Attachment_2_Procedure _SOW_and_CDRLS_500kW_New_Design_Commutators.pdf

PORTSMOUTH NAVAL SHIPYARD

500 KW "NEW DESIGN" SSMG

COMMUTATOR MANUFACTURE PROCEDURE

Enclosure (2)

COMMUTATOR REFURBISHMENT PROCEDURE

"NEW DESIGN"

The commutator shall be rebuilt in accordance with the following instructions. All materials shall be as specified. Equivalent materials may be used if approved by Portsmouth Naval Shipyard in writing or via E-mail. The commutator manufacturer is responsible to provide certified records including signatures required by this instruction, that the commutator has been rebuilt in accordance with this instruction. The manufacturer shall provide a copy of all spec or data sheets for all materials used during the manufacture of the commutator with the final certification package. Failure to meet any requirements shall be cause for rejection.

NOTES:

1. NO SILICONE OR SILICONE CONTAINING PRODUCTS SHALL BE USED IN THE

REFURBISHMENT OF THE COMMUTATOR.

2. ALL METERS AND MEASURING INSTRUMENTS USED FOR CERTIFICATION OF

DATA SHALL MEET THE REQUIREMENTS OF IS0-10012-1 "QUALITY

ASSURANCE REQUIREMENTS FOR MEASURING EQUIPMENT" AND/OR ANSI

Z540-1 "GENERAL REQUIREMENTS FOR CALIBRATION LABORATORIES AND

MEASURING AND TEST EQUIPMENT".

3. INSPECTION OF THE COMMUTATOR COMPONENTS AND COMPLETED

ASSEMBLY SHALL BE PER ISO 9001/ANSI Q9001. INSPECTION AT ORIGIN WILL

BE ACCOMPLISHED FOLLOWED BY INSPECTION AND ACCEPTANCE AT

DESTINATION.

4. THE GENERATOR THAT UTILIZES THIS COMMUTATOR HAS A DUST SEAL THAT

RIDES ON THE COMMUTATOR SURF ACE ADJACENT TO THE BRUSH-RIDING

SURFACE. IN ORDER TO MAINTAIN THIS SEALING SURFACE ADDITIONAL

DIMENSIONS AND DATA PERTAINING TO THE SEAL LOCATION AND BAR

DIAMETER WILL BE REQUIRED PRIOR TO DISASSEMBLING THE COMMUTATOR.

THE MICA MUST NOT BE UNDERCUT IN THE SEAL RIDING AREA. CONTACT PNS

IF FURTHER INFORMATION IS REQUIRED.

a) The commutator GFM carcass will be provided to the contractor after being removed from its shaft by Portsmouth Naval Shipyard. The commutator is for a General Electric 500 kW (New Design) DC generator, 210- 355 volts, 1200 RPM. The following data is provided for informational purposes only.

Number of Segments- 152 Mica segment thickness- .040" Armature Coil Wire Size - .080" x .300" No of Wires per slot- 8 Diameter (brush surface) 19 35/64" Min Diameter (dust seal surface) 19.925" +/- 0.005" After assembling the commutator, clean up the dust seal surface in a lathe the minimum amount necessary to obtain a total indicated runout (TIR) ofless then .003". The final outside dimension of the surface shall be not less than 19.680" and not more than 19.880".

Length of active surface 10 5/16" Bar length- 13 3/32" Front V-Ring Proj.- 1 7/8" Rear V-Ring Proj- 1 7/8" Riser Type - Double Inserted Dia. over risers- 29.50" (As Folded) Commutator weight - 854 LB Keyway - none Shaft (commutator mounting surface) Diameter:

Riser end (8.999- 9.000"); Front end (8.989"- 8.990") Commutator Bore Diameter: Riser end (8.996- 8.997");

Front end (8.987 - 8.988")

b) The commutator shall be completely stripped of all insulation material prior to replacing copper segments and insulation (including any varnish).

c) All commutator copper shall be new. Replacement commutator bars shall be manufactured from copper bar stock in accordance with the Copper Development Book, silver bearing type UNSC-11600 with 25-30 troy ounces of silver per ton. Copper bar hardness shall be at least 70 Rockwell F and have a tensile strength of not less than 30,000 PSI. Riser material shall be oxygen free silver bearing type UNSC-10700 copper.

Risers shall be brazed to the bars with BCuP-5 brazing rod per Fed Spec QQ-B-654 without the use of flux. The brazed joint shall have excess material removed as required to ensure that excess filler material does not interfere with the fit up of the completed assembly. Use Figure I for dimensions for copper segment manufacturing. Use Figure VII for formation of copper riser.

d) All the mica insulation shall be new. Segment insulation (between commutator bars) shall be inorganic bonded muscovite micapaper. The segment insulation shall be flush with the commutator segments in the area of the riser seal. The segment insulation shall be sub flush 1116" to 3/32" on the brush riding surface. Commutator ground insulation and the V-ring insulation shall be pasted mica, type PMM, in accordance with NEMA FI-

1. The thickness and the extent of all insulation shall be equal, as a minimum to the thickness and extent of insulation as found on the original commutator provided for rebuild. Each Mica V -ring and barrel shell insulator will be built in such a manner that it is one molded assembly consisting of built up layers that are scarfed or tapered to obtain uniform thickness when successive strips are lapped over in making the ring. V -rings consisting oftwo pieces with a joint at the apex of the V-ring are unacceptable. Use Figure V for dimensions for V -ring manufacturing.

e) Commutator steel parts shall be inspected for damage. Any damaged or missing parts shall be repaired or replaced. The V -ring barrel if replaced shall be manufactured from seamless steel tubing per ASTM A29, AISI 1020. Manufacture new barrel IA W Figure II.

The V -ring clamp rings if replaced shall be manufactured from carbon steel per ASTM A29, AlSI 1040. Manufacture new clamp rings IA W Figures III & IV. Hot rolled seamless steel tubing per ASTM A-106 is acceptable for barrel replacement. AISI-4140, normalized, quenched & tempered to meet ASTM A-668 is acceptable for v-ring replacement.

Note: epairs to steel parts shall consist of minor straightening, weld build-up, and plating in R dan g accor ce with MIL-STD-2197. A bushing or sleeve shall not be used to repair over sized sea tin surfaces.

SI

SI

SI

LAMP RINGS AND BARREL INPECTED/REPLACED, MAT'L AS SPECIFIED: c Gc:-N ATURE/DATE

f) V -ring studs shall be replaced with heat-treated and stress relieved alloy steel bar per AISI-4140. All nuts shall be replaced; the material for the nuts shall be at least SAE Grade 5 alloy steel. New locking tabs will be manufactured from 1/16" carbon steel plate lAW Figure VI. Note: The locking tabs will not be bent over by the commutator manufacturer. These will be bent at PNS after the commutator is mounted on a shaft and final torque has been applied.

ALL NUTS, STUDS AND LOCKTABS ARE NEW MAT'L AS SPECIFIED:

GN ATURE/DATE

g) The inside and outside V -rings shall be banded with 3/8" wide B-staged glass banding. No Teflon will be used in this area. Glass band to extend from the face of the clamp ring to the face of the commutator bars. Glass banding shall conform to Mil-l- 24178, such as Fibertek Inc. RES-I-GLASS B-0322-F, or equivalent. The bands shall be built up on the V -rings to a level that will completely seal any opening at the V -ring where grit or carbon dust could become lodged on the V -ring surface. NO STRING

BANDING, GLASS WEAVE OR TEFLON TYPE BANDING SHALL BE USED.

GLASS BANDING PER MIL-I-24178 APPLIED AS DESCRIBED ABOVE:

ATURE/DATE GN

h) The commutator steel mating surfaces (inside diameter) shall have a final dimension of: Riser end (8.996- 8.997"); Front end (8.987- 8.988"). Record actual dimensions below.

FINAL COMMUTATOR STEEL MATING SURF ACE DIMENSIONS

RIS REND: E

GN

IN I FRONT END: IN

SI ATURE/DATE

i) The commutator shall be spin seasoned after assembly. The commutator shall be seasoned at 1500-1550 RPM, at a temperature of at least 200°C for at least three five minute cycles. The maximum change in total indicator runout shall be 0.002 in.

COMMUTATOR SATISFACTORILY SPIN SEASONED:

SI GN ATURE/DATE

Enclosure ( 2)

j) The axial skew of the commutator bars shall b e checked from the riser to the end of the ot exceed 0.015-in. Excessive axial commutator. Commutator bar axial skew shall n skew shall be corrected.

I SIGNATURE/DATE

AXIAL SKEW IS LESS T HAN .015 IN:

k) The commutator shall successfully pass a 400 commutator bars. If the commutator does not sue

VAC bar to bar test between the cessfully pass this test, it shall be repaired as necessary.

400 V AC BAR TO BART EST SAT:

SIGNATURE/DATE

1) Wrap several turns of bare copper wire secure! y around the commutator to short bars n the commutator bars and ground to commutator and ground. If the together and conduct a 3500 VAC Hi-Pot betwee ensure there are no grounds or shorts between the commutator does not successfully pass this test, it shall be repaired as necessary.

3500 V AC HI-POT SA TISF ACTORY:

SIGNATURE/DATE

m) Measure for one minute the insulation resist ance to ground of all the commutator bars stance value shall be 10,000 megohms.

nity or greater than 1 00 megohms is connected together. The minimum insulation resi Log below the actual megohms (data such as infi unsatisfactory. Greater then 10,000 meg-ohms is an acceptable reading) If the commutator does not successfully pass this test, it shall be repaired as necessary.

ACTUAL MEGOHMS TO GROUND

I

MEGS

SIGNATURE/DATE:

chined to be concentric with the inside n) The commutator outside diameter shall be rna diameter of the mounting sleeve within 0.003 inc h TIR. The bar-to-bar runout shall not ntricity and bar-to-bar runout in the table exceed 0.0003 inch bar-to-bar. Log actual conce below.

Concentricity of the commutator surface with re spect to the mounting sleeve and runout: commutator bar-to-bar

Concentricity Bar-to-bar runout one inch from front middle one inch from dust seal On the dust seal surface Required: Concentricity less than 0.003-in. TIR, b ar-to-bar runout less than 0.0003 in.

TIR

SIGNATURE/DATE

o) The co mmutator manufacturer shall stamp or etch mark the outside V-ring (steel portion) in companyn a visible location with a unique serial number consisting of the abbreviated arne, two digit month and two digit year date code of when the commutator

Verify data below. was rebuilt.

Commutator S erial Number:

Company Abb reviation/Two Digit Month/Two Digit Year

/DATE SIGNATURE

p) All exp coated wit varnish per osed steel parts (with the exception of bore to shaft mounting surfaces) shall be hair dry varnish per MIL-I-24092 Grade CA (NON SILICONE) or baking

MIL-I-24092 Grade CB (NON SILICONE). NO PIGMENTED OR COLORE D VARNISHES AND RESINS ARE ALLOWED. Ensure that the commutator her remains visible. serial m.im

q) After co mpletion of all of the above work, the commutator shall be balanced to 5 es or less. ounce-inch

FINAL BALANCE DATA:

Required: Actual:

:S 5 OZ-IN

SIGNATURE /DATE

r) The co with anon-mmutator manufacturer shall cover the commutator bore/mounting surfaces silicone rust inhibitor such as Cosmoline or "Dolph Lamination Coater With cer". The completed commutator shall be wrapped in plastic or other suitable aterial to keep dirt and grit from the finished unit. The commutator shall then in a suitable crate and braced as required to prevent movement and damage to tator during shipping. A copy of all certification data shall be provided in the ate.

Orange Tra packingm be installed thecommu shipping cr

FIGURE I

New Design Commutator

111r·p£ _f!a . LEAD 00 FRONT END · II\ -- .... -------U6.80) ____ .-t

(9.010) (9.020)

J

8.988 8.98'7 • (SEE ~E fl)

FIGURE II

Commutator Barrel Core

. 12.52. soo

8. o.4s 12..48 . 9.040

12.12600 . • ;J z . 5 02.0 . \2.. JZSO . 8~40 . . z . f010.6oztsl loltzs.oozl~ :~!ciR

8.935 · ..

8 .. 930

.0 )2..\ t7 nC raJ I G )(J .

lo f0.oo2lal

.. L J . Q . . L . j (4).75-10 UNC-2E

· · · . - . · X 1.44-\.56 DEEP

· 3.52 . . . · . · 3.\4 . LOC oNtS.QoRf

3.48 . 3 ·' 0 (2) HOLES EACH

. . · END~EQ SP

sECTION THRU coMM SHELL l+ltZL\als oRe I

I:J:j (l I-' rJl s::

li

CD

17 .. c;IG

0 \7.GI4

ICI0~oozlzl . I .

IS.I4nt 1S.IOXo'

'A

1"HIS FINISH MUST

.EXTEND TO THIS UNE.

CS\!.C\ A-A

MA."-E' .I=R.Of-\

3<0~t731"2.la"'-b ~·.

12~ ALL OVER EXCEPT WHER£

OTHERWISE NOTE.D.

CD CALC NET WT= 88 .. 54 LB .

CALC WKZ =3"Z \39 LB-FT2 · .

· SHAl\P CORNERS .SHALLBEREMOVEtl FROM

ANY PART NOT SPECIFICALLY REQUESTED.

RAllfUS ~ CHAMFER MADE IN THIS OPERATION ·

SHALL NOT EXCEED .02 MAX. .

DOCUMENT INSPECTION PER P28A-cno- I

(12).~.t25!(J HOLES·

· EQ Sll E$10.0@_1

.I tl ~ n~

Cl ~ d

,(1 ~ ~ ~ '"d ~

't ~ =

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'TAP 1.40-1.50 .DP. ..

TAP OR\LL THRU t.

FOR DRAU~ . ~

\40Lt.S fi

. l-$-f0.oGOizl · ~ lC tzj

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(2.}.75-JO UHC-2.B TAP

1-. 1.40-1.5"0 DP-EQ SP

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IOifZ'.~oaiZI,:· · · ···

. 250 t.Sl I 2.. .. \ 1.:2. 1 .. 4a 1'2. .. l2..l --0-· / .os' soo

·.8125 DRILL~· .04X4o CHAM

G) MAKE F~Ot-.1 3GA\r3r~C>O\

·,~ALL. OVER EXCEPT WHERE.

OTHERWISE. NOTED.

CALC NET WT= 101.:38 LBS"l

CALC WK2. = 40.475 FT LBG.

SHARP CORNERS S\-\A.L\.. EE REMOVED FROM

ANY PART HOT SPECIF,CA\..LY REQUESTE'n.

RADIUS t, CHAMFER MADE IN THIS OPERATION SHALL i"OT E.XCE.ED .. 02 MAX~ . ·

DOCUMENT \NSPECTION PER P28A-CD0-1

J t t s :a I I 1-i--.- I I 1•------a.~• lb_.. .. ~· r-21

FIGUREV

Mica V-Ring

.:i .r I '"*--.....,;_.--.-. "4/t; -.az-...~_........__...._.~

'\ .. 078 . ·, I

·.· .1aosR

Figure VI Locking Tab

(21.8125 ¢· r 1.30

I~L_--~-------------T--~~ 1.10

1..------4.53 -----~

La-------5.63 ------~

Figure VII ·Riser

N00189-XX-X-:XXXX

STATEMENT OF WORK

Work consists of disassembly, data recording, and manufacturing 500 KW commutators. The commutators, government furnished material (GFM), will have already been removed from their shafts. The GFM will be supplied to the contractor as an example of the commutators to be manufactured by this procedure. The front and back clamp rings may be reused on the new commutators provided they are suitable for reuse. The clamp rings shall be verified as meeting all dimensional requirements of this contract. If the clamp rings fail to meet all dimensional requirements of this contract, they shall be manufactured new. The commutator core barrel shall be manufactured new. All copper and insulating materials shall be replaced. All studs, nuts, washers and locking plates shall be replaced. Work shall be for a period of one calendar year with two additional option years from the date of the contract being awarded. Exact work quantities are unknown; however, historical data indicates that the levels will be about three commutators per year. Work shall be a guaranteed minimum of one commutators to a maximum of nine commutators over the three-year period. The commutators shall be completely stripped, re-insulated, copper bars replaced, spin seasoned, electrically tested, machined, and balanced in accordance with the Commutator Refurbishment Procedure enclosed. A separate copy of the Commutator Refurbishment Procedure shall be completed for each commutator refurbished.

1. The refurbishment of the 500 KW commutators called for in this procedure can be performed without reference to any original equipment manufacturer (OEM) armature drawings. The refurbishment of these commutators must meet the specifications in the Commutator Refurbishment Procedure herein.

2. The contractor is to complete and forward a detailed commutator data and dimension sheet on the first commutator refurbished during initial disassembly. The data sheet is to be forwarded to the Portsmouth Naval

·Shipyard (PNS) contracting official for review and approval prior to reassembly. Subsequent commutators are to be compared to the original data sheet during disassembly. Any discrepancies are to be noted and forwarded to PNS.

3. The drawings provided in this contract are provided for informational purposes only. The drawings provided in this procedure are for a similar GE 500 KW commutator. Although the commutator is similar in size and makeup, several dimensions vary slightly. The commutators to be refurbished by this procedure are to be built to the dimensions of the original commutator data sheet that was completed by the contractor, and the dimensions provided in the Commutator Refurbishment Procedure enclosed.

4. In the event no carcass is available for refurbishment, all parts will be manufactured new in accordance with this procedure. These commutators will be completed within 45 calendar days of the request from PNS in writing.

5. Dimensional tolerances unless otherwise specified in the contract shall be the same as standards used for high quality commutator manufacture and/or the "Twenty Eighth Edition of Machinery's Handbook".

6. The contractor awarded the contract shall notify PNS prior to subcontracting any of the work such as, segment manufacture or commutator balance or spin seasoning to a different contractor. PNS reserves the right to verify the subcontractor has extensive experience in the field.

Enclosure (3)

N00189-XX-X-:X:XXX

STATEMENT OF WORK

In the event that PNS deems the subcontractor unqualified, the subcontractor shall not be used.

7. The commutator contractor shall contact the local Defense Contract Management Agency (DCMA) representative and PNS Technical Point of Contact 10 days prior to shipment of the commutators so that an on site representative can review the refurbishment data before shipment. The local DCMA and/or a PNS representative shall also be allowed to do spot checks on the commutators during manufacturing to ensure that the requirements of the contract are being followed.

Enclosure (3)