IFB 182C-21 Specification EEQA806-D.pdf

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

EE&QA-806

REQUIREMENT FOR THE OVERHAUL

OF

TRACTION MOTOR ARMATURES

ISSUED: February 01, 2010

REVISIONS: February 21, 2017

VEHICLE PROCUREMENT & QUALITY ASSURANCE

Equipment Engineering and Quality Assurance Technical Specification

Specification:

SUBJECT: REQUIREMENT FOR THE OVERHAUL OF

Page: 3 o f 92

Date: February 01, 2010 Revised: February 21, 2017

Revision: D

1.0 SCOPE AND DECSRIPTION OF WORK

1.1 SCOPE

1.2 DESCRIPTION OF WORK

1.2.1 Basic Work

1.2.2 Extra Work

2.0 APPLICABLE DOCUMENTS AND DRAWINGS

2.1 DOCUMENTS

2.1.1 Institute of Electrical and Electronics Engineers, Inc. Documents

2.1.2 General Electric Company Publications

2.1.3 Westinghouse Electric Corporation Publications

3.0 REQUIREMENTS

3.1 GENERAL REQUIREMENTS

3.1.1 Intent and Purpose of Specification

3.1.2 Contractor's Responsibilities

3.1.3 Reports

3.1.4 Guarantees

3.1.5 Procedures and Instructions

3.1.6 Repair and Replacement Parts

3.1.7 Workmanship and Materials

3.1.7.1 General

3.1.7.2 Qualifications of Personnel

3.1.7.3 Materials and Supplies

3.1.8 Shop Equipment

3.1.8.1 Insulating Varnish Control

3.1.8.2 Baking Ovens

3.1.8.3 T.I.G. Welding Equipment

3.1.8.4 Spin Seasoning Equipment

3.1.8.5 Armature Banding Machines

3.1.8.6 Measuring and Test Equipment

3.1.8.7 Tooling and Fixtures

3.2 DESCRIPTION AND GENERAL DATA

3.3 HANDLING PRECAUTIONS

3.4 BASIC WORK

Page: 4 o f 92

3.4.1 General

3.4.2 Incoming Inspection and Test

3.4.3 Disassembly

3.4.4 Cleaning

3.4.5 Inspection

3.4.5.1 General Requirements

3.4.5.2 Inspection

3.4.6 Repair or Replacement

3.4.6.1 General Requirements

3.4.6.2 Commutator Replacement

3.4.6.3 Armature Rewinding

3.4.6.4 Armature Shaft Repair

3.4.6.5 Fan Repair

3.4.6.6 Commutator Press and Tighten

3.4.6.7 Commutator Spin Seasoning

3.4.6.8 Commutator V-Ring Creepage Band Replacement

3.4.6.9 Armature Vacuum Pressure Impregnation

3.4.6.10 Armature Varnish Immersion Treatment

3.4.6.11 Armature Balancing

3.4.7 Reassembly

3.4.8 Final Inspection and Test

3.4.8.1 Pre-Test Inspection

3.4.8.2 Insulation Resistance Test

3.4.8.3 Polarization Index Test

3.4.8.4 Dielectric Test

3.4.8.5 Armature Winding Tests

3.4.8.6 Post-Test Inspection

3.5 EXTRA WORK

3.5.1 Armature Shaft Replacement

4.0 QUALITY ASSURANCE PROVISIONS

4.1 QUALITY ASSURANCE PROGRAM

4.1.1 General Requirements

4.1.2 Quality Assurance Program Certification

Page: 5 o f 92

4.1.3 Organization

4.1.4 Procedures Manual

4.1.5 Drug and Alcohol Free Workplace Requirement

4.2 TEST METHODS AND PROCEDURES

4.2.1 Polarization Index Test

4.2.2 Alternating Current High-Potential Test

4.2.3 Oscillograph Surge Comparison Test

4.2.4 Bar-to-Bar Resistance Test

4.2.5 Core Loss Test

4.3 RESPONSIBILITY FOR INSPECTION AND TEST

4.4 AUTHORITY ACCESS TO WORK

4.5 QUALIFICATIONS OF BIDDERS

5.0 PREPARATION FOR DELIVERY:

5.1 GENERAL REQUIREMENTS

5.2 DELIVERY LOCATIONS

6.0 NOTES

6.1 INTENDED USE

6.2 PROPOSAL

6.3 DEFINITIONS

7.0 REVISION RECORD:

8.0 MOTOR DATA - APPENDIX A

9.0 SHAFT REPLACEMENT COST - APPENDIX B

10.0 REQUIRED DOCUMENTS FOR REWORKED ARMATURES

10.1 Incoming Inspection Report

10.2 Final Test Report

10.3 Armature Rewind Quality Control Checklist

10.4 VPI Process QC Sheet

10.5 Machining, Balancing, and Undercutting Quality Control Checklist

10.6 Balance Report

10.7 Small Parts Quality Control Checklist

Page: 6 o f 92

1.0 SCOPE AND DECSRIPTION OF WORK

1.1 SCOPE

This specification establishes the general procedures and processes and the Contractor requirements for the overhaul of traction motor armatures.

1.2 DESCRIPTION OF WORK

All work listed and summarized in Section 1.2.1 as Basic Work is required on each traction motor armature turned over to the Contractor for overhaul. It shall be the responsibility of the Contractor to determine what part of the Extra Work listed in Section 1.2.2, plus any additional work not listed, will be necessary to completely overhaul and repair the armature and restore it to an as-new condition. The funds reserved for Extra Work are not guaranteed to be paid to the Contractor without the Extra Work being performed.

1.2.1 Basic Work

The Basic Work shall consist of the following:

Item Summary Description Reference Section

1 Contractor to pick up armature upon notification at the Subway Main Repair Facility- 80 Broadway, Everett MA 02149

5.2

2 Incoming Inspection and Test 3.4.2

Inspect and test armature for obvious defects. Log defects and missing parts on the Incoming Inspection Report (Appendix C, 10.1)

3 Disassembly 3.4.3

Disassemble armature to extent necessary

Page: 7 o f 92

4 Armature Cleaning 3.4.4

Clean as necessary and oven dry.

5 Inspection and Test 3.4.5

Thoroughly inspect armature for mechanical defects and faults. Check all parts, including core, fan, armature shaft, etc. for damage, distortion, straightness, wear and proper dimensions. Log all defects on the Incoming Inspection Report (Appendix C, 10.1).

6 Commutator Replacement 3.4.6.2

7 Armature Rewind 3.4.6.3

8 Replace Core Laminations 3.4.6.3.g.2

9 Reassembly 3.4.7

Reassemble armature as required.

10 Final Inspection and Test 3.4.8

Thoroughly test and inspect completed motor armatures for proper operation and acceptance by the Authority. Log test results on the Final Test Report (Appendix C, 10.2).

11 Preparation for Shipment 5.1

Prepare repaired and tested motor armatures for shipment to the Authority.

Contractor to ship repaired motor armatures to the Authority.

5.2

Page: 8 o f 92

1.2.2 Extra Work

In addition to performing the Basic Work outlined in Section 1.2.1 on each motor armature, the Contractor shall be responsible for determining the need for any and all additional repair work required to completely rebuild and remanufacture the motor armatures to an essentially as-new condition. Such additional work, or Extra Work, shall be approved by the Authority prior to commencement of said work. If the Contractor proceeds with any Extra Work without Authority approval, the Contractor shall assume all costs for performing such work.

Examples of such Extra Work are as follows:

Item Summary Description Reference Section

1 Replace Armature Shaft as needed 3.5.1 2 Replace Fan 3.4.6.5.b

2.0 APPLICABLE DOCUMENTS AND DRAWINGS

The following documents and drawings of the issue in effect on the date of signing of the Contract form a part of this Specification to the extent specified herein. In the event of conflict between the documents and drawings referenced herein and the contents of this Specification, the contents of this Specification shall be considered a superseding requirement unless stated otherwise by the Authority. Any conflicts within or between the documents and drawings referenced herein shall be promptly brought to the attention of the Authority for its resolution.

2.1 DOCUMENTS

2.1.1 Institute of Electrical and Electronics Engineers, Inc. Documents

I.E.E.E. Standard 11-2000; "IEEE Standard for Rotating Electric Machinery for Road and Rail Vehicles"

I.E.E.E. Standard 43-2000; "IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery"

I.E.E.E. Standard 304-1977; "IEEE Test Procedure for Evaluation and Classification of Insulation Systems for Direct-Current Machines"

Page: 9 o f 92

2.1.2 General Electric Company Publications

Publication GEI-21610 dated September, 1984; "General Electric Equipment for Presidents' Conference Committee Type Car furnished by Pullman Standard Car Manufacturing Company for Boston Elevated Railway," Part I - Type GE-1220- 300/600 Volt Motor.

Publication GEK-63192 dated April, 1978; "Inspection, Maintenance and Basic Overhaul Instructions, Traction Motor, Type GE1264"

2.1.3 Westinghouse Electric Corporation Publications

Instruction Book 5786-19 dated January, 1941; "Parallel Accelerator Control and Type 1432-D Motor for Boston Elevated Railway Co."

Publication I.B.20907; "Inspection and Maintenance of Control and Rotating Apparatus for Massachusetts Bay Transportation Authority South Shore Cars," Section 2.1 (Type 1460-B1 Traction Motors)

3.0 REQUIREMENTS

3.1 GENERAL REQUIREMENTS

3.1.1 Intent and Purpose of Specification

The intent of this Specification is to establish a minimum acceptable quality standard for the overhaul of traction motor armatures, but not to rule out better or more economical materials or techniques, if such exists. If the Contractor wishes to use different materials or procedures, he shall apply, in writing, to the Authority's Manager of Equipment Engineering and Quality Assurance for approval. If it is determined that it is in the best interest of the Authority, written approval for such alternates will be issued. Without such written approval, the Contractor shall not deviate from this Specification. Such written approval will be appended to this Specification and made an integral part thereof.

3.1.2 Contractor's Responsibilities

The Contractor shall be responsible for performing Basic Work on each motor armature in accordance with the requirements included in Section 3.4 and for

Page: 10 o f 92 performing any additional repairs that may be necessary, but not specifically included therein, as part of that Basic Work. Such work will restore the armature to an as-new condition.

In addition, the Contractor shall be responsible for identifying and, following approval by the Authority, performing as Extra Work additional tasks such as shaft replacement. Such work shall be in accordance with the requirements included in Section 3.5.

The Contractor shall be responsible for furnishing the various procedures, forms and data sheets required. Forms are included but not limited to those in Appendix C. If an alternative form is used, the format of the substitute form shall be submitted and approved by the Authority.

Unless otherwise specified herein or in any contractual documents, the Contractor shall complete all work required on each armature and return within fifteen (15) business days after receipt of a notice to pick up said armature. All “notice(s) to pick up” will be conveyed via email. Each armature delivered to the Authority shall be subjected to an incoming inspection; any deviation from the specification shall result in the armature(s) being returned to the vendor. The vendor shall have five (5) days to correct any problems found during the Authority’s incoming inspection process. Travel time to and from the vendor facility will not be included in the five (5) day restriction.

3.1.3 Reports

The Contractor shall submit the following reports to the Authority that are cumulatively updated to include but not limited to all inspections, checklists, repair actions, including warranty repairs, which occurred within the reporting period:

a. a summary report of cumulative frequency rates and unit costs for each type of overhaul action for each type of armature processed shall be submitted every six months.

b. a detailed report of cumulative repair work performed and costs thereof on individual armatures processed sorted by serial number, shall be submitted with each shipment of repaired armatures.

Page: 11 o f 92

c. a cumulative listing of all purchased and/or Contractor manufactured repair and replacement parts (reference Section 3.1.6) shall be submitted every six months.

d. a status listing of all required data submittals, including drawings, specifications, analyses, and procedures shall be submitted.

e. the original copy of the Incoming Inspection Report for each armature returned to the Authority (Appendix C, 10.1 or an approved substitute).

f. the original copy of the Final Test Report (Appendix C, 10.2 or an approved substitute) for each armature returned to the Authority.

g. the original copy of the Armature Rewind Quality Control Checklist (Appendix C, 10.3 or an approved substitute) for each armature returned to the Authority.

h. the original copy of the VPI Process QC Sheet (Appendix C, 10.4 or an approved substitute) for each armature returned to the Authority.

i. the original copy of the Machining, Balancing and Undercutting Quality Control Checklist (Appendix C, 10.5 or an approved substitute) for each armature returned to the Authority.

j. the original copy of the Balance Report (Appendix C, 10.6 or an approved substitute) for each armature returned to the Authority.

k. a detailed list of all insulation materials and compounds that are required as well as copies of the MSDS sheets at the time the contract is awarded and in the event that a material substitution is required.

3.1.4 Guarantees

All work performed and all parts and materials shall be unconditionally guaranteed by the Contractor for a period of 18 months after the motor in which the armature is installed is placed in service, or for 24 months following receipt of the repaired armature by the Authority, whichever comes first. The Contractor shall accept the Authority's records with respect to the date that the motor was placed in service.

Page: 12 o f 92

If at any time during the guarantee period the armature fails or is defective, in the opinion of the Authority, the Contractor shall pick up the armature and, in the presence of an Authority representative if deemed necessary by the Authority, disassemble, inspect and test the armature at his shop to determine the cause of failure or defect. The Authority may, at its discretion, perform such disassembly, inspection and test in its own shops in the presence of a Contractor representative.

If, in the opinion of the Authority, the failure or defect is due to the fault of the Contractor, either by negligence, oversight, inadequate or incomplete repair, inadequate or inferior parts, materials, procedures and processes, or poor workmanship, the Contractor shall perform all necessary replacement and repairs as determined by the Authority at no additional cost to the Authority.

The Contractor shall also reimburse the Authority for all direct and indirect labor costs incurred in removing the failed or defective armature from the vehicle and from the motor in which it was installed. This reimbursement shall be in the amount of $946, based on current Authority costs of removing and replacing a motor on a car ($373) and then removing and replacing the armature ($573).

The contractor will be assessed a charge of $100 per business day for any armature not returned to the Authority as specified in Section 3.1.2

If the Contractor establishes to the complete satisfaction of the Authority that the cause of the failure or defect was not due to the fault of the Contractor as above, no reimbursement for direct and indirect labor costs shall be assessed and the Authority may authorize the Contractor to perform the necessary repairs as determined by the Authority. If the Contractor performs such repairs, the costs there of shall be in accordance with the Price Schedule submitted with his proposal at the time of bidding. In either case, the work, parts and materials shall be re-guaranteed by the contractor as above.

3.1.5 Procedures and Instructions

Any work performed on Authority motor armatures shall be in accordance with the Original Equipment Manufacturers (OEM) requirements for that armature, unless otherwise noted herein, and in accordance with additional requirements of this Specification.

It shall be the responsibility and obligation of the Contractor to promptly inform

Page: 13 o f 92 the Authority if any of the procedures, instructions or requirements contained herein are incomplete, inadequate, unclear, improper, or deleterious to the equipment or if they affect personnel safety.

If requested by the Authority the Contractor shall prepare a separate comprehensive Armature Repair Procedure for any or all motor armatures covered by this Specification and Contract, in a format as approved by the Authority. All procedures shall be submitted to the Authority's Manager of Equipment Engineering and Quality Assurance for approval. The procedure shall be in accordance with Original Equipment Manufacturer and Authority requirements and shall include all information and steps required to properly overhaul, repair and rebuild the armature in question containing, at a minimum, all applicable manufacturing processes and procedures, assembly drawings, coil construction drawings, insulation details, materials and parts listings, and test procedures, except for proprietary information, which shall be made available to the Authority on an as-needed basis but will not be reproduced by the Authority except for internal evaluation

Once approved, the Contractor shall not make any change in the procedure or implement any procedure not covered therein or in this Specification unless written approval and permission is granted by the Authority's Manager of Equipment Engineering and Quality Assurance.

Failure to submit these procedures, data and drawings in a timely manner may constitute grounds for cancellation of the contract.

All approvals shall be made in writing by the Authority's Manager of Equipment Engineering and Quality Assurance. All such requests for approval and all data submittals, data sheets, reports, etc. shall be forwarded to:

Massachusetts Bay Transportation Authority Manager of Equipment Engineering and Quality Assurance Subway Operations- Main Repair Facility 80 Broadway Everett, Massachusetts 02149

3.1.6 Repair and Replacement Parts

All repair and replacement parts required in the repair of equipment covered in

Page: 14 o f 92 this Specification shall meet or exceed the specifications and shall be purchased by the Contractor only from the Original Equipment Manufacturer. If repair or replacement parts are either purchased from another manufacturer or supplier or manufactured by the Contractor, prior written approval from the Authority's Manager of Equipment Engineering and Quality Assurance must be obtained.

The approval request will only be considered after complete drawings and specifications of the alternate parts offered are submitted, together with a complete analysis of how the necessary drawings and specifications were derived from the Original Equipment Manufacturer's parts. All such drawings, specifications, and analyses shall be first reviewed, approved, and signed by the Contractor's qualified engineer. Documents and data that have not been so approved shall be rejected by the Authority. The process of approvals shall not affect delivery of repaired units and the Authority will not be responsible for delays in the process.

All missing parts and all repair and replacement parts shall be provided and installed by the Contractor as Extra Work at an additional cost to the Authority, except for any minor parts and consumable items, such as balance weights and fasteners, which shall be provided as part of the Basic Work, at no additional cost to the Authority.

All discrepant parts replaced at additional cost to the Authority shall be tagged by the Contractor, including armature serial number, job number, etc., and returned to the Authority, as requested, at no extra expense to the Authority.

All parts replaced or repaired shall be appropriately logged on the Small Parts Quality Control Checklist (Appendix C, 10.7 or an approved substitute)

The costs for such replacement parts shall be as listed by the Contractor in the Price Schedule submitted with his proposal at the time of bidding. The costs for any part not listed therein shall be borne by the Contractor as part of the Basic Work.

3.1.7 Workmanship and Materials

3.1.7.1 General

Workmanship and materials shall, in every respect, be of high-grade and quality and in accordance with the best modern industry practice. Whenever the Specification or any directions of the Authority are vague or in doubt as to what is

Page: 15 o f 92 permissible, or fail to note the quality of any construction or work, the requirement of best quality shall be followed. Materials shall be new, except as otherwise specifically stated herein. Materials and workmanship shall be free from defects of any kind.

3.1.7.2 Qualifications of Personnel

All work under this Contract shall be performed by fully trained and qualified personnel. Those personnel engaged in special processes (e.g. welding, non-destructive testing, etc.) shall be certified as appropriate. Proof of certification shall be supplied if requested by the Authority.

3.1.7.3 Materials and Supplies

All materials and supplies required shall be provided by the Contractor, at his expense. It is the responsibility of the Contractor to provide insulation materials and compounds that are Service Proven and that have been fully qualified and rated as Class H, or better, per the requirements of the Institute of Electrical and Electronics Engineers, Inc. Suggested materials and supplies are listed in this Specification where appropriate, but it shall remain the responsibility of the Contractor to select such materials and supplies in accordance with the above requirements. A full listing, with manufacturers data sheets and thermal rating certification data as required, of all materials and supplies used by the Contractor to perform the work herein shall be forwarded to the Authority for information and/or approval prior to the commencement of any work.

3.1.8 Shop Equipment

The Contractor shall possess motor armature repair and test equipment available for use on this contract and shall employ personnel thoroughly trained and skilled in their use. Due to the high performance required of traction motors, the following additional specialty equipment not usually found in an industrial motor repair facility shall be provided at the Contractor's facility.

a. Automatic T.I.G. (Tungsten Inert Gas) welding equipment for welding armature conductors to commutator risers

b. Commutator and core pressing and tightening tooling

Page: 16 o f 92

c. Automatic commutator undercutting equipment

d. Voltage surge tester

e. V.P.I. (Vacuum Pressure Impregnation) equipment

f. Armature banding equipment

g. Commutator heating and spin seasoning equipment

h. Armature balancing equipment

Specific equipment requirements are presented in the following sections.

3.1.8.1 Insulating Varnish Control

Gel time and viscosity of insulating varnish shall be checked at least once per week. Inhibitor solutions and viscosity reducers shall be added in the amounts as recommended by the varnish manufacturer to bring gel time and viscosity within the limits prescribed by the varnish manufacturer.

A sample of the varnish shall be taken and analyzed by the varnish manufacturer for proper formulation at least once per month. Any additives recommended by the varnish manufacturer shall be added to maintain the proper formulation.

The Contractor shall prepare and maintain periodic reports on these checks and analyses. A copy of this report, including a listing of armature and stator assemblies impregnated with the varnish during the period covered by the report shall be submitted to the Authority every three months. A copy of the VPI Process QC Sheet (Appendix C, 10.4 or equivalent) shall be submitted with each armature returned to the Authority.

3.1.8.2 Baking Ovens

Baking ovens shall be of the circulating type with accurate temperature control and shall be capable of achieving and sustaining the temperatures specified herein for the times stated. If not specified, the drying cycle shall be of sufficient duration to insure that the armature attains the highest possible insulation resistance. The maximum temperature shall not exceed that imposed by the limitations of the insulation system (temperature classification).

Page: 17 o f 92

3.1.8.3 T.I.G. Welding Equipment

T.I.G. (Tungsten Inert Gas) welding shall be accomplished with Linde Company, or approved equal, heli-arc welding equipment using Argon gas. Operators shall be thoroughly trained and experienced in T.I.G. welding traction motor commutators, and machines and equipment specifically designed for that purpose shall be utilized. Power supplies shall include an adjustable millisecond timer switch and an adjustable current limiting device.

3.1.8.4 Spin Seasoning Equipment

Spin seasoning equipment shall be as manufactured by CAM Industries of Hanover, Pennsylvania, or approved equal. It shall be designed for use on high speed traction motor armatures and capable of handling the complete armature. It shall be capable of reaching and maintaining armature rotational speeds up to 6,500 RPM and commutator temperatures up to 170ºC(338ºF) and shall include an insulated commutator heating chamber that protects the armature windings and banding from direct heating. The equipment shall include variable heat and speed controls capable of maintaining control over the set speeds and temperatures.

3.1.8.5 Armature Banding Machines

Banding machines shall be as manufactured by CAM Industries of Hanover, Pennsylvania, or approved equal, and shall insure uniformity of banding tape tension in banding applications.

3.1.8.6 Measuring and Test Equipment

Procedures shall be established to verify that all tools, gauges, instruments, and other inspection, measuring and test equipment used in tests, processes, and activities affecting quality are controlled, calibrated, and adjusted at specific periods, against standards traceable to the National Bureau of Standards, to maintain accuracy within necessary limits. Records of such control, calibration and adjustments shall be maintained by the Contractor and all equipment, as applicable, shall be clearly marked to indicate current calibration status. All such procedures and records shall be furnished to the authority upon request.

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3.1.8.7 Tooling and Fixtures

All tooling, fixtures and gauges required for the work herein shall be designed and manufactured, or otherwise provided, by the Contractor. The Contractor shall provide the Authority with drawings of such items for information and/or approval, as requested by the Authority if, in the opinion of the Authority, such items may be of use in its maintenance activities.

3.2 DESCRIPTION AND GENERAL DATA

This Specification may cover any and all of the following traction motors currently in use, or contemplated for use, on Authority vehicles:

Motors Manufactured by General Electric Company

Type Used On 5GE1264A1 No. 4 E.B.R.T. Cars or No. 12 M.L.R.T. Cars

Motors Manufactured by Westinghouse Electric Corporation Type Used On 1432-D P.C.C. Cars 1460-B No. 1 S.S.R.T. Cars 1460-B1 No. 2 S.S.R.T. Cars 1463-E1 No. 7 Surface Rail Cars

Appendix A includes a data sheet on these motors and contains currently available Original Equipment Manufacturer's information. Missing data, or revised data, necessary for the repair of armatures shall be obtained by the Contractor and forwarded to the Authority to revise the data sheets.

3.3 HANDLING PRECAUTIONS

Proper handling of all motor armatures is necessary to avoid damage and shall be done in accordance with the following guidelines:

a. Lift armatures by the use of a lifting nut screwed onto the end of the shaft or with the use of slings. Use a spreader to hold the two slings apart to prevent undue pressure from being applied to the armature. Do not lift more than one armature at a time.

Page: 19 o f 92

b. When turning an armature from the vertical to the horizontal position, and vice-versa, take precautions to prevent the weight of the armature from being momentarily transferred to the armature shaft extensions causing the armature to be gouged or bent.

c. Armatures may be turned by using a lifting nut on one end and a single sling on the other, with an independent hoist for each.

d. Do not roll armatures across the shop floor.

e. Rest armatures on a fixture that supports the two ends of the shaft.

3.4 BASIC WORK

3.4.1 General

The Contractor shall be responsible for performing all work listed in Section 1.2.1 as Basic Work in accordance with the procedures contained herein. In addition, it shall be the responsibility of the contractor to determine the need for any additional, or Extra Work, required to rebuild the motor armature to an as-new condition. Extra Work requirements are included in Section 3.5 of this Specification.

3.4.2 Incoming Inspection and Test

Each motor armature shall receive a preliminary visual inspection as necessary to determine the following:

a) Additional work requirements beyond Basic Work to insure complete repair of the armature.

b) Existing pre-repair condition of the armature to compare the condition after repairs prior to shipping back to the Authority.

c) Assemble data for failure analysis, if any.

d) Warranty responsibility determination as applicable.

Upon receipt of the armature, the Contractor shall log, in black ink, the condition

Page: 20 o f 92 of the armature and preliminary inspection results in the Incoming Inspection

Report (Appendix C, 10.1 or an approved substitute).

The Inspection Report shall include pertinent information such as the armature serial number, the contract number, the Contractor's Job Number, the general condition of the armature and a listing of missing and or broken parts. Additional items, including actual work performed, shall be logged on the Incoming Inspection Report as the work progresses.

Visually check the overall condition of the armature, including commutator, armature windings, armature shaft, banding, etc.

3.4.3 Disassembly

a. Disassemble the armature assembly by removing the fan and any other parts prior to any cleaning and inspection of the armature and its components.

CAUTION: TAKE EXTREME CARE TO AVOID DAMAGING THE

MICA INSULATION.

b. Carefully remove the creepage band and string banding from the mica V-ring extension.

3.4.4 Cleaning

Clean the armature in accordance with the following:

a. Clean carbon and dirt from the mica V-ring with a dry rag or fiber brush.

b. Remove any paint or varnish from the ends of the commutator bars by scraping.

c. Blow out armature with clean, dry compressed air at 50 psig.

d. Wash the armature by steam cleaning with high pressure stain in an Authority approved mild detergent.

e. Clean the armature with a soft bristle brush. Carefully clean the commutator

Page: 21 o f 92 slots with a stiff nylon brush, removing all traces of dirt.

f. Re-wash the armature as in part (d) above and rinse thoroughly with steam and hot water to remove all traces of cleaning compound.

g. Thoroughly dry the armature in a vacuum tank or in a circulating-type oven at 150C (300°F) for eight hours.

3.4.5 Inspection

3.4.5.1 General Requirements

After cleaning and drying, the armature shall be thoroughly inspected to more completely determine its condition and the extent of repairs required. All mechanical dimensions, shall be carefully checked and measured and compared against the Original Equipment Manufacturers data sheets and drawings as appropriate. Items of Extra Work required shall be determined by the Contractor at this time and specifically brought to the attention of the Authority for approval.

The Contractor is responsible for performing all necessary inspections to completely determine the condition of the armature.

All results and any defects and discrepancies shall be logged in black ink on the Incoming Inspection Report.

3.4.5.2 Inspection

Inspect the armature assembly, observing the following.

a. Inspect the outside surface of the armature assembly for evidence of scraping and damage.

b. If applicable, inspect the fan for any cracks, excessive abrasion, warpage, wear and any other damage and deformation. If in doubt, check for cracks by an Authority approved Dye Penetrant Inspection method. Damaged fans shall be repaired, or replaced as Extra Work.

c. Inspect the mica V-ring for damage.

d. Inspect the armature shaft observing the following:

Page: 22 o f 92

(1) Inspect the bearing surfaces for nicks, scoring or deep wear patterns. The surface finish must be 16 micro inches R.M.S. or better.

(2) Measure the diameters of the commutator and non-commutator end bearing surfaces. They shall be within the bearing manufacturer's recommendations for shaft bearing seat diameter limits for heavy load and shock load conditions.

(3) If applicable, inspect the coupling seat for damage. Check the taper fit with an Authority approved gauge.

(4) Support the armature on the bearing journals and measure the shaft run out with a 0.0001 inch per division dial indicator. The Full Indicator Run out (F.I.R.) relative to the bearing journals shall be within the following limits:

Surface F.I.R. (Maximum) Coupling Seat 0.001 Inch Bearing 0.001 Inch Spline Pitch Diameter 0.002 Inch (if applicable)

(5) Support the armature assembly between centers and indicate both bearing journal surfaces with a 0.0001 inch per division dial indicator. The Full Indicator Run out (F.I.R.) shall not exceed 0.0005 inch. If this run out is exceeded, scrape the shaft centers and re-indicate the bearing journal surface until the F.I.R. is as required.

(6) If applicable, check for shaft spline wear by measuring across two precision ground pins placed between diametrically opposite teeth.

Measure the wear on individual tooth pairs by moving both pins around the spline, one tooth at a time, and measuring the diameter for each pair.

Check the spline for general condition and other dimensions.

NOTE: The spline teeth must be completely clean with no dirt, fretting dust or grease on them, and all burrs and rolled-over edges must be removed, to insure accurate measurements.

(7) If applicable, gauge and chase any internal and external threads.

Page: 23 o f 92

3.4.6 Repair or Replacement

3.4.6.1 General Requirements

The following repair or replacement work shall be performed as part of the Basic Work unless specifically identified as Extra Work. All parts that do not pass inspection and are damaged beyond economical repair shall be replaced. Any work of a minor nature not specifically covered here or in Section 3.5 shall be accomplished as Basic Work.

All work performed and any parts replaced shall be logged in black ink on the appropriate report.

The following materials and supplies and manufacturers thereof are suggested for use in the repair of the armatures. All materials and supplies shall be approved by the Authority prior to the awarding of the contract and in the event of a change of material being used during the life of the contract and shall meet or exceed the requirements of Section 3.1.7.3.

Some work requirements already required as part of the Basic Work of Section

3.4.6.2 are repeated for emphasis and for sequence of operations in Section

3.4.6.3. The prices quoted for shall not include charges for accomplishing these steps more than once per completed armature.

TABLE 3-1

ARMATURE REPAIR MATERIALS

Nomex 414 paper tape, various thicknesses and widths (E.I. Dupont deNemours & Company, Wilmington, Delaware)

B-Stage Nomex 410 Sheet, Class 200ºC, epoxy resin coated on both sides (Type EI- 10L07-02, Electrolock, Inc., Shagrin Falls, Ohio; Type LN-508E, Lectromat, Inc., Mars, Pennsylvania)

Type F FEP-Kapton Film Tape, 0.0015 inch thick, (Type 150F019, E.I. Dupont deNemours & Company, Wilmington, Delaware)

Page: 24 o f 92

Type H Kapton Film, 0.002 inch thick (E.I. Dupont deNemours & Company, Wilmington, Delaware)

Type H Kapton adhesive tape with Acrylic thermosetting adhesive, 0.0025 inch thick (Type P-224, Permacel, New Brunswick, New Jersey

Woven glass tape, Medium Weave, (Pittsburgh Electrical Insulation Corp. (Hesgon Company), Munhall, Pennsylvania; Essex Magnet Wire and Insulation Division, Fort Wayne, Indiana)

Fiberglass acrylic adhesive tape, 0.005 inch thick (Type P-213, Permacel, New Brunswick, New Jersey)

Open weave fiberglass cloth, treated with polyester resin and cured, 0.030 inch thick (P.E.I. 800-M, Pittsburgh Electrical Insulation Corp., Munhall, Pennsylvania)

Glass sleeving, Class H (no silicone resins permitted)

Fiberglass polyester impregnated banding tape, Class 220oC (P.E.I. MHT Banding Tape, Pittsburgh Electrical Insulation Corp., Munhall, Pa.; Reli-A-Band Class 220 Banding Tape, Essex Magnet Wire and Insulation Division, Fort Wayne, Ind.)

Edging tape with nylon rod edge restraint, (Glass Band Edging Tape, Pittsburgh Electrical Insulation Corp., Munhall, Pa.)

Heat Shrinkable Mylar Tape, 0.003 inch thick, 0.75 inch wide (E. I. Dupont deNemours & Company, Wilmington, Delaware)

Thermosetting, 2 component, polyester compound (GE-3285, General Electric Co., Insulating Materials Dept., Schenectady, N.Y.)

Polyester impregnated glass cord, 1/16 inch diameter (Jonathan Temple and Co., Hackensack, N.J.)

Thermopoxy brushing compound (Sterling U-953 with C-12A catalyst, Reichhold, Chemicals Inc., Sewickley, Pa.)

R.T.V. Silastic adhesive/sealant (Type 899, Dow Corning Corp., Midland, Mich.)

Page: 25 o f 92

Class H Solventless Polyester Varnish (GE-702, General Electric Co., Insulating Materials Dept., Schenectady, N.Y.; Sterling Y996, Reichhold Chemical Inc., Sewickley, Pa.; Dolphon CC-1105, John C. Dolph Co., Monmouth Junction, New Jersey)

Thermosetting Epoxy Varnish (Sterling U-475-EH Thermopoxy Varnish, Reichhold Chemicals, Inc., Sewickley, Pa.)

Masking varnish (GE-271, General Electric Co., Insulating Materials Dept., Schenectady, N.Y.) Release agent (MS122, Miller-Stephenson Chemical Co., Danbury, Conn.)

Xylene Cleaner (G.E. Specification D5B9, General Electric Company)

Polyester impregnated fiberglass sheet, 1/16 inch thick, 1/8 inch thick (Glastic Corp.

Cleveland, Ohio)

Abrasive paper (Federal Specification P-P-101, Grit No. 320)

Primer (No. E42GP22, Federal Standard 595, Color No. 34151, mixed equal parts by volume with catalyst reducer, Sherwin-Williams Co., Los Angeles, California, or equivalent)

Glyptal insulating paint (GE1201, General Electric Co., Insulating Materials Dept., Schenectady, N.Y.)

3.4.6.2 Commutator Replacement

Replace the commutator with a new commutator, in accordance with the following procedures:

a. Strip and clean the armature in accordance with the procedures of Sections 3.4.6.3.b and 3.4.6.3.c.

b. Inspect and test the armature core in accordance with the requirements of Section 3.4.6.3.d through 3.4.6.3.f. Replace any defective laminations in accordance with the requirements of Section 3.4.6.3.g.

c. Remove the commutator from the armature shaft using a hydraulic puller, or the equivalent, being extremely careful not to damage the shaft.

Page: 26 o f 92

d. New commutators shall meet the following requirements:

(1) Commutators shall be approved by the Authority.

(2) All mica rings, sleeves and splittings shall be new.

(3) All commutator bars shall be new and diameter shall be at new.

(4) Commutators shall be completely spin/temperature seasoned and cycled in accordance with an Authority approved procedure prior to installation.

(5) Commutators shall be electrically tested in accordance with the requirements of Section 3.4.6.3.h.

(6) The commutator assembly shall be pre-balanced as an assembly to within one ounce-inch.

(7) The maximum accumulated error due to commutator bar and mica thickness variations shall not exceed 0.004 inch bar-to-bar.

(8) When dividing the commutator into eight sectors, or groups of bars, the maximum accumulated error due to commutator bar and mica thickness variations, as measured at the outside diameter of the commutator, shall not exceed 0.015 inch.

(9) Bare metal surfaces of the commutator shell shall be primed and then painted with a Glyptal insulating paint.

(10) The commutator bar centered over the keyway in the commutator shell, if applicable, shall be permanently identified with a period (.)

stamped on the end of the bar facing the V-ring.

(11) The skew allowance at the centerline of the commutator shell keyway, or the armature axial centerline, and the centerline of the above identified bar shall be 0.015 inch maximum over the length of the entire bar.

(12) The centerline of the commutator keyway and the centerline of the

Page: 27 o f 92 above identified bar shall be indexed radially within 0.0075 inch at the lateral centerline of the commutator brush surface. This indexing is independent of the skew allowance above.

e. Heat the commutator at 150ºC (302ºF) for two to three hours.

f. Lightly coat the appropriate shaft diameters with a suitable lubricant.

CAUTION: IF APPLICABLE,THE RADIAL INDEXING OF THE

CENTERLINE OF THE COMMUTATOR BAR

IDENTIFIED PER SECTION 3.4.6.3.d(10) ABOVE, OR

THE CENTERLINE OF THE COMMUTATOR SLOT,

WHICHEVER IS APPLICABLE FOR THE PARTICULAR

ARMATURE DESIGN AND THE CORE SLOT

IDENTIFIED PER SECTION 3.4.6.3.g(16) SHALL BE

WITHIN THE TOLERANCE SPECIFIED BY THE

ORIGINAL EQUIPMENT MANUFACTURER.

g. Press the new commutator onto the armature shaft, aligning the keyway slot in the commutator shell with the key in the armature shaft, if applicable. Check the alignment of the commutator to insure that it lines up with the core slots in accordance with Original Equipment Manufacturer's requirements. Apply a minimum of 40 tons of pressing force to the commutator shell and insure that the commutator is fully seated against the armature core pressure plate.

h. Press and tighten the commutator in accordance with the OEM procedure.

i. Rewind the armature in accordance with the procedures of Section 3.4.6.3

3.4.6.3 Armature Rewinding

Rewind the armature in accordance with the following procedure.

Replacement of shafts shall be at additional cost to the Authority. Replacement of minor parts such as pressure plates, collars, spacers, keys, etc. shall be included in the rewind cost.

NOTE: While the intent is to standardize on insulation methods and materials

Page: 28 o f 92 and on rewinding techniques, it is recognized that these instructions may not apply to all armatures. The Contractor shall modify these general instructions as appropriate to specific armatures, as approved by the Authority. In addition, variations to these general procedures may be permitted, with Authority approval, to allow the use of proven techniques and materials.

a. Armature and equalizer coils shall be designed and manufactured as approved by the Authority in accordance with the following general requirements:

(1) Armature and equalizer coils shall be in strict accordance with the latest design of the Original Equipment Manufacturer (OEM), including dimensions of conductor size, number of conductors, conductor orientation, insulation, twisting and forming.

The orientation of armature coils in the core slot shall not be changed from the OEM design unless the Contractor produces a written verification from the OEM, including appropriate technical analysis, that changing the conductor orientation would improve the design and operating characteristics of the motor and would be of benefit to the Authority.

Insulating materials used shall be updated to the present state of the art as approved by the Authority.

(2) Finished armature coils shall be a snug fit into the core slot.

(3) Conductors shall be of an electrolytic tough pitch copper suitably heat treated and annealed after forming to withstand the shock and vibration loads experienced on rail vehicle traction motors without failure. Lead ends shall be twisted and swage formed to fit the commutator riser slots.

(4) Armature and equalizer coil conductors shall be insulated over the entire length of the conductor with one layer, 1/2 lapped, of 0.0015 inch thick FEP- Kapton type F film tape, thermally sealed after wrapping to form an integral insulation.

Page: 29 o f 92

(5) Uninsulated armature coils shall be shaped by hot pressing after stacking the insulated coil conductors.

(6) Equalizer coils shall be covered with glass sleeving centered on the coil. If space does not permit this, glass sleeving shall be applied to every other equalizer coil, with Authority approval.

(7) Armature coils shall have filler strips of B-Stage Nomex added between all conductors at the knuckle end.

(8) Armature coil leads shall each be insulated with one layer, 2/3 lapped to result in three layers, of 0.002 x 3/8 inch type H Kapton film tape followed by one layer, 1/2 lapped, of 0.005 x 3/8 inch woven glass tape. The insulations shall begin no more than 1/8 inch from the commutator riser and shall extend to a point 1 1/2 inches from the slot where it shall tie in to the adjacent lead.

(9) Armature coils shall have a ground insulation of one layer, 1/2 lapped, of 0.002 x 3/8 inch type H Kapton film tape applied over the full length of the coil.

(10) Armature coils shall have a pre-shaped slot wrapper of 0.002 inch thick Nomex paper, 2 1/2 wraps with the overlap on the side, applied to the slot portion of the coil and extending at least 3/4 inch beyond each end of the slot.

(11) Armature coils shall have an overall insulation of one layer, 1/2 lapped, of 0.005 x 3/4 inch woven glass tape applied over the full length of the coil.

(12) Armature coils should not be Vacuum Pressure Impregnated at this time. The VPI process shall be performed when the armature is completely wound and welded

(13) Finished coils shall be hot die pressed and formed such that the coil leads line up with the appropriate commutator slots in accordance with the armature throw requirements.

Page: 30 o f 92

(14) Each finished armature coil shall be subjected to a high potential test, per the requirements of Section 4.2.2, with 1,000 volts A.C., R.M.S., 60 Hertz, applied between adjacent conductors to insure that they are free of electrical faults. There shall be no breakdown indicated.

(15) Each finished armature coil shall be subjected to a high-potential ground test, per the requirements of Section 4.2.2 at 3,000 volts A.C., R.M.S., 60 Hertz for 60 seconds. There shall be no breakdown indicated. The test voltage shall be applied between a slot-sized die and the coil with the slot section under pressure within the die.

(16) Each finished equalizer coil shall be subjected to a high-potential ground test, per the requirements of Section 4.2.2., at 1,000 volts A.C. R.M.S., 60 Hertz, for 60 seconds. There shall be no breakdown indicated. Each coil shall be wrapped with metal foil, to within 3/16 inch of the coil end with the test voltage applied between the coil and the metal foil.

(17) Each finished armature and equalizer coil shall be 100 percent inspected for dimension, defects and quality of workmanship.

(18) All coils shall be of first-class quality and shall be manufactured by fully qualified personnel.

(19) All conductors shall be individually glass sleeved up to the commutator riser.

b. Remove the armature windings and insulation observing the following procedure:

(1) Remove the fan.

CAUTION: AN ABSOLUTE MINIMUM OF COMMUTATOR

RISER MATERIAL SHALL BE REMOVED. BE

CAREFUL TO NOT BEND OR DAMAGE RISERS.

(2) Place the armature in a lathe and machine the T.I.G. welded face of the commutator risers just enough to release the welded ends of the coils

Page: 31 o f 92 from the risers. If the coil ends are soldered into the riser slots, carefully heat the area to remove the coils without damage to the commutator.

(3) Carefully remove the coil banding and coil wedges.

(4) Cut the coils in back of the risers and at the front and rear ends of the core using a 1/8 inch cut-off tool or a rotating carbide tip cutter. The cut shall be made at a distance between 1/8 and 3/8 inch outboard of components.

CAUTION: THE FOLLOWING TEMPERATURES SHALL

NOT BE EXCEEDED IN THE STRIPPING OPERATION:

CORE - 250ºC (482ºF)

COMMUTATOR - 200ºC (392ºF)

AS MEASURED ON THE BRUSH SURFACE

(5) Remove the armature and equalizer coils and all associated insulation, varnish and compounds.

NOTE: Coils and wedges in core slots shall be removed by mechanical means ("Thumm" method) or by high pressure water spray. The commutator shall be protected by a hood. When the high pressure water method is used, the armature must be baked in an oven for six hours at 150ºC (302ºF) following stripping.

CAUTION: USE EXTREME CARE TO AVOID BENDING

COMMUTATOR RISERS AND CRACKING OF

MICA SEGMENTS.

(6) Remove the cut-off leads from the commutator risers.

(7) Straighten any bent risers and clean out riser slots as necessary.

(8) Remove all balance weights from the commutator and non-commutator end of the armature.

Page: 32 o f 92

(9) Remove the commutator creepage band without damaging the mica V-ring.

c. Thoroughly clean the stripped armature observing the following:

(1) Clean off all insulation, varnish and compounds still remaining on the core and coil supports.

CAUTION: TAKE EXTREME CARE TO AVOID

DAMAGING THE MICA INSULATION.

(2) Carefully remove the old creepage band and string banding from the mica V- ring extension.

(3) Clean any carbon and dirt from the mica rings with a dry rag or a fiber brush.

(4) Remove any paint or varnish from the ends of the commutator bars by scraping.

CAUTION: USE EXTREME CARE TO PROTECT THE SHAFT

BEARING SURFACES AND THE COMMUTATOR

FROM DAMAGE FROM BLASTING.

(5) Thoroughly clean the armature by shell blasting, or by an Authority approved method, to remove all deposits of old varnish and compounds. Mask off any areas that are not required to be cleaned or that would otherwise be damaged.

(6) Clean the armature of all debris with dry compressed air. Inspect for and remove any copper chips from behind the risers.

d. Replace all armature core laminations. No part of the core laminations will be reused.

(1) Remove the commutator from the armature shaft using a hydraulic puller, or the equivalent, being extremely careful not to damage the shaft.

(2) Disassemble the core, inspecting the shaft and pressure plate for

Page: 33 o f 92 damage. Replace any defective parts.

CAUTION: ON SOME ARMATURES, A NUMBER OF END

LAMINATIONS AT EACH END OF THE CORE

ARE SPOT WELDED TOGETHER. IF THIS IS THE

CASE, THE SPOT WELDS SHALL BE LOCATED

MIDWAY BE TWEEN EACH TOOTH AND

POSITIONED 0.3 TO 0.7 INCHES FROM THE

OUTSIDE DIAMETER OF THE LAMINATION.

THE SIZE OF THE SPOT WELD SHALL BE 0.18 TO

0.25 INCHES IN DIAMETER.

CAUTION: LAMINATIONS SHALL BE STACKED WITH

BURRS, IF ANY, IN THE SAME DIRECTION.

BURRS SHALL BE AVOIDED TO THE MAXIMUM

EXTENT PRACTICABLE. IF PRESENT, THEY

SHALL NOT EXCEED 10 PERCENT OF THE

LAMINATION THICKNESS, OR 0.002 INCH,

WHICHEVER IS LESS.

(3) Assemble the coil support and the knuckle end laminations on a mandrel, with a key, if applicable, to line up the inside diameter.

(4) Line up the slots using at least four tight fitting steel drifts.

(5) Place the assembly in a press. Apply 40 tons, press and release twice.

Reapply the force and check the length of the core. Add or subtract center laminations as necessary to obtain…