Motor_Repair_Technical_Specifications.docx

Purchasing Department Gregory K. Spearman, CPPO, Director 306 E. Jackson Street, 2E Tampa, Florida 33602

Office (813) 274-8351 Fax: (813) 274-8355

TECHNICAL SPECIFICATIONS FOR

ELECTRIC MOTOR REPAIRS AT THE MCKAY BAY WASTE TO ENERGY (WTE) FACILITY

8. GENERAL

The work under these specifications requires the reliable and timely inspection, removal, transport, and repair of any electric motor at the (WTE) Facility located at 107 North 34th Street, Tampa, FL 33605. The Awardee shall furnish all labor, materials and equipment required in performing the services detailed in this specification. All work shall be done in a neat and professional manner and meet or exceed standards that are considered good practice.

9. BIDDER QUALIFICATIONS AND REFERENCES.

9.1 Bidders shall have been in the business of providing similar services of this award for a minimum of three years.

9.2 Bidder shall submit with the bid, a list of three references from present or former clients. This list shall demonstrate the successful completion of similar projects. Such list shall be complete with telephone numbers, email address and contact person(s). By submitting a bid, the Bidder authorizes the City Representative to conduct reference investigations as needed.

9.3 A list of employees that will be involved in performing the work under this award, including years of experience, resumes and any licensing and certifications received. In addition, any licenses for the company pertinent to the work described herein should also be included. Throughout the term of the award, the City reserves the right to request, and subsequently receive a replacement, for any person(s) that is deemed to be unqualified.

9.4 A list of equipment that is to be used in the execution of the work detailed herein. This list shall include the capabilities and any other relevant technical data of the equipment that is listed. This information shall be sufficient for the City to determine the suitability of the equipment to accomplish the work described herein. The City reserves the right to inspect the Awardee’s place of business to ensure adequacy in these aforementioned items prior to the start of the award resulting from this specification.

9.5 Documentation that details an established in-house safety training program or procedures for employees who will be involved in the performing of the work described herein.

Bidders that do not meet these requirements and/or do not submit the abovementioned information in their bid response package may not be considered.

10. ESTIMATES

10.1 The Awardee shall inspect and evaluate each piece of equipment after disassembly to determine if the unit can be economically repaired. If the piece of equipment cannot be economically repaired, the Awardee shall provide a replacement cost for a new piece of equipment.

10.2 All costs overrun from the original repair estimate given by the Awardee to the City shall be absorbed by the Awardee unless waived by the City.

10.3 The Awardee shall provide a repair estimate for equipment within ten (10) days of pickup.

11. PICKUP AND DELIVERY

11.1 The Awardee shall provide free pickup and delivery of all equipment to be repaired at the Awardee’s facility. If the equipment is unable to be transported to the Awardee’s facility, repairs shall be performed at the specified City facility.

11.2 The Awardee shall pickup equipment for repair within 24 hours from receiving verbal notification by the City Representative, including after normal/business hours, weekends and holidays. Under emergency conditions the Awardee shall respond within four (4) hours from receiving verbal notification by the City Representative.

12. SPECIFIC PROVISIONS

12.1 The Awardee shall remove and/or reinstall any motors, including all electrical, control, and mechanical connections, at the appropriate hourly labor rate plus crane rate if necessary. The City will be responsible to electrically and mechanically isolate the equipment for safe removal or installation.

12.1.1 The Awardee shall, at the City’s request, perform precision alignment on repaired motors, pumps, and/or shafts at the City’s WTE Facility at the appropriate hourly labor rate.

12.1.1.1 The Awardee shall provide a report showing ‘as found’ and final alignment conditions following precision alignments.

12.1.2 The Awardee shall have a crane capable of lifting, removing, and installing all types of motors up to 1000HP.

12.1.3 The Awardee shall be able to perform all motor repairs described in Section 13 on motors up to 1000 horsepower. The Awardee shall be capable of repairing motors up to 1000 horsepower.

12.1.4 The Awardee shall, at the City’s request, perform Vibration Analysis Testing for inboard/outboard motor bearings, inboard/outboard fan bearings, critical pumps, compressor motors, and turbine generator bearings.

12.1.4.1 The Awardee shall provide a report showing the Vibration Analysis Testing results.

12.2 The Awardee will be responsible for all costs related to the removal and replacement of equipment related to rework required due to faulty repair by the Awardee.

12.3 The Awardee shall provide a spreadsheet reporting the repair status of each outstanding job along with an estimated completion date weekly to the designated City contact.

12.4 SCHEDULE. The work of this award that is performed on-site shall be done during normal working hours of 7:00 AM to 3:00 PM, Monday through Friday. The City Representative will provide the Awardee written approval of the repair work and schedule before work should commence. The Awardee will not be compensated for any work that has not received prior written approval. The Awardee shall follow the normal work schedule time detailed above unless prior approval by the City Representative is given to proceed otherwise.

12.5 REPAIRS

12.5.1 The pricing for the repair work of this Award shall be the quoted hourly rate of work plus a bid markup on materials. However, if deemed necessary, the City shall allow additional work to exceed the normal eight-hour day including weekends and holidays. In this case, the Awardee shall be compensated at the overtime rate that is included on its Bid Response Page. All overtime work shall receive prior written approval from the City before work is performed.

12.5.2 The Awardee shall commence repairs on equipment within 24 hours from pickup by the Awardee or delivery to the Awardee’s facility by the City. This time frame applies to all equipment other than those specified as emergency repairs, which shall commence upon receipt.

12.5.3 Routine repairs, as designated by the City Representative, to electric motors shall be completed within 5 business working days from pickup by the Awardee or delivery to the Awardee’s facility by the City Representative.

12.5.4 Emergency repairs, as designated by the City to:

12.5.4.1 Electric motors less than 100 HP shall be completed within 72 hours from pickup by the Awardee to the Awardee’s facility.

12.5.4.2 Electric motors greater than 100 HP shall be completed within 120 hours from pickup by the Awardee or arrival to specified City facility.

12.6. EMERGENCY SERVICE

12.6.1 The Awardee shall provide emergency repair service on 24 hours, 7 days a week, basis including holidays when requested by the City Representative.

12.6.2 The Awardee shall communicate by verbal contact in response to the City Representative’s request for emergency services within 2 hours from notification by the City Representative. Awardee shall have a service truck or delivery/pickup truck on site within 4 hours of notification.

12.6.3 Compensation for emergency service shall be at the bid hourly rate, as specified on the Bid Response Page. All emergency work shall receive prior written approval from the City Representative before work is performed.

13. ELECTRIC MOTORS

13.1 GENERAL

13.1.1 Disassemble motor and clean all components.

13.1.2 Inspect electric motors for hot spots, core lamination loss, and assessment of the core’s condition to determine if repair of the electric motor is needed.

13.1.3 Core test stator for shorted lamination before rewinding. The City Representative will require both a Core Loss Test and Core Test.

13.1.4 Overhaul the components, rewind, repair and/or replace any assemblies including:

13.1.5 Surge test as specified in this specification.

13.1.6 Dynamically balance the rotating assemblies shall meet standard of IS0 1940 Balance Grade G 2.5.

13.1.7 Paint all external surfaces to match existing color.

13.1.8 Test overhauled motors under maximum design load conditions when requested to assure satisfactory operation.

13.1.9 All work, materials and work methods shall conform with the latest NEMA standards.

13.1.10 All work and materials shall be NEMA approved Class F or higher and rated for inverter duty unless otherwise requested.

13.1.11 The Awardee shall repair all electric motors in accordance with the manufacturer’s technical data (including tolerances, calibrations and specifications) and industry standards.

13.2 RECONDITION ELECTRIC MOTOR

13.2.1 GENERAL. Upon receipt of the motor, and if winding failure is not evident, the insulation resistance shall be read. The insulation resistance of the stator shall be read using a megger. If the insulation resistance reading permits, the motor shall be run on full rated voltage. Minimum acceptable insulation resistance readings are one megaohm per 1000 volts of rated voltage, but never less than one thousand megaohms.

13.2.1.1 While the motor is running, a visual examination shall be made for hot or noisy bearings and excessive vibration or other unusual conditions. After the motor has been disassembled, the rotor shall be tested for open circuits. In the event the stator winding has failed, the rotor shall be tested on a “growler”.

13.2.1.2 Micrometer measurements shall be taken on mechanical parts to ensure proper fit. Measurements shall include, but not limited to, bearing housings, seal housings and shafts, and all shall meet OEM specifications.

13.2.1.3 Test rotor for short lamination using a core test device. If the old stator windings have not failed, a surge comparison test and a DC HI potential test is required to test for: turn to turn for shorts, coil to coil for shorts, phase to phase for shorts, phase to ground for insulation resistance and dielectrically strength of windings, etc. Measurements to be performed by certified calibrated instruments.

13.2.1.4 All of the above information shall be recorded on a shop record and retained in a permanent file. This record shall include a description of failure and the probable cause of failure. Copies will be returned with each repaired piece of equipment prior to payment for those repairs. Electronic copies are required to be emailed to the City’s representative in PDF format. Measurements taken before and after repairs will be included in reports. The repair reports are considered to be part of the repair work and payment will not be processed by the City until all required reports are received.

13.2.1.5 All rotors shall be balanced to meet ISO 1940 BALANCE GRADE G 2.5 standards.

13.2.2 Squirrel Case Rotors. The rotor shall be visually inspected, tested for open bars, steam cleaned and baked.

13.2.3 Slip Ring Rotor (Wound Rotors). The same procedure as used on a squirrel cage rotor shall be followed. In addition, the open circuit voltage between rings shall be read and recorded.

13.2.4 Rotating Fields. The same procedure as used on a squirrel cage rotor shall be followed. In addition, the fields shall receive an AC and a DC drop-check test, and the readings recorded. Drop-check voltage reading will be recorded for each coil and the coils will be numbered. A surge comparison and DC HI potential test may be used to determine the condition of the rotating field.

13.2.5 Bearings. Ball and roller bearings shall always be replaced with equivalent or superior bearings unless otherwise requested. Sleeve bearings shall have babbitts refurbished to original manufacturer’s specification. Acceptable bearing manufactures are: SKF, Timken, Fafnir, NSK, NTN. Any other brand of bearing will require approval from the City of Tampa Representative before being installed.

13.2.6 Shafts and End Bells. All bearing surfaces shall meet Original Equipment Manufacturer (OEM) specifications. When out of limits, shafts and end bells shall be repaired using pre-approved methods. All grills shall be unbroken and secure in the frame.

13.2.7 Miscellaneous.

13.2.7.1 All defective items such as feet, lift rings, fans, fan covers, etc., shall be repaired and put in a first class condition.

13.2.7.2 All grease type bearings used shall be flushed thoroughly and packed with grease prior to final assembly.

13.2.7.3 Provide a written detailed description (make/manufacturer) of the type of bearing(s) utilized for each repair. Any change in type or style of bearing will require written pre-approval from the City of Tampa Representative, electronic versions are acceptable.

13.2.7.4 All O-Rings exposed through dismantling of equipment shall be replaced with new O-rings. Use of silicone or similar type caulking is not acceptable.

13.3 REWIND ELECTRIC MOTOR

13.3.1 Rewind shall include all work as defined in Section 13.2 Recondition Electric Motor.

13.3.2 Winding Removal and Core Preparation

13.3.2.1 Old windings shall be removed by using either a “Vapor-Phase” solvent system or a controlled temperature burn-out oven. In either case, the method must allow removal of the winding without the use of any excessive heat, which might warp the stator frame.

13.3.2.2 Upon removal of the winding and insulation, the core shall be tested for shorts in laminations (core test) and inspected for cleanliness and absence of burrs, sharp edges and damaged iron.

13.3.2.3 In the event the slots are not clean, the iron shall be sandblasted. Any damaged core iron shall be removed or individually treated to return the core to its original laminated condition. The iron and frame shall be in a first class condition before the rewinding procedure begins.

13.3.3 Winding Materials

13.3.3.1 All materials used in rewinding shall be guaranteed to be capable of a specified minimum temperature class. Data of the original material fabricator shall be available to substantiate the temperature class of each material used.

13.3.3.2 All insulation systems shall be specified by hot spot or limiting temperature. The type materials shall be Class F minimum. Without exception, the magnet wire in any equipment subject to heavy load and starting surges shall have a Dacron glass outer covering.

13.3.4 Winding Procedure

13.3.4.1 General. Coils shall be machine wound, with all wires individually tensioned to obtain uniformity and freedom from “crossovers”. Proper form shapes shall be used to give adequate end room clearance and prevent “buried” coils. All connections, jumpers and leads shall be laced down in a neat, secure manner with adequate clearance from the end bells.

13.3.4.2 Random Wound Stators. “U” shape wedges shall be used. In the event the coils are loose after the “U” wedge is installed, additional material shall be driven either in the bottom of the slot, between the top and bottom coils, or under the wedge to render the coils firm and tight. In some cases, it may be necessary to apply fillers in all three locations.

13.3.4.3 Random Wound Rotors. Maximum attention shall be given to installing the winding in a secure manner. The winding shall not be twisted or skewed while banding.

13.3.4.4 Form Wound Stators. The coils shall be spread properly so that the “side angles” are parallel to the slots and do not cause any “cutting in” due to non-parallelism. The coils shall have a secure and firm fit in the slots. All coils shall be securely tied to all surge and end rings. All group jumpers, connections and leads shall be securely laced. All wedges shall be fabricated to a “drive” fit and the proper amount of filler shall be installed with the coils to prevent any “up and down” movements.

13.3.4.5 Rotating Fields. The bottom collar shall be ground to the shape of the pole piece and spider rim. All amortisseur windings shall be sandblasted and visually examined for any evidence of cracking, mechanical damage or open connections. Any spots in the amortisseur winding found bad will be brazed before the winding is started. No phosphor bronze solder or brazing rod will be used on electrical connections. During final assembly, the mechanical joints shall be inspected for proper alignment and tightness. All electrical joints between coils shall be brazed, taped and epoxy coated.

13.3.5 Completed Winding Varnishing. The varnish shall be of the semi-rigid, high build type, capable of 155 degrees Celsius (Class F) operation or 180 degrees Celsius (Class H) operation as appropriate. A minimum of three (3) dips and bakes shall be scheduled to ensure a good coating. The baking shall be done in a temperature controlled, forced ventilation oven to give the best and most uniform cure. A rapid process system may be used with prior approval from the City. The City may elect to order a Vacuum Pressure Impregnated (VPI) sealing process versus the varnishing process specified herein. Awardee must be able to perform, or subcontract, VPI on motors up to 5000 series frames.”

13.3.6 Reassembly. All finished machine surfaces shall be cleaned of all varnish and foreign materials. The bore of the stator laminations and the periphery of the rotor laminations shall be cleaned of all varnish and foreign materials. All rings shall be turned and polished as necessary or specified. All brush holders will be cleaned of corrosion and foreign material.

13.3.7 Final Testing.

13.3.7.1 The insulation resistance shall be measured again with a megger. Minimum acceptable insulation resistance shall be one thousand megaohms.

13.3.7.2 The motor shall receive an AC high potential test as follows:

· New windings – twice rated voltage, plus 1000 volts.

· Old windings – rated voltage plus 25% unless specified differently

13.3.7.3 A surge comparison tester shall be used to test the windings for reverse coil, shorted turns, reverse phase, open circuit, short between phases, ground fault, etc.

13.3.7.4 The motor shall be run on rated voltage and the following items observed and recorded and must meet OEM specifications or current industry standards approved by the City of Tampa.

· No load current for each phase.

· Noise and/or endplay

· Bearing noise

· Vibration

· Bearing temperature

· No load speed.

13.3.7.5 In addition, drop-check and insulation test shall be performed and recorded. Copies of these final test results will be provided to the City with the repair report.

13.3.8 Painting and Finishing. The equipment shall be hand cleaned, removing all old paint and foreign materials, and painted. Final coating shall be same color as it was received. Exposed finished parts, such as shafts, shall be treated to prevent corrosion. Any design changes, such as horsepower re-rating, speed, etc., shall be shown as new nameplate data. Nameplates, which are missing or are not eligible, shall be replaced with a new nameplate giving as much information as possible.

13.4 EXPLOSION PROOF MOTORS. All explosion proof motors will be repaired only by facilities which are U.L. approved to perform these repairs. If the Awardee’s facility is not U.L. approved, the City will have the option to:

13.4.1 Arrange for the repairs with another vendor that meets this requirement.

13.4.2 Allow the Awardee to utilize a U.L. approved subcontractor upon prior approval by the City.

14. REPORTS. The Awardee shall provide the City all reports for all services performed on motors detailed herein. The reports should include an evaluation of the overall condition of the motor and any other data needed to predict future repairs or replacement. Copies of reports will be returned with each repaired piece of equipment prior to payment for those repairs. Electronic copies required in PDF format. Measurements taken before repairs and after repairs will be included in reports. Complete repair reports shall be submitted with or prior to any invoice for the work performed. Pictures must be taken of tear down and rebuilt of all major steps during the process.

15. RECORDS. The Awardee shall keep accurate and up to date records of repairs throughout the award period. These records shall be kept on forms furnished by the Awardee and should receive written acceptance by the City prior to utilization of the reports. These records shall be made available to the City upon request for examination and reproduction. A complete set of records shall be furnished to the City upon the termination of the award. Receipts for parts, other than expendable supplies and lubricants, shall be submitted to the City for written approval and shall become part of the permanent record for the piece of equipment.

16. REPLACEMENT PARTS. The Awardee shall, with the City's written approval, furnish replacement parts at the Awardee's cost plus the "mark-up" as listed on the Bid Response Page. As detailed on the Bid Response Page, the Bidder shall multiply this markup percentage by the estimated annual material cost of $100,000 in order to calculate an annual material cost for the award. The City may require more or less replacement parts than the initial estimate on the Bid Response Page. The Awardee shall furnish invoices or receipts of replacement parts for price verification for each repair. The invoice shall include the detail to list the Awardee’s cost and markup percentage for verification by the City. Only replacement parts of the highest quality shall be accepted by the City. The city reserves the right to have all replaced parts returned to the city. All replaced bearings will be returned to the city. The COT shall not be charged for consumables. Consumables are defined as common materials required completing the task that cost less than $100. Some examples of consumables are, electrical tape, welding rods, miscellaneous hardware and lubricants. Invoices or receipts for parts shall be provided to the City with or prior to any invoice for work performed. No payment for parts shall be made without copies of invoices or receipts.

17. CRANE SERVICES. Repair pickup and delivery of motors shall be at the expense of the awardee, including any needed crane services. Crane services requested by the City for removal or installation of motors not related to warranty repairs, shall be compensated at the crane rate as listed on the Bid Response Page

18. WARRANTY. The products used in the work described herein shall be covered by the manufacturer’s standard warranty. The workmanship shall be warranted for a period of at least two years from the date of equipment start up. Should any defect become apparent during these time periods, the Awardee shall repair the defective item at no cost to the City. Calls for warranty service shall be handled in a timely manner as described in sections 6.5 or 6.6. Cost related to removal and installation of equipment that has failed during the warranty period shall be absorbed by the awardee as described in section 6.2.

19. PROTECTION OF PROPERTY. The Awardee shall employ all means necessary to perform this work without damaging any of the buildings, structures, or equipment that is located in or around the areas where the work is taking place. The Awardee shall be responsible for any damage that is the result of performing the work of the award.

20. INSPECTION AND ACCEPTANCE. All work shall be inspected and approved by plant maintenance staff in order to receive acceptance by the City. Should any discrepancy be identified during the inspection process, the Awardee shall correct the defect prior to receiving any compensation for the work. Some tasks will require testing (vibration reading, current measurements, flow, etc.) as a part of the inspection procedure. The City will make every reasonable effort to ensure that such tests are performed in a timely basis. It should be understood by all Bidders that circumstances may arise which may delay the testing process. No additional compensation will be granted for a delay completing the inspection process or the correction of any discrepancies.

21. SAFETY. The Awardee shall be responsible for the safe conduct of his/her personnel at all times during the execution of the work detailed herein. The Awardee and their personnel shall adhere to the safety rules and regulations set forth by the City of Tampa. Should an unsafe condition or procedure be identified during this work, the activity shall be immediately suspended until such time as a safe method can be implemented with no compensation to the Awardee.

22. Contractor Safety Requirements: See Attachment D -- “City of Tampa McKay Bay Waste-To-Energy Facility Contractor Environmental, Health, and Safety Requirements”

23. Contractor Notice: See Attachment E – “City of Tampa McKay Bay Waste-To-Energy Facility Contractor Arsenic, Lead, Cadmium, and Hexavalent Chromium Notice

BID RESPONSE FOR

ELECTRIC MOTOR REPAIRS AT THE MCKAY BAY WASTE TO ENERGY (WTE) FACILITY

Please Print or Type

We the undersigned, as Bidders, hereby declare that we have carefully read this proposal or bid and the provisions, terms and conditions concerning the equipment, materials, supplies or services as called for, and with full knowledge and understanding of the requirements and conditions, do hereby agree to furnish and to deliver as indicated, FOB, City Facility Location, with all transportation charges prepaid, and for the prices quoted thereon as follows.

A. LABOR HOURS

Labor Type

Hourly Rate (A)

Hours(*) (B) Total Cost for Line Item TC = (A) x (B)

(*) = More or Less

TOTAL COST OF LABOR HOURS: $_______________

B. REPLACEMENT PARTS PRICING:

TOTAL AMOUNT OF BID (ITEMS A + B +C): $ __________________

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