild and retest until all tests are approved by the Contracting Officer at no expense to the Government.

3.2.11 Motor I SN 1S4OP262 Install Mica Strip Heaters

A. Contractor shall install mica strip heaters (such as Chromalox strip heaters or equivalent) and associated mounting blocks below the stator frame.

(AEDC PA # AEDC2018-032 & IRA-3622) Page 19

B. Strip heaters must be compatible with 208V supply power.

C. Total heater output (to be determined) should be sufficient to keep the motors warm; high enough (~ 10 ºF) above ambient temperature to eliminate condensation when not in operation.

D. Mounting location should provide even heating and not interfere with motor operation.

E. Strip Heater wires shall be run to the RTD box and dead ended. Running power to the heaters is outside the scope of this contract.

3.3 Option CLIN 0002: Motor I SN 1S4OP262 Blast Clean Rotor:

A. The government has the option to have rotor blast cleaned to allow for a more thorough inspection.

1. Blast clean using appropriate material from the list in section

9.9.2.4 of EPRI report 1000987. Sand or coal slag abrasives are not allowed.

B. Care shall be taken to cover the rotor laminations so as not to damage them during the blasting cleaning.

3.4 CLIN 0003: Motor II SN 1S4OP263

3.4.1 Motor II SN IS4OP263 shall be disconnected, transported and returned as described in section 3.1.

3.4.2 Motor II SN 1S4OP263 Stator Documentation:

A. Contractor shall document motor stator and rotor winding configuration (wye or delta) and shall be rewound in the same configuration as they were supplied (Picked up from Tunnel 9). This information shall be submitted to the contracting officer.

B. Existing Resistance Temperature Detector (RTD) locations and terminal identification shall be documented.

C. BOMs shall be submitted to the contracting officer before installation in the motor.

calendar days prior to all testing. The Government reserves the right to witness each test. Upon failure to notify the Government of testing at least

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3 calendar days prior to any planned tests the Government reserves the right to require the Contractor to conduct the tests again at no additional cost to the Government.

3.4.3 Motor II SN 1S4OP263 Stator Inspection:

A. Remove rotor from stator.

B. Clean and bake stator dry before testing.

C. Visually inspect the stator per IEEE 62.2 section 8.

D. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Test each phase and record winding temperature during the test and polarization index value.

3. Perform the test in accordance with the latest revision of IEEE 43.

E. DC Low Ohm Resistance

1. DC low ohm resistance reading of winding conductors to 4 significant digits. There shall be three resistance test results, one

𝐴𝐴𝐷𝐷𝐼𝐼𝐿𝐿𝐼𝐼𝐿𝐿𝐼𝐼 𝑅𝑅𝐼𝐼𝐴𝐴𝐷𝐷𝐴𝐴𝐴𝐴𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼

× 100

F. Perform a core loop test of the stator core prior to the removal of any stator material. Core Loop test is described in IEEE 432 section 9.1.

G. Fully inspect the core laminations and winding support structures in accordance with IEEE 62.2, 7.1.1.

H. Record the number of winding slots, core length, core depth, stator core bore diameter, and slot depth. Submit this information to the contracting officer.

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3.4.4 Motor II SN 1S4OP263 Stator Winding Removal:

B. Use of a burnout oven is permitted only after end turns have been removed end turns shall be removed manually without use of heat. Burnout oven shall be temperature controlled and shall use the lowest temperature deemed sufficient for successful burnout. Burnout temperature shall not exceed 680⁰F as measured in the stator core. Temperature log of burnout oven shall be made available to the contracting officer upon request. Use of open flame is not permitted.

C. Contractor will strip out the coils from the stator taking care to remove all copper and any sharp burs while preserving the laminations.

D. Contractor shall blast clean remaining core and steam clean and dry the core prior to new winding insertion.

1. Blast clean using appropriate material from the list in section

9.9.2.4 of EPRI report 1000987. Sand or coal slag abrasives are not allowed.

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1. No core hotspots higher than 50F above ambient temperature.

2. Maximum core loss of 4.0 watts/lb.

3. No more than 5.0% increase in watts/lb loss after removal of the stator windings for replacement.

H. If stator core fails core loop test after burnout and winding removal

(having previously passed the core loop test), the core shall be repaired or replaced to match the core as it was delivered. At no additional cost to the government.

3.4.5 Motor II SN 1S4OP263 Stator Rewind:

replacement windings will replicate the physical, mechanical, and electrical characteristics of the existing windings. Such data shall include, but not be limited to type of winding (lap or concentric, balanced or unbalanced), insulated and uninsulated wire size, number of strands, turns per coil, mean turn length, coil pitch, end-turn length, end-turn fit to end-shield, and lead cable size. Effort shall be made to determine the configuration and materials used in the existing winding system. This information shall be used to demonstrate that the replacement insulation system is equivalent or superior to the existing system. Photographs sufficient to document the incoming motor condition and construction, shall be taken.

B. Stator shall be rewound to match the winding as it was when picked up from Tunnel 9 with no loss in conductor and winding coil cross sectional area. Conductor cross section shall be measured to match the

1. A detailed list of all materials and their application shall be submitted for approval to the Government.

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2. All materials shall be compatible with VPI.

F. Individual Wire strands shall have Class H enamel coating and Dacron wrap as specified in EPRI 1000897.

G. Utilize DMD or similar slot strips to provide sufficient ground wall insulation per EPRI Report 1000897.

H. Each coil shall be turn to turn surge tested per IEEE 522 section 5.1.a before insertion in the stator slots.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

I. Two (2) sample coils for testing will be provided by the contractor

1. After VPI, sample coils shall be Surge tested to destruction or Hi- Pot to failure if surge does not cause failure.

2. Sample coils shall be cut and examined to ensure full resin impregnation per EPRI 1000897. Void spaces shall not exceed EPRI standards.

3. Provide results to the contracting officer.

L. New RTDs shall be installed in the same location as they were originally provided. New RTDs shall be 100Ω @ 25⁰C platinum 3-wire Resistance Temperature Detectors.

M. Installation of New Stator Winding shall be accordance with EPRI 1000897 section 9.2:

1. Install and connect the new coil windings to the stator. Install coils so they are wedged in place in a manner that will not damage the

(AEDC PA # AEDC2018-032 & IRA-3622) Page 24 insulation system during installation or while in service.

2. Install coils in a manner to ensure that air passages are not blocked, and such that the end turns protrude evenly from the stator iron.

N. Stator Winding Bracing shall be accordance with EPRI 1000897 section

9.2 specifically sections 9.2.2.13 – 9.2.2.16:

1. Insulated Surge Rings

2. Blocking and Tying

3. Fillers and Packing

4. Wedges

5. All materials shall be suitable for VPI Flammable materials such as wood shall not be allowed. Submit materials descriptions before beginning work. Submit any alternate materials for approval.

O. Individual Stator Coil Testing:

1. Perform testing on coils inserted and wedged in slots as described in EPRI report 1000897 section 9.2.2.17 following IEEE procedure 522 section 5.1.d for conducting a surge test.

2. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

P. Coil connections shall be performed in a manner consistent with

EPRI report 1000897 section 9.2.2.18.

Q. Global VPI is required on the stator. Contractor shall only use Class H Epoxy resin. Polyester resins are not permitted.

R. Stator shall have two VPI treatments with epoxy resin system.

S. Motor Lead Connections:

1. Contractor will install new stator leads to the connection box in the same configuration with a spare cable length of at least 4’.

2. Vendor shall match the size and insulation rating of the lead connection cables to cables the motor had when removed from

AEDC.

3. Vendor shall use two hole, long barrel compression lugs on all

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T. The Contractor shall repaint the exterior of the stator frame assembly in gray. Take care to protect the stator core and windings from paint contamination and debris during the surface preparation and paint applications.

3.4.6 Motor II SN 1S4OP263 Post Rewind Acceptance Testing:

A. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Perform this test before and after the High Potential test.

3. The minimum acceptable test value for these motor stators shall be 1000 megohms when corrected to a 40°C temperature.

4. Test each phase and record winding temperature during the test and polarization index value.

5. Perform the test in accordance with the latest revision of IEEE 43.

Submit test results to the Contracting Officer for approval.

C. DC Low Ohm Resistance

D. Motors are installed and operated at Tunnel 9 to pull vacuum on the sphere down to at least 8.6 mmHg as read in the 403 control room.

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E. If the upgraded stator fails to pass any test, the stator shall be rejected. The Contractor shall rebuild and retest until all tests are approved by the Contracting Officer at no expense to the Government.

3.4.7 Motor II SN 1S4OP263 Rotor Inspection:

A. Remove rotor from stator and visually examine rotor and rotor windings.

Inspect the rotor per all requirements listed in IEEE 1068 section 6.2 as applicable specifically section 6.2.e.

1. Visually inspect and take TIR readings of the slip rings.

B. Perform IR and PI resistance check on megger minimum of 1,000 volts.

1. Record the value at 30 seconds, one minute, and ten minutes.

2. Perform the test in accordance with the latest revision of IEEE 43.

C. DC Low Ohm Resistance

1. DC low ohm resistance reading of winding conductors to 4 significant digits. There shall be three resistance test results, one

2. The contractor shall record the DC low ohm resistance for each

E. Observe and notify the Government of any other damage not specifically covered in this Statement of Work. Submit all inspections results and records to the contracting officer.

right to witness each test. Upon failure to notify the Government of testing at least 3 calendar days prior to any planned tests the Government

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3.4.8 Motor II SN 1S4OP263 Remove Rotor Windings:

A. Remove rotor windings in a manner to protect the core laminations, prevent damage to the magnetic characteristics of the motor, or shaft.

B. Use only non-flame cleaning methods on rotor; Use of a burnout oven is NOT permitted on the rotor. Contractor shall inform the contracting office of chosen winding removal method before proceeding with removing any rotor windings.

C. The contractor shall coordinate the removal and disposal of all removed stator winding material and is responsible for its removal and disposal or recycle. The Government will make no claim on recycle value.

D. Perform an Induced Current and Loop Test on the rotor laminations as described in EPRI 1000897 (Ref J) Section 10.2.3.1 to check for local hot spots. Submit all hot spot with thermal pictures results to the contracting officer.

3.4.9 Motor II SN 1S4OP263 Rewind Rotor:

D. Contractor shall at a minimum follow all requirements listed in EPRI

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Report 1000897 (Ref J) Section 9.2 in rewinding the rotor coils more stringent requirements are stated in this contract in some cases. This includes but is not limited to documentation, coil construction, strand insulation, ground wall insulation, turn insulation, wedges, surge rings, support systems, and testing.

1. A detailed list of all materials and their application shall be submitted for approval to the Government.

2. All materials shall be compatible with VPI.

F. Individual Wire strands shall have Class H enamel coating and Dacron wrap as specified in EPRI 1000897.

G. Utilize DMD or similar slot strips to provide sufficient ground wall insulation per EPRI Report 1000897.

H. Each coil shall be turn to turn surge tested per IEEE 522 section 5.1.a before insertion in the stator slots.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

I. Two (2) sample coils for testing will be provided by the contractor

2. Sample coils shall be cut and examined to ensure full resin impregnation per EPRI 1000897. Void spaces shall not exceed EPRI standards.

3. Submit results to the contracting officer.

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J. Contractor shall include rotor end winding to retaining ring insulation.

K. Installation of New rotor Winding shall be accordance with EPRI 1000897 section 9.2:

1. Install and connect the new coil windings to the rotor. Install coils so they are wedged in place in a manner that will not damage the insulation system during installation or while in service.

2. Install coils in a manner to ensure that air passages are not blocked, and such that the end turns protrude evenly from the rotor iron.

L. Rotor Winding Bracing shall be accordance with EPRI 1000897 section

9.2 specifically sections 9.2.2.13 – 9.2.2.16:

1. Blocking and Tying

2. Fillers and Packing

3. Wedges

4. All materials shall be suitable for VPI Flammable materials such as wood shall not be allowed. Submit materials descriptions before beginning work. Submit any alternate materials for approval.

M. Individual Coil Testing:

1. Perform testing on coils inserted and wedged in slots as described in EPRI report 1000897 section 9.2.2.17 following IEEE procedure 522 section 5.1.d for conducting a surge test.

2. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

N. Coil connections shall be performed in a manner consistent with EPRI report 1000897 section 9.2.2.18.

O. Conduct a phase to phase surge comparison test of all coils in the rotor following IEEE 522. This test must be passed before proceeding to VPI the stator.

P. Global VPI is required on the rotor. Contractor shall only use Class H Epoxy resin. Polyester resins are not permitted.

1. Rotor shall have two (2) VPI treatments with epoxy resin system.

Q. Brush Rig Lead Connections:

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1. Contractor will install new stator leads to the connection box in the same configuration with a spare cable length of at least 4’.

2. Vendor shall match the size and insulation rating of the lead connection cables to cables the motor had when removed from

AEDC.

3. Vendor shall use two hole, long barrel compression lugs on all motor leads.

3.4.10 Motor II SN 1S4OP263 Rotor Shop Acceptance Testing:

A. Balance rotor per ISO 1940-1 standard before insertion into the stator.

Balance grade quality must meet G2.5. Balancing shall be achieved using standard half key seat.

B. Take a megger reading at a minimum of 1,000 volts for thirty seconds, one minute, and ten minutes before and after the high potential test and surge test. The minimum acceptable test value for these motor rotors shall be 1000 megohms when corrected to a 40⁰C temperature. Perform the test in accordance with the latest revision of IEEE 43. Submit results to the Contracting Officer for approval.

C. Contractor shall perform a high potential withstand test, for a period of one minute.

1. Contractor shall perform a High Potential withstand test on new rotor windings with the voltages based on ANSI/EASA AR100- 2010 VAC 5920 or VDC 10064.

D. Perform Surge test on motor connections following standard IEEE 522 listed in section 5.1.e.

1. Withstand capacity shall be 3.5 pu x 0.1 µs at a minimum.

2. Carefully select impulse voltage levels to avoid over stressing ground insulation per IEEE 522.

E. Low Ohm Resistance

1. DC low ohm resistance reading of winding conductors to 4 significant digits.

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