N3904019Q0252_A02.pdf

SEE SCHEDULE

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of this Amendment is to include Attachment 3 and 4 for the detailed Procedure that w as incorrectly missed at time of RFQ and extend the due date for quotes to 13 May 2019. All other terms and conditions remain the same.

1. CONTRACT ID CODE PAGE OF PAGES

1 3

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 07-May-2019

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X N3904019Q0252

X 9B. DATED (SEE ITEM 11)

01-May-2019

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

07-May-2019

CODE

PORTSMOUTH NAVAL SHIPYARD

CODE 410

KITTERY ME

N39040 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

alexandra.regazzini@navy.milEMAIL:207-438-6224TEL:

ALEXANDRA REGAZZINI / CONTRACTING OFFICER

N3904019Q0252

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION A - SOLICITATION/CONTRACT FORM

The required response date/time has changed from 10-May-2019 05:00 PM to 13-May-2019 05:00 PM.

SECTION B - SUPPLIES OR SERVICES AND PRICES

CLIN 0001

The CLIN extended description has changed from:

Line item 0001 to be in accordance with Attachment 1 - Classic Commutators.

To:

Line item 0001 to be in accordance with Attachment 1 - Classic Commutators and Attachment 3 Classic Commutator Procedure.

CLIN 0002

Line item 0002 to be in accordance with Attachment 2 - New Design Commutators.

Line item 0002 to be in accordance with Attachment 2 - New Design Commutators and Attachment 4 - New Design Commutators Procedure.

CLIN 0003

Line item 0003 to be in accordance with Attachment 2 - New Design Commutators.

Line item 0003 to be in accordance with Attachment 2 - New Design Commutators and Attachment 4 - New Design Commutators Procedure.

N3904019Q0252

CLIN 0004

Line item 0004 to be in accordance with Attachment 1 and 2.

Line item 0004 to be in accordance with Exhibit A.

SECTION J - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACHMENTS

The Table of Contents has changed from:

Exhibit/Attachment Table of Contents

DOCUMENT TYPE DESCRIPTION PAGES DATE

Attachment 1 Attachment 1 01-MAY-2019 Attachment 2 Attachment 2 01-MAY-2019 to:

Exhibit/Attachment Table of Contents

DOCUMENT TYPE DESCRIPTION PAGES DATE

Attachment 1 Attachment 1 01-MAY-2019 Attachment 2 Attachment 2 01-MAY-2019 Attachment 3 Attachment 3 07-MAY-2019 Attachment 4 Attachment 4 07-MAY-2019 Attachment 5 Exhibit A 07-MAY-2019

(End of Summary of Changes)

Encl (1)

Part (2)

PORTSMOUTH NAVAL SHIPYARD

500 KW CLASSIC SSMG

COMMUTATOR MANUFACTURING

CONTRACT AND QUALITY CONTROL REQUIREMENTS

COVER SHEET

COMMUTATOR REFURBISHMENT PROCEDURE

“CLASSIC”

The commutator shall be rebuilt in accordance with the following instructions. All materials shall be as specified. Equivalent materials may not be used without written authorization from Portsmouth Naval Shipyard. 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 for each commutator manufactured. 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 ISO-

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.

a) The commutator carcass will be provided to the contractor after being removed from its shaft. The commutator is for a General Electric 500KW DC generator, 210 - 355 volts, 1200 RPM. The following data is provided for informational purposes only.

Number of Segments - 152 Mica segment thickness- .040"

Wire Size - .050" x .300" No of Wires per slot - 12

Diameter (brush surface) 19 1/2" Dust Groove - 3/8"W

Length of active surface 10 3/8" Bar length - 11 3/4"

Dia over front V-Ring - 18" Dia over back V-Ring - 18"

Front V-Ring Proj. - 1 5/8" Rear V-Ring Proj - 1 3/4"

Riser Type - Double Inserted Dia. over risers - 29.75" (As Folded)

Commutator weight approx. - 718 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 (8.986 - 8.987")

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 UNS C11600 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 UNS C10700 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. Dimensions to be per the detailed commutator data sheet.

d) All the mica insulation shall be new. Segment insulation (between commutator bars) shall be inorganic bonded muscovite micapaper. The segment insulation shall be sub flush 1/16" 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 of two pieces with a joint at the apex of the V-ring are unacceptable.

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 A-106. Dimensions are to be as found on the original commutator data sheet. The V-ring clamp rings if replaced shall be manufactured from carbon steel per ASTM A668, AISI 4140. Dimensions are to be as found on the original commutator data sheet.

Note: Repairs to steel parts shall consist of minor straightening. A bushing or sleeve shall not be used to repair damaged or over sized seating surfaces.

CLAMP RINGS AND BARREL INPECTED/REPLACED, MAT'L AS SPECIFIED:

SIGNATURE/DATE

f) V-ring studs shall be replaced with heat-treated and stress relieved alloy steel bar per

AISI-4140. All nuts, washers and locking plates 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. 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. Dimensions are to be as found on the original commutator data sheet.

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

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-I-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:

h) The commutator steel mating surfaces (inside diameter) shall have a final dimension of: Riser end (8.996 - 8.997"); Front end (8.986 - 8.987"). Record actual dimensions below.

FINAL COMMUTATOR STEEL MATING SURFACE DIMENSIONS:

RISER END: IN

FRONT END: IN

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

COMMUTATOR SATISFACTORILY SPIN SEASONED:

j) The axial skew of the commutator bars shall be checked from the riser to the end of the commutator. Commutator bar axial skew shall not exceed 0.015-in. Excessive axial skew shall be corrected.

AXIAL SKEW IS LESS THAN .015 IN:

k) The commutator shall successfully pass a 400 VAC bar to bar test between the commutator bars. If the commutator does not successfully pass this test, it shall be rebuilt.

400 VAC BAR TO BAR TEST SAT:

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

3500 VAC HI-POT SATISFACTORY:

m) Measure for one minute the insulation resistance to ground of all the commutator bars connected together. The minimum insulation resistance value shall be 10,000 megohms. Log below the actual megohms (data such as infinity or greater than 100 megohms is unsatisfactory. Greater then 10,000 is an acceptable reading) If the

ACTUAL MEGOHMS TO GROUND MEGS

SIGNATURE/DATE:

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

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

Change in TIR Change in Bar-to-bar one inch from front middle one inch from riser Required: Concentricity less than 0.003-in. TIR, bar-to-bar runout less than 0.0003 in.

TIR

o) The commutator manufacturer shall stamp or etch mark the outside V-ring (steel portion) in a visible location with the abbreviated company name, two digit month and two digit year date code of when the commutator was rebuilt. Verify data below.

Company Abbreviation/Two Digit Month/Two Digit Year

p) All exposed steel parts (with the exception of bore to shaft mounting surfaces) shall be coated with air dry varnish per MIL-I-24092 Grade CA (NON SILICONE) or baking varnish per MIL-I-24092 Grade CB (NON SILICONE). NO PIGMENTED OR COLORED VARNISHES AND RESINS ARE ALLOWED. Ensure that the commutator serial number remains visible.

q) After completion of all of the above work, the commutator shall be balanced to 5 ounce-inches or less.

FINAL BALANCE DATA:

Required:

≤ 5 0Z-IN

Actual:

r) The commutator manufacturer shall cover the commutator mounting surfaces with a non-silicone rust inhibitor such as Cosmoline or "Dolph Lamination Coater With

Orange Tracer". The completed commutator shall be wrapped in plastic or other suitable packing material to keep dirt and grit from the finished unit. The commutator shall then be installed in a suitable wooden crate and braced as required to prevent movement and damage to the commutator during shipping. A copy of all certification data shall be provided in the shipping crate.

COMMUTATOR PROPERLEY CRATED AND BRACED IN CRATE. ALL DATA

REQUIRED IS IN CRATE:

Enclosure (2)

PORTSMOUTH NAVAL SHIPYARD

500 KW “NEW DESIGN” SSMG

COMMUTATOR MANUFACTURE PROCEDURE

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 ISO-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 SURFACE 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) of less 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.

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 1/16" 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 of two pieces with a joint at the apex of the V-ring are unacceptable.

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. The V-ring clamp rings if replaced shall be manufactured from carbon steel per ASTM A29, AISI 1040. 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: Repairs to steel parts shall consist of minor straightening, weld build-up, and plating in accordance with MIL-STD-2197. A bushing or sleeve shall not be used to repair over sized seating surfaces.

CLAMP RINGS AND BARREL INPECTED/REPLACED, MAT'L AS SPECIFIED:

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.

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:

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-I- 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:

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

FINAL COMMUTATOR STEEL MATING SURFACE DIMENSIONS

RISER END: IN

FRONT END: IN

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

COMMUTATOR SATISFACTORILY SPIN SEASONED:

j) The axial skew of the commutator bars shall be checked from the riser to the end of the commutator. Commutator bar axial skew shall not exceed 0.015-in. Excessive axial skew shall be corrected.

AXIAL SKEW IS LESS THAN .015 IN:

k) The commutator shall successfully pass a 400 VAC bar to bar test between the commutator bars. If the commutator does not successfully pass this test, it shall be repaired as necessary.

400 VAC BAR TO BAR TEST SAT:

l) Wrap several turns of bare copper wire securely around the commutator to short bars together and conduct a 3500 VAC Hi-Pot between the commutator bars and ground to ensure there are no grounds or shorts between the commutator and ground. If the

3500 VAC HI-POT SATISFACTORY:

m) Measure for one minute the insulation resistance to ground of all the commutator bars connected together. The minimum insulation resistance value shall be 10,000 megohms.

Log below the actual megohms (data such as infinity or greater than 100 megohms is unsatisfactory. Greater then 10,000 meg-ohms is an acceptable reading) If the

ACTUAL MEGOHMS TO GROUND MEGS

SIGNATURE/DATE:

n) The commutator outside diameter shall be machined to be concentric with the inside diameter of the mounting sleeve within 0.003 inch TIR. The bar-to-bar runout shall not exceed 0.0003 inch bar-to-bar. Log actual concentricity and bar-to-bar runout in the table

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

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, bar-to-bar runout less than 0.0003 in.

TIR

o) The commutator manufacturer shall stamp or etch mark the outside V-ring (steel portion) in a visible location with a unique serial number consisting of the abbreviated company name, two digit month and two digit year date code of when the commutator was rebuilt. Verify data below.

Commutator Serial Number:

Company Abbreviation/Two Digit Month/Two Digit Year

p) All exposed steel parts (with the exception of bore to shaft mounting surfaces) shall be coated with air dry varnish per MIL-I-24092 Grade CA (NON SILICONE) or baking varnish per MIL-I-24092 Grade CB (NON SILICONE). NO PIGMENTED OR COLORED VARNISHES AND RESINS ARE ALLOWED. Ensure that the commutator serial number remains visible.

q) After completion of all of the above work, the commutator shall be balanced to 5 ounce-inches or less.

FINAL BALANCE DATA:

Required:

≤ 5 0Z-IN

Actual:

r) The commutator manufacturer shall cover the commutator bore/mounting surfaces with a non-silicone rust inhibitor such as Cosmoline or "Dolph Lamination Coater With

Orange Tracer". The completed commutator shall be wrapped in plastic or other suitable packing material to keep dirt and grit from the finished unit. The commutator shall then be installed in a suitable crate and braced as required to prevent movement and damage to the commutator during shipping. A copy of all certification data shall be provided in the shipping crate.

DD FORM 1423-1, FEB 2001

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

PREVIOUS EDITION MAY BE USED.

Form Approved OMB No. 0704-0188

The public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to the Department of Defense, Executive Services and Communications Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. Please do not return your form to the above organization. Send completed form to the Government Issuing Contracting Officer for the Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

TDP ________ TM _______ OTHER

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE

7. DD 250 REQ

8. APP CODE

9. DIST STATEMENT

REQUIRED

10. FREQUENCY

11. AS OF DATE

12. DATE OF FIRST SUBMISSION

13. DATE OF SUBSEQUENT

SUBMISSION

14. DISTRIBUTION

a. ADDRESSEE

b. COPIES

Draft Final

Reg Repro

15. TOTAL

16. REMARKS

17. PRICE GROUP

18. ESTIMATED

TOTAL PRICE

G. PREPARED BY H. DATE I. APPROVED BY J. DATE

Page of Pages

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

TDP ________ TM _______ OTHER

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

16. REMARKS (Continued)

DD FORM 1423-1, FEB 2001 Page of Pages

INSTRUCTIONS FOR COMPLETING DD FORM 1423

(See DoD 5010.12-M for detailed instructions.)

FOR GOVERNMENT PERSONNEL

Item A. Self-explanatory.

Item B. Self-explanatory.

Item C. Mark (X) appropriate category: TDP - Technical Data Package;

TM - Technical Manual; Other - other category of data, such as "Provisioning,""Configuration Management," etc.

Item D. Enter name of system/item being acquired that data will support.

Item E. Self-explanatory (to be filled in after contract award).

Item F. Self-explanatory (to be filled in after contract award).

Item G. Signature of preparer of CDRL.

Item H. Date CDRL was prepared.

Item I. Signature of CDRL approval authority.

Item J. Date CDRL was approved.

Item 1. See DoD FAR Supplement Subpart 4.71 for proper numbering.

Item 2. Enter title as it appears on data acquisition document cited in Item 4.

Item 3. Enter subtitle of data item for further definition of data item (optional entry).

Item 4. Enter Data Item Description (DID) number, military specification number, or military standard number listed in DoD 5010.12-L (AMSDL), or one-time DID number, that defines data content and format requirements.

Item 5. Enter reference to tasking in contract that generates requirement for the data item (e.g., Statement of Work paragraph number).

Item 6. Enter technical office responsible for ensuring adequacy of the data item.

Item 7. Specify requirement for inspection/acceptance of the data item by the Government.

Item 8. Specify requirement for approval of a draft before preparation of the final data item.

Item 9. For technical data, specify requirement for contractor to mark the appropriate distribution statement on the data (ref. DoDD 5230.24).

Item 10. Specify number of times data items are to be delivered.

Item 11. Specify as-of date of data item, when applicable.

Item 12. Specify when first submittal is required.

Item 13. Specify when subsequent submittals are required, when applicable.

Item 14. Enter addressees and number of draft/final copies to be delivered to each addressee. Explain reproducible copies in Item 16.

Item 15. Enter total number of draft/final copies to be delivered.

Item 16. Use for additional/clarifying information for Items 1 through 15.

Examples are: Tailoring of documents cited in Item 4; Clarification of submittal dates in Items 12 and 13; Explanation of reproducible copies in Item 14.; Desired medium for delivery of the data item.

FOR THE CONTRACTOR

Item 17. Specify appropriate price group from one of the following groups of effort in developing estimated prices for each data item listed on the DD Form 1423.

a. Group I. Definition - Data which is not otherwise essential to the contractor's performance of the primary contracted effort (production, development, testing, and administration) but which is required by DD Form 1423.

Estimated Price - Costs to be included under Group I are those applicable to preparing and assembling the data item in conformance with Government requirements, and the administration and other expenses related to reproducing and delivering such data items to the Government.

b. Group II. Definition - Data which is essential to the performance of the primary contracted effort but the contractor is required to perform additional work to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, or quality of the data item.

Estimated Price - Costs to be included under Group II are those incurred over and above the cost of the essential data item without conforming to Government requirements, and the administrative and other expenses related to reproducing and delivering such data item to the Government.

c. Group III. Definition - Data which the contractor must develop for his internal use in performance of the primary contracted effort and does not require any substantial change to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, and quality of the data item.

Estimated Price - Costs to be included under Group III are the administrative and other expenses related to reproducing and delivering such data item to the Government.

d. Group IV. Definition - Data which is developed by the contractor as part of his normal operating procedures and his effort in supplying these data to the Government is minimal.

Estimated Price - Group IV items should normally be shown on the DD Form 1423 at no cost.

Item 18. For each data item, enter an amount equal to that portion of the total price which is estimated to be attributable to the production or development for the Government of that item of data.

These estimated data prices shall be developed only from those costs which will be incurred as a direct result of the requirement to supply the data, over and above those costs which would otherwise be incurred in performance of the contract if no data were required. The estimated data prices shall not include any amount for rights in data. The Government's right to use the data shall be governed by the pertinent provisions of the contract.

DD FORM 1423-1 (BACK), FEB 2001

CONTRACTOR SHALL PROVIDE:

1) Technical content of Enclosure 1 Part 2, "Commutator Refurbishment Procedure" for Classic 500kW Commutator Manufacturing.

2) Technical content of Enclosure 2 Part 2, "Commutator Refurbishment Procedure" for New Design 500kW Commutator Manufacturing.

3) Contractor to complete all data and signatures at the time of performance and provide the "original" completed "Commutator Refurbishment Procedure" in the crate with each commutator.

4) A copy of all specification and/or data sheets for all materials used during the manufacture of the commutator.

**Note: The Final Certification Package is composed of items 1 or 2, 3 and 4 as listed above**

PNS C/133 RECEIPT INSPECTION SHALL INSPECT FOR THE FOLLOWING:

1) All signature blocks in the "Commutator Refurbishment Procedure", for both Classic and New Design, have been signed by the vendor.

2) Ensure all data recorded at paragraphs (h), (m), (n) and (q) are within the required specifications (applies to both Classic and New Design Procedure).

3) Ensure a signed copy of the "Commutator Refurbishment Procedure" is included in the shipping crate with each commutator.

4) Ensure a copy of all specification and/or data sheets for all materials used during the manufacture of the commutator are included in the shipping crate with each commutator.

5) Remove the crate top and bracing beneath. Inspect the visible portion of the commutator for damage. Reinstall bracing and crate top when inspections are complete.