R-310-0005.pdf

USCG - ELC DTCG40-

DATE - 1/88 PAGE of

R-310-005 PART SECTION C

CHANGE 1/88

Repair Specification for 110 WPB Ship Service Generators

1.0 SCOPE

1.1 This specification covers the repair and or overhaul of

Kato Engineering Corp. Ship Service Generators on 110 ft Coast Guard Patrol Vessels, type KAMAG 18, p/n 91572-01, model 4P2-0963. Generator A.C. stock number 6115-01-218- 4352.

1.2 GOVERNMENT FURNISHED PROPERTY (GFP) - The listed item is

managed by the Coast Guard Engineering Logistics Center Baltimore, Md.

2.0 APPICABLE DOCUMENTS

2.1 DOCUMENT AVAILABILITY - For the methods and conditions

for obtaining the referenced documents see section 6.

(fill in).

2.2 GOVERNMENT DOCUMENTS - The following specifications and

standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements thereto.

2.1.1 STANDARDS

MIL-STD-705B - DATED,

2.3 OTHER GOVERNMENT DOCUMENTS - The following documents form a part of this specification to the extent specified herein.

The documents listed shall be by title and effective date, unless otherwise documented.

2.2.1 HANDBOOKS

MIL-HDBK-705 - DATED,

2.2.2 TECHNICAL MANUALS

Naval Ships Technical Manual - Chapter 300, S9086-KC-STM- 000, Electrical Plant General.

2.3 COMMERCIAL DOCUMENTS - The following documents form a

part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of

Specifications and Standards (DODISS).

2.3.1 Kato Engineering Div. 350-04001-00A Single Bearing

KAMAG Generators Instruction manual Aug. l985.(for s/n 95250)

2.3.2 National Electric Manufacturers Association

(NEMA)MG-1-78 Motors & Generators (DOD adopted)

2.4 ORDER OF PRECEDENCE - In the event of a conflict between

the text of this specification and the references cited herein, this specification shall take precedence.

3.0 REQUIREMENTS

3.1 PARAMETERS (see fig-1A&B,2B,3B also O.E.M. manual 350-

04001-00A)

3.1.1 Type & output-A.C. brushless, 3 phase, synchronous

continuous duty fan cooled, single bearing 440VAC, 99KW 60HZ 162.3 amps, 80 degrees C. rise, 123.75 VA, at 1800

RPM.

3.1.2 Exciter field output, no load 12 V - 0.3 amps, full

load 45 V - 1.25 amps.(see fig 2B)

3.1.3 Windings-4 pole revolving field & revolving D.C.

outboard exciter.

3.1.4 Resistance Readings- Alternator armature (stator)

0.084 ohms, (line to line), OHMS, Alternator field (rotor) 3.24 OHMS, Exciter armature 0.34 ohms, Exciter field 36.0 OHMS, all readings are + 10 %.

3.1.4.1 Coil resistance temperature compensation, corrected to 25 degrees C.

234.5 + 25 Measured Resistance X ----------------------

234.5 + winding temp. in degrees C.

3.1.5 Reactances, per O.E.M. standards.

3.1.5.1 % XD direct axis synchronous 180.7.

% X'D direct axis transient 22.2.

% X''D direct axis sub transient 9.8.

% X2 negative sequence 9.4.

% XO Zero - sequence 1.04.

% XQ quadrature axis synchronous 105.7.

% X''Q quadrature axis sub - transient 9.0.

3.1.6 Time constants (seconds).

3.1.6.1 1.45 sec. T'do, Direct axis transient open circuit time constant. Armature circuit open, field suddenly shorted.

3.1.6.2 0.78 sec. T'd, Direct axis transient short circuit time constant. Armature short circuited, field suddenly shorted.

3.1.6.3 0.006 sec. Ta, Armature time constant, DC component of AC short circuit output.

3.2 REPAIRS & TESTING

3.2.1 INSULATION RESISTANCE - (MIL-STD 705B test method

301.1B) shall be no lower than , alternator stator 50 meg ohms, rotor (field) 50 meg. ohms, exciter stator 50 meg ohms, rotor 50 meg ohms.

3.2.2 D.C. COIL RESISTANCE

3.2.2.1 Shall be in accordance with MIL-STD-705B, test method 401.1A and section 3.1.4. of this specification.

3.2.3 MANDATORY REPLACEMENT PARTS(see fig. 2A & 3B), O.E.M. reference serial number 95259, 203-24362, code 4P2-0963.

3.2.3.1

P/N QUAN. DESCRIPTION

012-21102-00 1 Bearing 864-10111-13 2 Space Heater 150 watts

3.2.4 INSPECTION-DISASSEMBLY - Inspect and test all wearing or electrical components, check castings for cracking. List the unit serial number and all defective parts. by part number, key number, quantity required and total price (see section 4.1 & Figs 2A & 3B).

3.2.4.1 Include in the testing per MIL-STD-705B all the

coils in the exciter and alternator stator and rotor, use tests 301.1B, 401.1A, and 302.1A (This test is optional see 4.1.2.1) see section 4.1.2.1, MIL-HDBK-705B shall be used as so instructed in the MIL-STD.

3.2.4.2 Please see fig 2 for a complete parts list less

misc. hardware.

3.2.5 After preliminary inspection and testing are

complete a priced out list of total overhaul cost shall be sent to the contracting officer for approval prior to any other work being preformed. (see section 4.1.3)

3.2.6 MANDATORY PROCESSES

3.2.6.1 Disassemble and completely clean all parts, remove all lose paint and sand the exterior smooth.

3.2.6.2 Repaint the exterior with an under coat and a

finish coat of baked on enamel (light gray).

3.2.7 COILS & CORES

3.2.7.1 If coil rewinding or core restacking is

required nondestructive retesting shall be done after rewinding coils and all data recorded (see section 4.1.3)

3.2.7.2 When any coil rewinding is required a core

iron loop test shall be preformed (when applicable).

Procedures for conducting this test shall be submitted along with the results and recommendations to the contracting officer for approval prior to any repair or replacement action.

3.2.7.3 A high potential TEST (D.C. only) shall be

performed on any new or rewound coils.

3.2.7.3.1 This test shall be in accordance with

Naval Ships Technical Manual chapter 300 paragraphs 300.3.30 thru 300.3.40 .

3.2.8 ARMATURE

3.2.8.1 After armature reassembly, balancing, testing

and installation into the generator housing air gap readings shall be taken and recorded (see sec.

4.1.3).

3.3 RECYCLED AND RECLAIMED MATERIAL

3.3.1 This material may be used except for any items used

for electrical insulation.

3.4 WORKMANSHIP

3.4.1 Appearance-Free of any foreign matter and

completely assembled.

3.4.2 Finish-Shall be covered completely, smooth, and of

uniform thickness.

3.4.3 Test reports- Shall be complete and verified by the

signature of the contractors rep..

3.5 NOTIFICATION & INSPECTIONS

3.5.1 The contractor shall be responsible for notifying

the contracting officer at least 7 working days prior to said contractor being ready for any QA monitored inspections or testing required herein.

3.5.2 The contracting officer or appointed representative

are the only persons authorized to negotiate or accept material on behalf of the U.S. Coast Guard.

3.6 MATERIAL RELEASE - See section 6. for instructions

covering release of GFP required in this specification.

4.0 QUALITY ASSURANCE

4.1 RESPONSIBILITY FOR INSPECTION - The contractor is

responsible for the performance of all inspection requirements as specified herein. The contractor may use his own or any other facilities for the performance of the inspections and tests, unless disapproved by the government.

The government reserves the right to perform any of the inspections and tests set forth in this specification at any time.

4.2 RESPONSIBILITY FOR COMPLIANCE - All items shall meet the

provisions of Sections 3 & 5. The inspections set forth in this specification shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract.

Sampling in 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.

4.1.2 MIL-STD-705B tests shall be used for all coil

tests, use only methods 301.1B ,401.1A, and as optional 302.1A.

4.1.2.1 Test method 302.1A is the High Potential test

and could result in damage to the coils tested, if used it shall be at the contractors own risk. Any damage resulting shall be at the contractors expense (see section 3.2)

4.1.3 All test results test methods and price estimates

shall be recorded and verified by a contractors representatives signature, one copy shall be sent to the contracting officer and a copy given to the Coast Guard QA rep. when he arrives.

4.4 INSPECTION CONDITIONS - All test facilities shall be

acceptable to the Contracting Officer. The approval of the facilities can be made verbally or in writing, depending upon the writers judgement, the KO's wishes, or the type and dollar size of the contract. Whatever is best for this particular specification.

4.5 NONCOMPLIANCE - Shall mean any single failure of any

individual part or subsystem during inspection or testing.

4.5.1 The contractor can, at his choice repair or replace

the failed part and continue testing, unless the Contracting Officer or his representative requests a total retest.

4.2 DISCARDED & INSPECTED PARTS

4.2.1 All discarded parts shall be turned over to the

Coast Guard QA rep. on his arrival for disposal.

4.2.2 Each part shall be visually inspected and tested as

needed (see section 3.2.4)

4.2.3 The testing shall consist of nondestructive type

testing, for coils it shall include insulation quality & coil resistance per O.E.M. specifications and standards, MIL-STD-705B & MIL-HDBK-705. ( see sections 3.1.4, 3.2.1, and 3.2.2)

4.4 POST REPAIR TESTING

4.4.1 After repair, cleaning and or baking (coils only), all tests shall be redone to verify the repairs preformed were effective or the cleaning did not degrade the coils in any way. (see 4.1.2 & 4.1.3 for recording information).

4.5 INSPECTIONS

4.5.1 The Coast Guard QA rep. shall be notified of the

units availability for inspection after disassembly, initial and final testing also after final assembly and during packing and marking.

4.8 PACKAGING INSPECTION - The Coast Guard shall be notified

as in section 3.__ prior to the preservation, packaging, and marking of the completed units.

4.9 TEST & INSPECTION REPORTS - One copy of any required

inspection and test reports shall be sent to the Contracting Officer. A copy of any test or inspection reports shall also be turned over to, the Coast Guard QA Inspector upon his arrival at the contractors plant.

4.11 DISCARDED PARTS - All discarded parts shall be turned

over to the Coast Guard QA Inspector at the contractors plant for destruction. The contractor shall then dispose of said parts as the QA Inspector directs.

4.12 CALIBRATION SYSTEM - The contractor shall be required to maintain a test equipment calibration program documented and traceable to the National Institute of Standards (NIST) formerly the National Bureau of Standards (NBS).

4.12.1 If a delivered copy is not necessary, than require

the contractor to have a copy on hand during the term of this contract for inspection.

5.0 PRESERVATION,PACKING and MARKING

5.1 PRESERVATION

5.1.1 Each generator shall be sealed in a plastic wrap

with desiccant to insure all water vapor is removed.

5.2 PACKING

5.2.1 Each generator shall be placed in a closed wooden

or triple wall card board box supported for common carrier transport.

5.2.2 Each container in 5.2.1. shall be skid mounted for

easy access by fork lift trucks form the two long sides.

5.3 MARKING

5.3.1 Each preserved and packed generator shall be marked

in the upper left on the two longest sides of each container.

5.3.2 The marking shall be in legible black ink lettering

two inches high.

5.3.3 This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, SHIPPING WT. in lbs., and the words COAST GUARD ELC MATERIAL , CONDITION A.(See 6.1) for detailed information).

6.0 NOTES

6.1 Marking as required in section 5.3.3.

Stock No. 6115-01-218-4352 Item Name Generator A.C.

Part No. 91572-01 Contract No. DTCG40 see contract Shipping Wt. as determined by the contractor Info. COAST GUARD S.I.C.P. MATERIAL Condition Cond. A

6.2 ABBREVIATIONS

K.W. - Kilowatts P.F. - Power Factor PAR. - Parallel Connected SER. - Series Connected

O.E.M.- Original Equipment Manufacturer QA - Quality Assurance Rep.- Representative

6.3 SPECIFICATION DISTRIBUTION

6.3.1 For military and federal specifications & Standards

6.3.1.1 Navy Publication & Forms Center

5801 Tabor Ave.

Philadelphia Pa. 19120 215-697-2000

6.3.2 For commercial specifications & standards

6.3.2.1 Kato Engineering Div.

P.O. Box 47 Mankato Mi. 56001 507-625-4011

6.3.2.2 National Electric Manufacturers Association

2101 L Street N.W.

Washington D.C. 20037 202-457-8400

6.4 MATERIAL RELEASE

6.4.1 The contracting officer will arrange to furnish the

contractor the government property for inspection and overhaul as listed in section 3.0 .

FIG. 1 A

B = 25.06" C = 36.06" F = 19.81" G = 2.50" M = 4.00"

S = 18.375" W = 17.25" Y = 1.00" X = 8 EA. Z = .53125"

AK = 20.125"AJ = 20.88" CG = 13.50" SAE ADAPTER no.1, CLUTCH NOMINAL SAE 14 WEIGHT - 1300 LBS, 590 kg., O.E.M. DRAWING 101- 20395-01.

FIG. 1 B

A = .69" B = 4.82" W1 = 49 lbs W2 = 355 lbs W3 = 15 lbs W4 = 99 lbs J1 = 935 lb/in squared J2 = 6210 lb/ in squared J3 = 63 lb/in squared J4 = 222 lb/in squared, Nominal Clutch SAE #14

FIG. 2 A

FIG. 2 B

R-310-005 PART SECTION C

FIG. 3 A

FIG. 3 B

QUAN. O.E.M. P/N DESCRIPTION

1 004-20106-00 K18 Exciter Endbell 1556 1 006-20014-00 Adapter K18 (1357) 1 008-20027-00 Dripproof Shield 1 008-20050-00 Adapter Band 1 016-00048-06 Fan K18 (3.87 Bore) 1597-02 1 016-16024-29 Fan Assembly (1597-02) 1 020-00115-00 K-18 Alum Baffle 1 031-18007-00 Coupling Hub P1347-00 2 034-90173-23 Spark Shield 1 034-90177-01 Use Up 508-00239-00 Box 2 034-90177-02 Outlet Box 2 034-90177-12 Air Inlet

1 034-90211-01 Regulator Cover 1 034-90216-00 Outlet Box 2 034-90216-01 CB Housing 14 ga.

2 034-90216-02 Cover 14 ga.

2 034-90216-03 C.B. Bracket 14 ga.

2 034-90216-04 C.B. Housing Stabilizer 2 034-90216-05 CO Board Housing 2 034-90216-06 CO Board Bracket 2 034-90216-07 Cover 14 ga.

1 130-14002-03 Drive Plates (K18) ORDE 1 130-14002-23 Drive Plate 1 213-24001-02 Wound Stator Assy.

1 230-98115-23 Exc Fld.

1 231-24000-74 Rotating Assy.

1 012-21102-00 Bearing

FIG. 3 B (cont.)

1 093-98244-23 Exc. Arm Assy. Wound 1 040-10150-15 Rotating Rectifier Assy.

3 850-33604-40 Diode 22A 600V K-Stud, Standard Diode 3 850-33604-50 Diode 22A 600V A-Stud, Reverse Diode 1 852-33521-20 ZNR. 200V 20% 10W A-Stud, Zener Diode

1 852-33521-30 ZNR. 200V 20% 10W C-stud, Zener Diode 1 510-07133-30 C.B. 1P 5A 250VDC, Circuit Breaker 2 514-01344-11 C.B. Operator # 314C386G01 2 864-10111-13 Space Heater OT815 150W Strip Type