Attachment_2_Specification_Thruster_Motor.pdf

REVISION No. 2 . Date: 16 February 2017

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

SPECIFICATION FOR THE PROCUREMENT OF

550 HORSEPOWER (HP) DIRECT CURRENT (DC)

THRUSTER MOTORS FOR 225’ WLB

ORIGINATED BY: Wade Williams DATE 7 Jun 2016

ORIGINATOR’S COMMAND: SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT/DIVISION: ICE BREAKER, BUOY AND CONSTRUCTION TENDER

PRODUCT LINE (IBCT PL)

Specification for the Procurement of

550 HP DC Thruster Motors for 225’ WLB

1.0 SCOPE – This specification covers the procurement of vertical direct current (DC) thruster motors for use on 225-foot long sea going buoy tenders (WLB).

2.0 APPLICABLE DOCUMENTS

2.1. 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.

2.1.1. U.S. COAST GUARD SPECIFICATION

a. D-000-100 REV G (dated 02/23/06) Bar Coding for USCG SFLC Material

b. SFLC Std Spec 0860, 2014, General Requirements for Technical Publication

2.1.2. U.S. COAST GUARD DRAWINGS

a. 225-WLB 568-1, rev D, , Bow Thruster Arrangement and Detail

b. 225-WLB 568-2, rev B, Stern Thruster Arrangement and Detail

c. 225B-WLB 568-1, rev A, Bow Thruster Arrangement and Detail

d. 225B-WLB 568-2, rev A, Stern Thruster Arrangement and Detail

e. 225-WLB 568-202, rev E, sheet 5, Bow & Stern Thruster

2.1.3. MILITARY SPECIFICATIONS

a. MIL-STD-2073-1E (dated 1/7/2011) Standard Practice for Military Packaging

2.2. 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.

2.2.1. INSTITUTE of ELECTRICAL and ELECTRICAL ENGINEERS (IEEE).

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

Electric Machinery.

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

2.2.2. AMERICAN SOCIETY FOR QUALITY (ASQ)

a. ASQ/ANSI/ISO 9001:2015, Quality Management Systems – Requirements

2.2.3. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA MG 1-2014 Motors and Generators.

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

2.2.4. NATIONAL CONFERENCE OF STANDARDS LABORATORIES (NCSL)

a. NCSL Z540.3-2006(R2013), Requirements for Calibration Measuring and Test

Equipment

2.2.5. AMERICAN SOCIETY FOR TESTING AND MATERIALS

a. ASTM D7478-11, Standard Specification for Heavy Duty Sheathed Wood

Crates

2.3. SPECIFICATION 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 – The thruster motor shall conform to NEMA MG-1 and the specifications below. Each assembled thruster motor shall contain all parts described in

Sections 3.1 through 3.3 below, excluding the tachometer and lower shaft coupling.

3.1. THRUSTER MOTOR PARAMETERS

3.1.1. Electrical

a. Continuous duty DC motor with single reversing armature.

b. Armature circuit ratings (must meet both conditions):

1. 500 VDC, 871 A, 550 HP, 1800 RPM

2. 475 VDC, 767 A, 460 HP, 1700 RPM

c. Shunt field circuit ratings:

1. Voltage: 300 VDC

2. Current: 9.0 A (1700 RPM), 9.2 A (1800 RPM)

d. Designed for vertical mounting.

e. Suitable for operation from a six-pulse SCR power supply.

f. Operable at maximum ambient temperature of 50°C.

g. Motor lifespan must be equal to, or greater than, the remaining life of the cutter: approximately 25,000 operating hours.

h. Temperature class H non-hygroscopic insulation.

i. Field coils shall be treated with varnish or other insulating compound while being wound or vacuum pressure impregnated with varnish after winding. The finished winding shall be water and oil resistant.

j. Copper windings and current carrying parts.

k. Equipped with a three wire 100 Ω platinum resistance temperature detector

(RTD), at the following locations:

1. Shunt field

2. Armature circuit winding

3. Lower bearing

4. Upper bearing

l. Terminal boxes where single hole crimped terminals on external cable conductors can be connected to internal and accessory wiring:

1. Main – Mates with the following:

Two positive and two negative 373 MCM rectangular tongue cable lugs with ½” diameter hole for bolting through copper bus bar (armature circuit)

One positive and one negative 9 MCM ring tongue cable lug with ¼” diameter hole for landing on terminal stud (field circuit)

2. Auxiliary – Double row barrier block screw terminal board (grounding brush, heater, tachometer, and RTDs) to accommodate ring tongue cable lugs with #6 or #8 hole.

3.1.2. Mechanical

a. Open drip proof enclosure with separate blower motor.

b. Two or more pad eyes to facilitate rigging.

c. Carbon brushes and brush holders with constant force spring assemblies.

d. Cooling flow path shall be such that air passing over the commutator and brushes is immediately discharged to the surrounding compartment to minimize carbon dust deposition on the windings and interior surfaces.

e. Sealed anti-friction bearings.

f. Shaft grounding brush with shunt cable running to the auxiliary terminal box.

g. Provision for coupling the upper motor end to General Electric tachometer

Model #5PY59JY2, P/N D123 and running the output cable to the auxiliary terminal box.

h. Materials containing silicone shall not be used within the airstream of the motor.

i. Marine duty construction

1. Operation not impaired by vibration or shock likely to arise under normal service conditions.

2. Components treated or manufactured to resist salt laden moist air corrosion and fungus growth in a damp, unconditioned below decks environment.

j. Fasteners securing current-carrying parts shall be provided with means to prevent loosening caused by vibration.

k. The motor must conform to the fit, form, and function of the existing model.

l. Shaft, double ended with key slot & key, see drawings references 2.1.2.a – d for dimensions.

m. Circular flange face mounting with eight equally spaced (45° angular separation) 0.9448-inch diameter unthreaded holes on a 29.134 inch diameter bolting circle.

n. The thruster motor length shall not exceed 66.5 inches. The assembled unit with blower shall not exceed an overall length of 80 inches.

o. The thruster motor (excluding the blower) must be able to pass through a 33 inch square opening, representative of the most limiting hatch or door to the weather.

3.2. BLOWER PARAMETERS

3.2.1. Electrical

a. 460 VAC, 3 phase, 60 Hz, approximately 5 HP, not to exceed 7½ HP

b. Connection box with studs or terminals for making external cable connections to 4 MCM cable with crimped ring tongue terminals.

3.2.2. Mechanical

a. Motor and fan mounted externally on the thruster motor housing.

b. Meets space restrictions shown in references 2.1.2.a – d.

c. Direction of rotation arrow marked on blower housing.

d. Supply air filter to trap airborne particulate.

3.3. ANTI-CONDENSATION HEATER PARAMETERS

3.3.1. Electrical

a. 120 VAC, 1 phase

b. Not to exceed 12½ A (1500 W)

3.4. THRUSTER MOTOR PERFORMANCE & LABELING

3.4.1. Each motor shall have an engraved metal plate attached by rivets mounted in a conspicuous location with the following information:

a. Thruster Motor

1. Manufacturer and frame

2. Rated armature voltage, current, power, and speed

3. Rated shunt field voltage and current

4. Heater voltage, current, and phases.

5. Ambient temperature rating and insulation class

6. Weight

7. Serial number

b. Blower Motor

1. Manufacturer, frame, and model.

2. Voltage, current, frequency, phase

3. Serial number

3.5. TECHNICAL MANUAL

3.5.1. A technical manual, meeting the requirements of SFLC Std Spec 0860 for contractor developed manuals, shall be furnished with the first article. The technical publication shall provide, at a minimum, the necessary information and instructions to operate and maintain the equipment at the organizational level.

3.5.2. The technical manual shall contain at a minimum the following drawings:

a. Thruster motor outline

b. Thruster blower outline

c. Connection box stud and terminal board configuration

d. Thruster motor cross section and assembly

e. Thruster motor winding diagram and field data

f. Electrical schematic showing all circuits and connection points

g. The technical manual shall contain the conducted first article test data (located in section 4.7), including the following:

h. Measurements at 25%, 50%, 75%, 92%, 100%, and 110% of rated power

1. Armature voltage, current, and rotational speed

2. Field voltage and current

3. Winding and bearing temperatures

i. Cold resistances

1. Armature, field, and heater insulation

2. Armature and field conductors

3.6. GENERAL – The requirements described herein are the minimum necessary and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to insure quality of the product.

3.7. TEST CONDITIONS – Tests should be made under conditions similar to those expected during normal shipboard operation, except that vibration and ship motion will not be present. The thruster motor shall be powered by a six pulse rectified power supply.

3.8. TEST AND INSPECTION PLAN –

3.8.1. This document, developed by the vendor or subcontracted testing facility, will be used to test and inspect each component to the requirements of the specification.

The document shall contain all the applicable test setups, equipment, references to drawings, etc. required to provide sufficient information.

3.8.2. The contractor shall submit a Test and Inspection Plan to the Contracting Officer for approval not less than 15 days prior to beginning of test to ensure it contains the required information in accordance with this specification.

3.8.3. The plan shall include the specific inspections and tests specified herein, and all other inspections and tests needed to verify conformance to every requirement in this specification. The test plan shall include, but not be limited to:

1. Contractor Name, Address, and Phone Number

2. Time and date of test.

3. Environmental condition requirements.

4. Procedures for the test configuration and pass/fail criteria.

5. Test data sheets to be used to record observed performance data.

6. A complete listing of all equipment to be used and current calibration data.

3.9. TEST REPORT – Final calibration and testing shall be conducted in accordance with the manufacturers’ written procedures and IEEE Standards in Sections 2 and 3 herein.

3.9.1. The contractor shall develop and submit an individual, written, Test Report for each motor manufactured. This report shall be submitted to the Contracting

Officer and the Coast Guard Contracting Officer’s Representative (COR) for review prior to acceptance.

a. Test data sheets to be used to record observed performance data, and shall include all deficiencies found and the corrective action taken.

b. Dimensional report, and all final clearances, with tolerances.

c. Industry standards compliance.

d. Testers Name with signature and Date.

e. Identification of units by serial number, part number, and stock number

f. Results of tests identified in Section 4.5 herein.

g. Comments, if any, pertaining to any unusual observations during testing.

h. Signature of Government witness. (First Article only)

3.10. NOTIFICATIONS & INSPECTIONS – The contractor shall notify the Contracting

Officer at least seven (7) calendar days prior to any inspections or testing required herein.

3.11. WARRANTY - A warranty of one year from installation or 3600 operating hours, whichever occurs first and 24 months of storage is required covering the entire

Thruster Motor. Storage commences upon receipt of thruster motor at the designated

Coast Guard facility. The Contractor shall provide a Project Manager who shall be responsible for all Contractor warranty work performed under this specification.

3.11.1. The Contractor shall repair/rebuild the failed thruster motor including painting and preservation to the condition level necessary for the contractor to honor a new full warranty. The Contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

3.12. FAILURE ANALYSIS- Failure analysis is the systematic investigation of a part failure with the objectives of determining the root causes of failure and the corrective actions needed to prevent future failures. The failure analysis report should include at a minimum the following information:

1) Name and address of Contractor (including phone number and POC)

2) Name of technician(s) conducting the analysis

3) Contract Number

4) Thruster Motor Serial Number

5) Purpose

6) Methodology

7) History

8) Inspection Criteria and Results

9) Conclusion

10) Recommendations

4.0 QUALITY ASSURANCE

4.1. 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 for the conduct of all inspection requirements. All inspection and testing shall be performed at a Contractor’s facility within the continental United States. A Coast Guard Quality Assurance (QA)

Representative will visit the Contractor’s facility to assure that supplies and services conform to the prescribed requirements. The QA Representative will witness testing, preservation, packaging, and marking. The Contractor is responsible for the maintenance and calibration of all inspection and test equipment necessary to assure that supplies and services conform to contract requirements. The additional testing requirements of paragraph 4.7 apply only to the first article.

4.2. RESPONSIBILITY FOR COMPLIANCE – All items shall meet the requirements of sections 3 and 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 this specification shall not relieve the contractor of the responsibility of assuring that all products or services submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3. QUALITY SYSTEM – The Contractor shall maintain a quality system, which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with

ANSI/ASQ/ISO-9001. The system shall be documented and available for review by the

Coast Guard inspector...

4.4. CALIBRATION SYSTEM – The Contractor, as well as any subcontractors, shall maintain a test equipment calibration program conforming to NCSL Z540.3. The program shall be documented and traceable to the National Institute of Standards

(NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.5. FIRST ARTICLE INSPECTION (F.A.I.) -Verification that the First Article manufactured using the normal production process (planning, technical /work instructions, material processing systems and controls, tools, fixtures, test equipment and personnel proficiency) will produce a component in compliance with the specification requirements (such as drawing dimensional characteristics, material content meet the physical and performance requirements such as drawing dimensional characteristics, material content, process, capability and performance.

4.6. FIRST ARTICLE TEST (F.A.T.)- Tests conducted to verify that the First Article meet the performance and dimensional requirements of the of the specification before, during and after all specified environmental and durability/endurance conditions.

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

4.7.1. Verify and document the following; verify the brush holders are properly spaced and set at the proper height above the commutator on the neutral plane. Verify that the seat brushes fit the commutator curvature in the brush holders.

4.7.2. Test and document results as described by IEEE-STD-113 Forms A and B.

Specific parameters of Input Power (whether 475V or 500V) and other terminal conditions shall be annotated at the start of each test.

a. Winding Resistance Test – A resistance test shall be performed in accordance with IEEE STD 113 section 4.2.

b. Air Gap Measurements – Measurements shall be performed in accordance with

IEEE STD 113 section 4.3.

c. Insulation resistance test (cold) – This test shall be done in accordance with

IEEE STD 113 section 4.7.

d. High Potential Test – This test shall be done in accordance with IEEE STD

113 section 4.8.

e. No Load Operational Test – Run the motor for no less than 1 hour at no load, a minimum of 30 minutes in each direction. Observe that no brush is sparking or pin arcing. Verify that bearing and winding temperatures, as measured using the installed RTDs, are in the expected range.

4.7.3. The first motor to be manufactured and delivered is subject to First Article

Testing requirements not imposed on subsequent motors. Tests shall be performed at six load points: 25%, 50%, 75%, 92%, 100%, and 110% of rated power. The testing and result will be documented as outlined in section 3.9 of this specification.

a. Rectified power dynamometer tests from IEEE-STD-113 Form C.

b. Temperature rise and cooling tests from IEEE-STD-113 Form A.

4.8. FAILURE RESPONSIBILITY – If a motor fails to pass any inspection or test, the

Contractor shall report the failure and their recommendation for corrective action to the

Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

4.8.1. The Contracting Officer reserves the right to totally reject any failed motor without considering any suggested corrective action(s).

4.8.2. The inspection/test shall be discontinued until all corrective action has been taken.

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

4.8.4. Acceptance shall occur when the item satisfactorily passes all inspections and tests.

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

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

4.9. REPORTS. One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer and the Contracting Officer’s Representative for each motor covered herein with the final report.

4.9.1. A copy of any test, inspection, or calibration record for the motor to be tested shall also be turned over to the Quality Assurance representative upon his or her arrival at the contractor’s facility during the witness of the first article testing.

5.0 PACKING, PRESERVATION, PACKAGING AND MARKING (PPP&M)

5.1. PRESERVATION

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

5.1.2. Each motor shall be preserved in accordance with MIL-STD-2073-1, paragraph

5.2.3.7.1, Method 51 (water vapor proof bag with desiccant, heat sealed).

5.2. PACKAGING

5.2.1. Each new motor shall be individually packed in its own reusable wooden crate with a removable cover, constructed as described below and in accordance with

ASTM D7478, Type II, Class 1 or 2, Style a.

a. The crate shall be designed for the motor to be bolted to the base in the vertical position.

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

(bolted) to it.

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

5.2.2. The fitted carbon brushes used during acceptance testing shall be removed from the brush holders and packaged in one or more cardboard boxes, and clearly labeled to describe the contents. Such boxes shall be placed inside the wooden crate with the thruster motor, suitably restrained to prevent damage and movement during shipping.

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

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

STOCK NUMBER NSN 6150-01-461-7953

ITEM NAME Motor, Direct Current

PART NUMBER As Determined by Contractor

CONTRACT NUMBER See Contract

DELIVERY ORDER NUMBER See Contract

GROSS WEIGHT As Determined by Contractor

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 EA

DATE OF MANUFACTURE As determined by Contractor

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

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

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

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

"b" with plastic laminate.

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

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

6.0 NOTES

6.1. DOCUMENT SOURCES

6.1.1. COAST GUARD DOCUMENTS

a. USCG Surface Forces Logistics Center

Contracting & Procurement Division (C&P2-IBCT)

1301 Clay Street, Suite 807N

Oakland, CA 94612-5249

6.1.2. OTHER GOVERNMENT DOCUMENTS

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

6.1.3. COMMERCIAL DOCUMENTS

a. American Society for Quality (ASQ)

600 North Plankinton Avenue

Milwaukee, WI 53203 http://www.asq.org

b. American Society for Testing and Materials (ASTM)

100 Barr Harbor Drive

P.O. Box C700

West Conshohocken, PA 19428-2959 http://www.astm.org/ http://www.asq.org/ http://www.astm.org/

c. National Conference of Standards Laboratories (NCSL)

2995 Wilderness Place, Suite 107

Boulder, CO 80310 http://www.ncsli.org

d. Institute of Electrical and Electronic Engineers (IEEE)

445 Hoes Lane

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

e. National Electrical Manufacturers Association (NEMA)

1300 North 17 th

Street, Suite 1847

Rosslyn, VA 22209 http://www.nema.org http://www.ncsli.org/ http://www.ieee.org/ http://www.nema.org/