RD_6125-01-456-9753.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME MOTOR-GENERATOR

STOCK NUMBER 6125-01-456-9753

PART NUMBER 11221

USED ON WAGB 420 CGC HEALY

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

Overhaul/Repair Specification for Reliance Electric-Kato Engineering Motor Generator Set

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of the Reliance Electric-Kato Engineering Division Motor Generator Set, Serial No. 11221, 1800 RPM, Motor Model D263440000, Type 26344, 700 KW, Generator Model A2634000 used on the U.S. Coast Guard Cutter Healy, WAGB 20.

1.2. Government Furnished Property (GFP)

1.2.1. Reliance Electric-Kato Engineering Division Motor Generator Set, Serial No. 11221, 1800 RPM, Motor Model D263440000, Type 26344, 700 KW, Generator Model A2634000, NSN 6125-01-456-9753

1.2.2. The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model or part number delivered for overhaul does not conform to the Motor Generator Set cited above.

2.0 APPLICABLE DOCUMENTS

2.1. General The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

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 Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. United States Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

2.2.2. MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

2.2.3. Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

2.2.4. Mil- PRF-16173E(SH)w/INT. Amendment 1 , dated 09/07/2006, Corrosion Preventive Compound, Solvent Cutback, Cold-application, Grade 2, Class II.

2.2.5. MIL-PRF-131 Revision K dated 08/2005, Barrier Materials, Water-vapor-proof, Greaseproof, Flexible, Heat Sealable.

2.2.6. MIL- PRF-24635E dated 15 September 2009, Performance Specification Coating Systems, Weather-Resistant, Exterior Use.

2.2.7. DoD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging material (WPM).

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

The Coast Guard does not possess or have access to Original Equipment Manufacturer (OEM) documents pertaining to the inspection, repair or testing of these Motor Generator Sets. It is the responsibility of the vendor to obtain all the applicable/required documents from the OEM.

2.3.1. National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.3.2. American Society for Quality (ASQ) Q9001-2008, dated 2008, Quality Management Systems-Requirements

2.3.3. American Society for Testing & Materials (ASTM) D3951, dated 8/15/2010, Standard Practice for Commercial Packaging

2.3.4. American Society for Testing & Materials (ASTM) D7478/D7478M-11 dated 11/01/2011, Standard Specification for Heavy Duty Sheathed Wood Crates

2.3.5. American Society for Testing & Materials (ASTM) E1417/E1417M dated06/01/2013, Standard Practice for Liquid Penetrant Testing

2.3.6. National Electrical Manufacturers Association NEMA MG1-2014, dated December 15, 2014, Motors and Generators

2.3.7. Institute of Electrical and Electronics Engineers, IEEE 43-2013, dated December 11, 2013, Recommended Practice for Testing Insulation Resistance of Rotating Machinery

2.3.8. Institute of Electrical and Electronics Engineers, IEEE 112-2004, dated February 09, 2004, Standard Test Procedure for Polyphase Induction Motors and Generators

2.3.9. Steel Structure Painting Council, SSPC-SP 3, dated 11/01/2004, Power Tool Cleaning

2.3.10. Reliance Electric-Kato Engineering Division specifications, standards, references and drawings

2.4. Specification Order of Precedence In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

SHELF LIFE CD 0

Overhaul/Repair Specification for Reliance Electric-Kato Engineering Motor Generator Set

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of the Reliance Electric-Kato Engineering Division Motor Generator Set, Serial No. 11221, 1800 RPM, Motor Model D263440000, Type 26344, 700 KW, Generator Model A2634000 used on the U.S. Coast Guard Cutter Healy, WAGB 20.

1.2. Government Furnished Property (GFP)

1.2.1. Reliance Electric-Kato Engineering Division Motor Generator Set, Serial No. 11221, 1800 RPM, Motor Model D263440000, Type 26344, 700 KW, Generator Model A2634000, NSN 6125-01-456-9753

1.2.2. The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model or part number delivered for overhaul does not conform to the Motor Generator Set cited above.

2.0 APPLICABLE DOCUMENTS

2.1. General The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

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 Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. United States Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

2.2.2. MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

2.2.3. Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

2.2.4. Mil- PRF-16173E(SH)w/INT. Amendment 1 , dated 09/07/2006, Corrosion Preventive Compound, Solvent Cutback, Cold-application, Grade 2, Class II.

2.2.5. MIL-PRF-131 Revision K dated 08/2005, Barrier Materials, Water-vapor-proof, Greaseproof, Flexible, Heat Sealable.

2.2.6. MIL- PRF-24635E dated 15 September 2009, Performance Specification Coating Systems, Weather-Resistant, Exterior Use.

2.2.7. DoD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging material (WPM).

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

The Coast Guard does not possess or have access to Original Equipment Manufacturer (OEM) documents pertaining to the inspection, repair or testing of these Motor Generator Sets. It is the responsibility of the vendor to obtain all the applicable/required documents from the OEM.

2.3.1. National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.3.2. American Society for Quality (ASQ) Q9001-2008, dated 2008, Quality Management Systems-Requirements

2.3.3. American Society for Testing & Materials (ASTM) D3951, dated 8/15/2010, Standard Practice for Commercial Packaging

2.3.4. American Society for Testing & Materials (ASTM) D7478/D7478M-11 dated 11/01/2011, Standard Specification for Heavy Duty Sheathed Wood Crates

2.3.5. American Society for Testing & Materials (ASTM) E1417/E1417M dated06/01/2013, Standard Practice for Liquid Penetrant Testing

2.3.6. National Electrical Manufacturers Association NEMA MG1-2014, dated December 15, 2014, Motors and Generators

2.3.7. Institute of Electrical and Electronics Engineers, IEEE 43-2013, dated December 11, 2013, Recommended Practice for Testing Insulation Resistance of Rotating Machinery

2.3.8. Institute of Electrical and Electronics Engineers, IEEE 112-2004, dated February 09, 2004, Standard Test Procedure for Polyphase Induction Motors and Generators

2.3.9. Steel Structure Painting Council, SSPC-SP 3, dated 11/01/2004, Power Tool Cleaning

2.3.10. Reliance Electric-Kato Engineering Division specifications, standards, references and drawings

2.4. Specification Order of Precedence In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General Inspections, repair/overhaul and testing of each Motor Generator Set shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. It is the Contractor's responsibility to obtain the OEM procedures, specifications, references and standard practices from Reliance Electric-Kato Engineering Division, the OEM.

3.1.1. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the Motor Generator Set is intended to return the Motor Generator Set's performance and appearance to a like new condition.

3.2. Overhaul - The Contractor shall provide all labor, parts, tools, equipment (including all testing equipment) and materials to perform the overhaul services and testing as described below for each Motor Generator Set.

3.2.1. The following are known discrepancies/mandatory work items.

a. Inspect and replace any failed or damaged amortisseur rods

b. Prepare and TIG weld all 48 amortisseur rod joints to ring

c. Perform NDT (Liquid Penetrant Inspection in accordance with ASTM E1417/E1417M) of new welds

3.2.2. Preliminary disassembly and inspection of the Motor Generator Set shall be conducted in accordance with the Motor Generator Set OEM procedures, specifications, references and standard practices to determine the total estimated cost to repair including material, labor, testing, Preservation, Packaging, Packing and Marking (PPP&M) costs.

3.2.3. A detailed cost estimate shall be submitted to the Coast Guard Contracting Officer for review and approval prior to the start of any repair or order of material. The Contractor shall also provide the replacement cost of an identical new Motor Generator Set for comparison to the overhaul cost.

At a minimum, mandatory replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the Contractor.

a. The detailed cost estimate shall contain the following as a minimum:

1. The part number, NSN and serial number of the Motor Generator Set

2. The contract number for each Motor Generator Set

3. A listing of individual parts by part number, cost and quantity

4. A listing of labor hours and labor rate to perform the overhaul, testing, and PPP&M

5. The cost of an identical new Motor Generator Set (see section 3.2.4.a. of this specification)

6. Condition of shipping crate and cost of any repairs. The Contractor shall conduct a thorough inspection of the shipping crate to ascertain any needed repairs up to and including a complete replacement of the shipping container.

If the as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shipping crate/packaging conforms to the Phytosanitary Requirements for Wood Packaging Material (WPM) in accordance with paragraph C2.1.1 of DoD 4140.01-M-1, Compliance for Defense Packaging, Ref. 2.2.7 of this specification.

b. Upon acceptance of the cost estimate and authorization to proceed by the Contracting Officer, the Contractor shall overhaul the Motor Generator Set in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.2.4. The Coast Guard Contracting Officer will determine the disposition of any Motor Generator Set delivered for overhaul that is Beyond Economical Repair (BER).

a. If the Motor Generator Set is BER, the government reserves the right to purchase an identical new Motor Generator Set from the Contractor.

3.2.5. All replacement parts used in the overhaul shall be new OEM parts.

Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball/roller type bearings which are not manufactured by the Motor Generator Set manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the Motor Generator Set manufacturer and by their part number.

3.2.6. Where any carbon steel zerk fittings exist, they shall be replaced with a non-magnetic grade of stainless steel. Protective red plastic caps shall be installed on each zerk fitting.

a. A decal or permanent type label shall be affixed to the side of the Motor Generator Set informing the user of the manufacturer's recommended amount and type of grease to be used.

3.2.7. New label plates shall be installed at the conclusion of the painting.

The label plate shall contain Motor Generator Set make, model and serial number and pertinent characteristic information as a minimum requirement. A

3.0 REQUIREMENTS

3.1. General Inspections, repair/overhaul and testing of each Motor Generator Set shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. It is the Contractor's responsibility to obtain the OEM procedures, specifications, references and standard practices from Reliance Electric-Kato Engineering Division, the OEM.

3.1.1. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the Motor Generator Set is intended to return the Motor Generator Set's performance and appearance to a like new condition.

3.2. Overhaul - The Contractor shall provide all labor, parts, tools, equipment (including all testing equipment) and materials to perform the overhaul services and testing as described below for each Motor Generator Set.

3.2.1. The following are known discrepancies/mandatory work items.

a. Inspect and replace any failed or damaged amortisseur rods

b. Prepare and TIG weld all 48 amortisseur rod joints to ring

c. Perform NDT (Liquid Penetrant Inspection in accordance with ASTM E1417/E1417M) of new welds

3.2.2. Preliminary disassembly and inspection of the Motor Generator Set shall be conducted in accordance with the Motor Generator Set OEM procedures, specifications, references and standard practices to determine the total estimated cost to repair including material, labor, testing, Preservation, Packaging, Packing and Marking (PPP&M) costs.

3.2.3. A detailed cost estimate shall be submitted to the Coast Guard Contracting Officer for review and approval prior to the start of any repair or order of material. The Contractor shall also provide the replacement cost of an identical new Motor Generator Set for comparison to the overhaul cost.

At a minimum, mandatory replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the Contractor.

a. The detailed cost estimate shall contain the following as a minimum:

1. The part number, NSN and serial number of the Motor Generator Set

2. The contract number for each Motor Generator Set

3. A listing of individual parts by part number, cost and quantity

4. A listing of labor hours and labor rate to perform the overhaul, testing, and PPP&M

5. The cost of an identical new Motor Generator Set (see section 3.2.4.a. of this specification)

6. Condition of shipping crate and cost of any repairs. The Contractor shall conduct a thorough inspection of the shipping crate to ascertain any needed repairs up to and including a complete replacement of the shipping container.

If the as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shipping crate/packaging conforms to the Phytosanitary Requirements for Wood Packaging Material (WPM) in accordance with paragraph C2.1.1 of DoD 4140.01-M-1, Compliance for Defense Packaging, Ref. 2.2.7 of this specification.

b. Upon acceptance of the cost estimate and authorization to proceed by the Contracting Officer, the Contractor shall overhaul the Motor Generator Set in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.2.4. The Coast Guard Contracting Officer will determine the disposition of any Motor Generator Set delivered for overhaul that is Beyond Economical Repair (BER).

a. If the Motor Generator Set is BER, the government reserves the right to purchase an identical new Motor Generator Set from the Contractor.

3.2.5. All replacement parts used in the overhaul shall be new OEM parts.

Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball/roller type bearings which are not manufactured by the Motor Generator Set manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the Motor Generator Set manufacturer and by their part number.

3.2.6. Where any carbon steel zerk fittings exist, they shall be replaced with a non-magnetic grade of stainless steel. Protective red plastic caps shall be installed on each zerk fitting.

a. A decal or permanent type label shall be affixed to the side of the Motor Generator Set informing the user of the manufacturer's recommended amount and type of grease to be used.

3.2.7. New label plates shall be installed at the conclusion of the painting.

The label plate shall contain Motor Generator Set make, model and serial number and pertinent characteristic information as a minimum requirement. A separate label plate made of similar material, as the original label plate, shall be attached stating the Contractor's name, contract number and date of overhaul.

3.2.8. Any existing paint shall be removed in accordance with section 2.3.9.

of this specification where practicable. An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.2.9. The entire Motor Generator Set shall be painted with a base coat (primer) of high build epoxy 5.0 - 6.0 mils Dry Film Thickness (DFT) compatible with the finish coat. The finish coat shall be in accordance with MIL-PRF-24635 (section 2.2.6. of this specification) Silicone Alkyd, Type II Class 1, 2.0 - 3.0 mils DFT. The color shall be Machinery Gray, color number 26307 (or match the OEM color), in accordance with the, FED-STD-595C (section

2.2.3. of this specification). Total paint thickness shall be 7.0 - 9.0 mils

DFT.

a. The Contractor shall record the paint thickness in mils, using a certified/calibrated dry film thickness gauge, at each stage in the painting process. The Contractor shall include this information along with the paint gauge serial number and date of calibration on the Motor Generator Set test report.

3.2.10. The winding resistance shall be inspected in accordance with section

2.3.7. of this specification. Windings that do not meet the standard of IEEE 43-2004, shall be reinsulated in a qualified insulation material recommended by the Motor Generator Set OEM. Reinsulated windings shall be subjected to a follow up resistance test once thoroughly dry. This process shall be repeated until acceptable resistance readings are achieved.

3.2.11. The Motor Generator Set rotating element shall be balanced in accordance with section 2.3.6. of this specification. The final result of imbalance shall be documented.

3.2.12. The Contractor shall provide written certification to the Contracting Officer that the Motor Generator Set was reconditioned to the same standards as a new Motor Generator Set and a copy shall be turned over to the Coast Guard Quality Assurance Representative (QAR). All test results shall be made available for review by the QAR upon his request.

3.3. Motor Generator Set Tests

3.3.1. To ensure the Motor Generator Set turns freely, the Motor Generator Set shaft shall be rotated a minimum of five revolutions The QAR shall inspect for smoothness of rotation and check for signs of binding, dragging, or unusual noises using a Mechanics Stethoscope (provided by the Contractor).

The Contractor shall investigate any questionable test results and correct as necessary.

3.3.2. Prior to the operational testing, the following tests, at a minimum, shall be conducted and the results documented.

a. Ductor test of all four coils

b. Insulation test at 500 volts

3.3.3. The Motor Generator Set shall be operationally tested. The Motor Generator Set shall be able to meet the original performance shown on the OEM Motor Generator Set data sheet.

a. The Contractor shall provide all equipment, tooling and test equipment necessary to operationally test the Motor Generator Set in accordance with OEM requirements and the references cited within this specification.

b. The bearing temperatures on the Motor Generator Set shall be monitored during the entirety of the test and recorded on the Motor Generator Set test report including the OEM allowable temperature range.

c. Testing shall be conducted to certify, document, and report all parameters found on Annex B, Typical Report, in IEEE Std 112-2004 section 2.3.8. of this specification.

3.3.4. The test results shall be documented on a report and provided to the Contracting Officer. A copy of the test report shall be packed with each Motor Generator Set and a copy shall be provided to the QAR. The report shall contain the following information as a minimum:

a. Contractor's name

b. Contract number

c. Motor Generator Set model number, part number and serial number

d. Date of test

e. Description of each test conducted and the results of each test

f. Name of the person conducting the testing

3.4. Motor Generator Set Configuration - The overhauled Motor Generator Set shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configured to Original Configuration.

3.5. Photo Documentation - The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the Motor Generator Set after receipt.

b. When significant findings that will affect cost of repair/overhaul or time are discovered.

c. When other significant or unusual findings such as failed parts or damages are discovered.

d. When the Motor Generator Set is tested to document configuration.

e. When the Motor Generator Set is prepared for shipment to document "as shipped" configuration to include images of the PPP&M.

separate label plate made of similar material, as the original label plate, shall be attached stating the Contractor's name, contract number and date of overhaul.

3.2.8. Any existing paint shall be removed in accordance with section 2.3.9.

of this specification where practicable. An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.2.9. The entire Motor Generator Set shall be painted with a base coat (primer) of high build epoxy 5.0 - 6.0 mils Dry Film Thickness (DFT) compatible with the finish coat. The finish coat shall be in accordance with MIL-PRF-24635 (section 2.2.6. of this specification) Silicone Alkyd, Type II Class 1, 2.0 - 3.0 mils DFT. The color shall be Machinery Gray, color number 26307 (or match the OEM color), in accordance with the, FED-STD-595C (section

2.2.3. of this specification). Total paint thickness shall be 7.0 - 9.0 mils

DFT.

a. The Contractor shall record the paint thickness in mils, using a certified/calibrated dry film thickness gauge, at each stage in the painting process. The Contractor shall include this information along with the paint gauge serial number and date of calibration on the Motor Generator Set test report.

3.2.10. The winding resistance shall be inspected in accordance with section

2.3.7. of this specification. Windings that do not meet the standard of IEEE 43-2004, shall be reinsulated in a qualified insulation material recommended by the Motor Generator Set OEM. Reinsulated windings shall be subjected to a follow up resistance test once thoroughly dry. This process shall be repeated until acceptable resistance readings are achieved.

3.2.11. The Motor Generator Set rotating element shall be balanced in accordance with section 2.3.6. of this specification. The final result of imbalance shall be documented.

3.2.12. The Contractor shall provide written certification to the Contracting Officer that the Motor Generator Set was reconditioned to the same standards as a new Motor Generator Set and a copy shall be turned over to the Coast Guard Quality Assurance Representative (QAR). All test results shall be made available for review by the QAR upon his request.

3.3. Motor Generator Set Tests

3.3.1. To ensure the Motor Generator Set turns freely, the Motor Generator Set shaft shall be rotated a minimum of five revolutions The QAR shall inspect for smoothness of rotation and check for signs of binding, dragging, or unusual noises using a Mechanics Stethoscope (provided by the Contractor).

The Contractor shall investigate any questionable test results and correct as necessary.

3.3.2. Prior to the operational testing, the following tests, at a minimum, shall be conducted and the results documented.

a. Ductor test of all four coils

b. Insulation test at 500 volts

3.3.3. The Motor Generator Set shall be operationally tested. The Motor Generator Set shall be able to meet the original performance shown on the OEM Motor Generator Set data sheet.

a. The Contractor shall provide all equipment, tooling and test equipment necessary to operationally test the Motor Generator Set in accordance with OEM requirements and the references cited within this specification.

b. The bearing temperatures on the Motor Generator Set shall be monitored during the entirety of the test and recorded on the Motor Generator Set test report including the OEM allowable temperature range.

c. Testing shall be conducted to certify, document, and report all parameters found on Annex B, Typical Report, in IEEE Std 112-2004 section 2.3.8. of this specification.

3.3.4. The test results shall be documented on a report and provided to the Contracting Officer. A copy of the test report shall be packed with each Motor Generator Set and a copy shall be provided to the QAR. The report shall contain the following information as a minimum:

a. Contractor's name

b. Contract number

c. Motor Generator Set model number, part number and serial number

d. Date of test

e. Description of each test conducted and the results of each test

f. Name of the person conducting the testing

3.4. Motor Generator Set Configuration - The overhauled Motor Generator Set shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configured to Original Configuration.

3.5. Photo Documentation - The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the Motor Generator Set after receipt.

b. When significant findings that will affect cost of repair/overhaul or time are discovered.

c. When other significant or unusual findings such as failed parts or damages are discovered.

d. When the Motor Generator Set is tested to document configuration.

e. When the Motor Generator Set is prepared for shipment to document "as shipped" configuration to include images of the PPP&M.

f. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting Officer's Representative via email.

3.6. Notifications & Inspections - The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to said Contractor being ready for any inspections or testing.

4.0 QUALITY ASSURANCE

4.1. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.2. Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with section 2.3.1. of this specification. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.3. Responsibility for Inspection - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all required inspections. All inspection and testing shall be performed at the Contractor'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 or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the Coast Guard's intention for the QAR to witness the testing of all Motor Generator Set overhauled by the Contractor.

4.3.1. The Contractor shall provide the OEM specifications, standards, drawings, tolerances, parameters and test requirements in order for the QAR to verify all readings, measurements and tolerances.

4.4. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. 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 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.

4.5. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with section

2.3.2. of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.6. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.6.1. The following inspections are required and will be witnessed by the

QAR.

a. Verify paint requirement and paint thickness (section 3.2.9. of this specification)

b. Motor Generator Set winding resistance check (section 3.2.10. of this specification)

c. Motor Generator Set certification (section 3.2.12. of this specification)

d. Motor Generator Set rotation check (section 3.3.1. of this specification)

e. Operational Motor Generator Set test (section 3.3.3 of this specification)

f. Verify PPP&M requirements (section 5.0 of this specification)

4.7. Packing Inspection - The Contracting Officer shall be notified prior to the packaging and marking of the completed Motor Generator in accordance with section 3.6 of this specification.

5.0 PRESERVATION, PACKING, & MARKING

5.1. Preservation - An overhauled Motor Generator Set is typically intended for warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled Motor Generator Set undergo the following preservation requirements.

5.1.1. All unpainted surfaces on the Motor Generator Set shall be sprayed with a thin film of Corrosion Preventive Compound (section 2.2.4. of this specification).

5.1.2. Each Motor Generator Set shall be placed in a heat sealable protective envelope that complies with MIL-PRF-131 Class 1 (section 2.2.5. of this specification).

a. Before sealing the protective envelope, ten (16) units of dry active desiccant Type 1 (section 2.2.2. of this specification) shall be placed inside of the heat sealable protective envelope.

5.2. Wood Packaging Material (WPM) Requirements - All packaging and packing material shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1. of DoD 4140.01-M-1, Compliance for Defense Packaging, (section 2.2.7. of this specification).

5.3. Packaging of Motor Generator Set - Each Motor Generator Set shall be individually packaged in its own enclosed wooden container. The Motor Generator Set shall be bolted to the skid base using carriage bolts. Where the carriage bolts penetrate the heat sealable protective envelope, a 1/8 inch thick rubber gasket and RTV shall be used to seal the envelope from the entrance of moisture.

5.3.1. The wooden container shall be constructed in accordance with ASTM D7478/D7478M (section 2.3.4. of this specification) Type II - Bolted, Class 2

f. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting Officer's Representative via email.

3.6. Notifications & Inspections - The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to said Contractor being ready for any inspections or testing.

4.0 QUALITY ASSURANCE

4.1. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.2. Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with section 2.3.1. of this specification. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.3. Responsibility for Inspection - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all required inspections. All inspection and testing shall be performed at the Contractor'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 or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the Coast Guard's intention for the QAR to witness the testing of all Motor Generator Set overhauled by the Contractor.

4.3.1. The Contractor shall provide the OEM specifications, standards, drawings, tolerances, parameters and test requirements in order for the QAR to verify all readings, measurements and tolerances.

4.4. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. 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 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.

4.5. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with section

2.3.2. of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.6. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.6.1. The following inspections are required and will be witnessed by the

QAR.

a. Verify paint requirement and paint thickness (section 3.2.9. of this specification)

b. Motor Generator Set winding resistance check (section 3.2.10. of this specification)

c. Motor Generator Set certification (section 3.2.12. of this specification)

d. Motor Generator Set rotation check (section 3.3.1. of this specification)

e. Operational Motor Generator Set test (section 3.3.3 of this specification)

f. Verify PPP&M requirements (section 5.0 of this specification)

4.7. Packing Inspection - The Contracting Officer shall be notified prior to the packaging and marking of the completed Motor Generator in accordance with section 3.6 of this specification.

5.0 PRESERVATION, PACKING, & MARKING

5.1. Preservation - An overhauled Motor Generator Set is typically intended for warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled Motor Generator Set undergo the following preservation requirements.

5.1.1. All unpainted surfaces on the Motor Generator Set shall be sprayed with a thin film of Corrosion Preventive Compound (section 2.2.4. of this specification).

5.1.2. Each Motor Generator Set shall be placed in a heat sealable protective envelope that complies with MIL-PRF-131 Class 1 (section 2.2.5. of this specification).

a. Before sealing the protective envelope, ten (16) units of dry active desiccant Type 1 (section 2.2.2. of this specification) shall be placed inside of the heat sealable protective envelope.

5.2. Wood Packaging Material (WPM) Requirements - All packaging and packing material shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1. of DoD 4140.01-M-1, Compliance for Defense Packaging, (section 2.2.7. of this specification).

5.3. Packaging of Motor Generator Set - Each Motor Generator Set shall be individually packaged in its own enclosed wooden container. The Motor Generator Set shall be bolted to the skid base using carriage bolts. Where the carriage bolts penetrate the heat sealable protective envelope, a 1/8 inch thick rubber gasket and RTV shall be used to seal the envelope from the entrance of moisture.

5.3.1. The wooden container shall be constructed in accordance with ASTM D7478/D7478M (section 2.3.4. of this specification) Type II - Bolted, Class 2

- Plywood Sheathed, Style A - Skid Base with the following modifications.

a. Corrosion resistant fasteners shall be used to attach the hood (boxed cover) to the skid base. A two inch red painted area shall be applied to each of the fasteners (and surrounding area) that must be extracted in order to remove the hood (boxed cover) from the skid base.

b. The container shall be capable of protecting the Motor Generator Set from damage during multiple shipments by commercial carrier (section 2.3.3. of this specification).

5.4. Marking - Each preserved and packed Motor Generator Set shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 3/4 inches minimum height black characters on a white painted background. NOTE: ALL PREVIOUS

MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE REMOVED FROM A REUSABLE

SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.4.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION "A", of issue with quantity (i.e. 1-EA), and the words COAST GUARD SFLC

MATERIAL AND REUSABLE CONTAINER, DO NOT DESTROY. REMOVE RED PAINTED SCREWS

TO REMOVE COVER

STOCK NUMBER 6125-01-456-9753

ITEM NAME Motor Generator Set (SSMG)

PART NUMBER A26343000

CONTRACT NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CODITION "A"

QUANTITY & OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

REMOVE RED PAINTED SCREWS TO REMOVE COVER

5.5. Bar Coding - The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. Two bar code labels shall be applied, one on each of the two longest sides.

5.5.1. All bar code labels shall be in accordance with SFLC specification D- 000-0100 Rev G.

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.,

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point (DODSSP Documents) 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5098

FAX (215) 697-9398

http://dodssp.daps.dla.mil/

b. DOD & Navy Publications and Forms (Other Than DODISS) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA. 19120 215-697-2197

c. USCG Surface Forces Logistics Center Long Range Enforcer Product Line Mail Stop 26, Bldg. 3, 2nd Floor, CPD-2 2401 Hawkins Point Road Baltimore, MD 21226-5000

410-762-XXXX

6.1.2. Commercial Documents

a. American Society for Testing & Materials (ASTM) 1916 Race Street Philadelphia PA. 19103-1187 215-299-5585

FAX 215-977-9679

b. American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, NY 10036 212-642-4900

FAX 212-398-0023

www.ansi.org

c. American Society for Quality (ASQ) P.O. Box 3005 Milwaukee, WI 53201-3005 800-248-1946 www.asq,org

d. IEEE-USA 2001 L Street, NW. Suite 700 Washington, DC 20036-4910 USA 202-785-0017 Fax: 202-785-0835

e. National Electrical Manufacturers Association 1300 North 17th Street Suite 1752 Rosslyn, VA 22209 703-841-3200

- Plywood Sheathed, Style A - Skid Base with the following modifications.

a. Corrosion resistant fasteners shall be used to attach the hood (boxed cover) to the skid base. A two inch red painted area shall be applied to each of the fasteners (and surrounding area) that must be extracted in order to remove the hood (boxed cover) from the skid base.

b. The container shall be capable of protecting the Motor Generator Set from damage during multiple shipments by commercial carrier (section 2.3.3. of this specification).

5.4. Marking - Each preserved and packed Motor Generator Set shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 3/4 inches minimum height black characters on a white painted background. NOTE: ALL PREVIOUS

MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE REMOVED FROM A REUSABLE

SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.4.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION "A", of issue with quantity (i.e. 1-EA), and the words COAST GUARD SFLC

MATERIAL AND REUSABLE CONTAINER, DO NOT DESTROY. REMOVE RED PAINTED SCREWS

TO REMOVE COVER

STOCK NUMBER 6125-01-456-9753

ITEM NAME Motor Generator Set (SSMG)

PART NUMBER A26343000

CONTRACT NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CODITION "A"

QUANTITY & OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

REMOVE RED PAINTED SCREWS TO REMOVE COVER

5.5. Bar Coding - The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. Two bar code labels shall be applied, one on each of the two longest sides.

5.5.1. All bar code labels shall be in accordance with SFLC specification D- 000-0100 Rev G.

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.,

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point (DODSSP Documents) 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5098

FAX (215) 697-9398

http://dodssp.daps.dla.mil/

b. DOD & Navy Publications and Forms (Other Than DODISS) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA. 19120 215-697-2197

c. USCG Surface Forces Logistics Center Long Range Enforcer Product Line Mail Stop 26, Bldg. 3, 2nd Floor, CPD-2 2401 Hawkins Point Road Baltimore, MD 21226-5000

410-762-XXXX

6.1.2. Commercial Documents

a. American Society for Testing & Materials (ASTM) 1916 Race Street Philadelphia PA. 19103-1187 215-299-5585

FAX 215-977-9679

b. American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, NY 10036 212-642-4900

FAX 212-398-0023

www.ansi.org

c. American Society for Quality (ASQ) P.O. Box 3005 Milwaukee, WI 53201-3005 800-248-1946 www.asq,org

d. IEEE-USA 2001 L Street, NW. Suite 700 Washington, DC 20036-4910 USA 202-785-0017 Fax: 202-785-0835

e. National Electrical Manufacturers Association 1300 North 17th Street Suite 1752 Rosslyn, VA 22209 703-841-3200 www.nema.org

f. Steel Structure Painting Council 40 24th Street Pittsburgh, PA 15222 412-281-4331

WARRANTY:

X A. Standard Manufacturer's Warranty

B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

6125-01-456-9753

MOTOR-GENERATOR

11221

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

KATO ENGINEERING INC.

DBA KATO ENGINEERING

2075 HOWARD DRIVE

NORTH MANKATO, MINNESOTA 56003-1525

WRITTEN BY:

DATE :

BRANDON ANDREWS

24 MAR 16

Cost Estimate for Overhaul NOT TO EXCEED: