REV_DEC2016_31100_SSDGBrngNRTDRplce_418.pdf

3100_TAB_0116_418

WORK ITEM 1: Ship Service Diesel Generator Bearings, Replace

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to support and supply technical guidance to USCG personnel in replacement of Drive End/Non Drive End bearings and oil pan gasket of the Ship Service Diesel Generator (SSDG) listed in the Table 1.

TABLE 1 – NAME PLATE DATA

NATIONAL OIL

WELL VARCO

(BAYLOR

GENERATOR)

DESCRIPTION

LOCATION

T437STT-611 No.2 Ship Service Diesel Generator, 1360 KW, 450 Volt AC, 3 Phase, 60 Hz

Forward Main Machinery Room (5-44-01-E)

1.2 Government-furnished property.

TABLE 2 – GOVERNMENT FURNISHED PROPERTY

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y PARTS LISTED ON BILL OF MATERIALS,

INSTL, END FRAME DE 4P370 VER 3

11466477-001 1 16250

Y PARTS LISTED ON BILL OF MATERIALS,

INSTL, END FRAME NDE 4P370 VER 3

11466469-001 1 18265

N HUB, COUPLING, VULKAN 4X40208544-

ABS

1 2510

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-801-001, Rev B, Booklet of General Plans (ASC801001) Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangement (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 7119, 22-JUN-07, Ship Service Diesel Generators Coast Guard Technical Publication (TP) 7368, 22-JUN-07, Ship Service Diesel Generators

(SSDG) Model 3512B parts manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 3100 (SFLC Std Spec 3100), 2014, Inspection, Test and Recondition AC Synchronous Machines In-Place

Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041), 2014, Shipboard Electrical Cable Test

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2014, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

National Oilwell Varco – Installation, End Frame Drive End Modification 3 RTD’s -11466477-

ASM

National Oilwell Varco – Installation, End Frame Non Drive End Modification 3 RTD’s -

11466469-ASM

National Oilwell Varco – Drawing, End Frame Modification, Drive End, 11370494-DAD, Rev 2 National Oilwell Varco – Drawing, End Frame Modification, Non Drive End, 11370491-DAD, Rev 2 National Oilwell Varco – Drawing, Cap, Bearing Inner Modification, Non Drive End, 11370497-

DAD, Rev 2 National Oilwell Varco – Drawing, Cap, Bearing Outer Modification, Drive End, 11376853-

DAD, Rev 1 Caterpillar – Special Instruction, Alignment of Diesel Generator Sets with the Two-Bearing

Generator, REHS7485-02

3. REQUIREMENTS

3.1 General.

3.1.1 Critical Inspection Report. The Contractor shall submit a Critical Inspection Report (CIR) for the inspections listed in the following paragraph(s).

• Paragraph 3.3

• Paragraph 3.4

3.1.2 Tech Rep. The Contractor shall provide the services of a certified Tech Rep, who is familiar with the Caterpillar SSDG (Model No. 3512B) and National Oilwell Varco (i.e. Baylor Generator) to accomplish the following tasks – on site:

• Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

• Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

• Ensure compliance with manufacturer's procedures and standards during disassembly, inspection, reassembly and alignment of the SSDG.

3.1.2.1 Ensure the Tech Rep has a résumé of demonstrated experience with the system/equipment stated above.

3.1.2.2 Submit the Tech Rep’s name and résumé to the Contracting Officers Representative (COR) at the Arrival Conference.

3.1.3 Electrical requirements. The Contractor, with the assistance of the Coast Guard, shall accomplish all electrical work in accordance with SFLC Std Spec 3042, and test cables in accordance with SFLC Std Spec 3041. Disconnect electrical cables to SSDG listed in the Table 1 in accordance with SFLC Std Spec 3042.

3.1.4 The Contractor shall provide oversight and technical guidance to the Coast Guard on all work on this item. The Contractor shall perform critical inspections in the presence of the Coast Guard Inspector.

3.1.5 Special tools. The Contractor shall provide all special tools required to perform the work described in this work item.

3.2 Operational Test- initial. Prior to commencement of work, the Contractor shall witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.3 Renew oil pan gasket. The Coast Guard, with the guidance provided by the Contractor, will replace the oil pan gasket (P/N 479-8430) on the generator in Table 1. Parts shall be provided by the Contractor.

Submit a CFR.

3.4 Inspection. The Contractor shall perform insulation resistance and air gap measurements in accordance with the Para 3.2.2 and 3.2.3.3 of SFLC Std Spec 3100 and submit a CIR. The Contractor shall record the engine hours and provide a CAT Electronic Technician Product Status report. The Contractor shall note the condition of the grease and bearing and provide pictures to thoroughly document and preserve bearing for future analysis. The Contractor shall conduct inspection of PMG, including rotor, stator, and rectifier. The Contractor shall remove any visible grease from PMG parts and windings around the NDE bearing. Submit CFR documenting condition of PMG and any corrective action taken.

3.5 Initial shaft alignment. The Coast Guard will measure the existing Generator shaft to Engine shaft alignment using the two dial indicator method or Laser Shaft Alignment as described in TP 7119 and Caterpillar Special Instruction, REHS7485-02. The Contractor shall record and document measurements via CIR.

3.6 RTD Bearing signal verification. The Contractor shall perform pre-test on RTD Bearing signal in the presence of Coast Guard Inspector. Verify RTD Bearing signal input to Caterpillar Engine Control Unit and Coast Guard Machinery Control System (CGMCS). Submit a CFR.

3.7 Bearing renewal. The Coast Guard, with the guidance of the Contractor, will replace Drive End and Non Drive End bearings and RTD on the generator in Table 1 with parts listed in Table 2 in accordance with TP 7119 and NOV Drawings 11466477-ASM / 11466469-ASM. Reserve the parts indicated by a “Y” under MTI column in Table 2 for overhaul.

NOTE

Renewal of generator bearing requires special tools e.g. Bearing Puller.

Bearing renewal requires significant disassembly of generator including removal of coupling and guards.

3.7.1 Install Drive End and Non Drive End RTD on SSDG as shown in NOV Drawings 11466477-ASM / 11466469-ASM. Install the coupling hub. After installation, verify RTD Bearing signal input to Caterpillar Engine Control Unit and Coast Guard Machinery Control System (CGMCS). Submit a CFR.

3.7.2 The Contractor shall protect the stator winding by installing rubber mat or Teflon wedges.

3.8 Final Generator-Engine alignment. After replacement of bearings, The Coast Guard will measure the existing Generator shaft to Engine shaft alignment using the two dial indicator method or Laser Shaft Alignment as described in TP 7119 and Caterpillar Special Instruction, REHS7485-02. The Contractor shall record and document measurements via CFR.

3.8.1 After satisfactory alignment, the Contractor shall provide and install dowel pins on each side of the driven end of the generator.

3.9 Final air gap measurement. The Contractor shall perform air gap measurement in accordance with the Para 3.2.2 and 3.2.3.3 of SFLC Std Spec 3100. Submit a CFR.

3.10 Post repair insulation resistance test. The Contractor shall perform insulation resistance in accordance with the Para 3.2.3.3 of SFLC Std Spec 3100. Submit a CFR.

NOTE

During the operational test on the SSDG, the Government may elect to perform vibration analysis by installing the accelerometers at various locations on the SSDG.

3.11 Operational test – post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector, and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Perform operational test on the generator at various loads including parallel operation until bearing temperature stabilizes. Submit a CFR.

3.12 Load Banking. The Contractor shall provide a resistive load bank (i.e. 450 Volt, 1500 KW) with cabling and accessories to test the SSDG listed in Table 1, estimate 250’ of cabling for bidding purposes.

The Contractor shall provide any additional labor or crane services as necessary for the set up, operation, and disassembly of the load bank and associated cabling or accessories. The load bank shall be placed onboard the cutter. Cables may not be run from the ship to a load bank on the pier.

3.12.1 The Contractor shall perform load test on SSDG listed in the Table 1. Contractor shall follow Test Procedure for the Bearing System Re-Build on Ship’s Service Generators on the USCG National Security Cutter. See appendix A. Submit CFR.

3.13 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with the SFLC Std Spec 6310, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

4. NOTES

This section is not applicable to this work item.

APPENDIX A

Test Procedure for the Bearing System Re-Build on Ship’s Service Generators on the USCG National Security Cutter

Print this page and fill out all information during testing, submit to Product Line upon completion.

Record the following data:

Cutter Name Generator Set Location Engine Serial No.

Generator Serial No.

During the initial startup following the generator repair, run the generator set at low idle speed (900 rpm) for 10 minutes. During this time, check for leaks, loose fasteners, proper operating temperatures, and pressures, etc. Once satisfied that the generator set is operating properly, operate the generator set at normal speed (1800 rpm) and begin the test plan below.

The generator set should be operated at the loads and for the time as follows:

Test No. Load Time 1 0% 15 Minutes 2 50% 15 Minutes 3 75% 15 Minutes 4 100% 15 Minutes 5 100% 1 Hour, 45 Minutes 6 50% 15 Minutes

Record the following data at the end of each load run prior to changing to the next load step:

Test No. 1 2 3 4 5 6 Load Time Temperatures (°C)

Gen Stator RTD 1 Gen Stator RTD 2 Gen Stator RTD 3 Gen DE Brg RTD Gen NDE Brg RTD Gen Air Inlet RTD

Performance Power (kW)

Speed (RPM) Frequency(Hz) Voltage – Phase A Voltage – Phase B Voltage – Phase C Voltage - Average

Current – Phase A Current – Phase B

Current – Phase C Current - Average Vibration Readings Gen DE - Vert Gen DE - Hor Gen DE – Axial Gen NDE - Vert Gen NDE - Hor Gen NDE - Axial

Notes:

1. For vibration readings, record overall vibration levels in displacement (preferably mills pk-pk), so data can be compared to original factory test at both NOV and Caterpillar. Also record frequency spectrum to determine the major frequency components. Additional recordings of the overall vibration level and frequency spectrum can be recorded in velocity and acceleration if time permits.

2. Note all test equipment used.