RD 01-579-1794 Generator Alternating 2024.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME GENERATOR,ALTERNATING CURRENT

STOCK NUMBER 6115-01-579-1794

PART NUMBER 9Y-0436

USED ON 210

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

Ship Service Diesel Generator, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul each designated Ship Service Diesel Generator ashore in a suitable repair facility.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3367, Manufacturer's Instruction Book

- SWBS Group(s) 311 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

IEEE Recommended Practice for Testing Insulation Resistance of Electrical Machinery, Std 43-2013 ANSI/NCSL Z540.3, Calibration laboratories and Measuring and Test Equipment General Requirements 2006.08.03 (R 2013).

ANSI/ASQ Q9000-2, Quality Management Systems - Requirements 10/2015.

3. REQUIREMENTS

3.1 General. Overhaul Ship Service Diesel Generators ashore in a suitable repair facility in accordance with SFLC Std Spec 3101. Generator data is shown in Table 1 below.

GENERATOR DATA

MANUFACTURER: Caterpillar, Arrangement 9Y0436 CHARACTERISTICS:250 KW, 450 VAC, 60 Hz, 3 phase, 1800 RPM, 0.8 power factor.

3.2 Initial inspection. Assembly as received by the contractor must be complete and of the proper cited part number. Inspect the mounting brackets (Legs) to ensure they match the attached photograph. Discrepancies shall be reported to the Coast Guard Contracting Officer. Perform the initial inspection and tests of section 3.3 of SFLC Std Spec 3101. A condition found report and part list shall be submitted which details all findings, recommendations and parts. A total refurbishment cost shall be submitted which includes all labor and material to assemble, test, paint, preserve, package and mark each generator. Upon submittal of this documentation, no additional work or cost shall be incurred unless authorized by the contracting officer. Upon review of all documents, the Coast Guard shall make a determination and advise the contractor as to the follow on disposition of the generator.

3.3 Shop work. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

3.3.1 Reconditioning. Recondition each generator per Appendix B.

Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.2 Rewinding. Rewinding per Appendix C is not expected to be necessary, but may become the subject of a change order if reconditioning efforts are unsuccessful. Varnish shall be applied to new windings using the vacuum pressure impregnation (VPI) method. Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.3 Miscellaneous repairs. None of the miscellaneous repairs of Appendix D is expected to be needed, but may become the subject of a change order if deficiencies are found during the initial inspection. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.4 Balancing. Dynamically balance each rotor assembly per Section 3.4.4 of SFLC Std Spec 3101.

3.5 Reassembly. Reassemble each machine per Section 3.4.5 of SFLC Std Spec 3101. For exciter armature (rotor - L2) bolts on Caterpillar SR4 generators, apply thread locking compound per Caterpillar service manual Form No.

SENR3985, contained within the generator technical publication, and tighten 5/16 inch bolts to 26 lb-ft and 3/8 inch bolts to 41 lb-ft.

3.6 Shop acceptance testing. Accomplish the shop acceptance tests of Section 3.5 of SFLC Std Spec 3101.

3.7 Final assembly. Complete reassembly work per Section 3.6 of SFLC Std Spec 3101.

3.8 Clean and Paint. The equipment shall be prepared to commercial blast cleaning (SSPC-SP6/NACE3) standards, cleaned, and the paint renewed to OEM specifications. *** DO NOT PAINT DATA PLATES OR TAGS ***

3.9 Preservation, packing and marking. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.9.1 Preservation. Surfaces dependent on lubricant for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to three years; lubricant shall not be detrimental to the equipment operation. The generator shall be packed with desiccant and heat shrink-wrap with heavy plastic film.

SHELF LIFE CD 0

Ship Service Diesel Generator, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul each designated Ship Service Diesel Generator ashore in a suitable repair facility.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3367, Manufacturer's Instruction Book

- SWBS Group(s) 311 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

IEEE Recommended Practice for Testing Insulation Resistance of Electrical Machinery, Std 43-2013 ANSI/NCSL Z540.3, Calibration laboratories and Measuring and Test Equipment General Requirements 2006.08.03 (R 2013).

ANSI/ASQ Q9000-2, Quality Management Systems - Requirements 10/2015.

3. REQUIREMENTS

3.1 General. Overhaul Ship Service Diesel Generators ashore in a suitable repair facility in accordance with SFLC Std Spec 3101. Generator data is shown in Table 1 below.

GENERATOR DATA

MANUFACTURER: Caterpillar, Arrangement 9Y0436 CHARACTERISTICS:250 KW, 450 VAC, 60 Hz, 3 phase, 1800 RPM, 0.8 power factor.

3.2 Initial inspection. Assembly as received by the contractor must be complete and of the proper cited part number. Inspect the mounting brackets (Legs) to ensure they match the attached photograph. Discrepancies shall be reported to the Coast Guard Contracting Officer. Perform the initial inspection and tests of section 3.3 of SFLC Std Spec 3101. A condition found report and part list shall be submitted which details all findings, recommendations and parts. A total refurbishment cost shall be submitted which includes all labor and material to assemble, test, paint, preserve, package and mark each generator. Upon submittal of this documentation, no additional work or cost shall be incurred unless authorized by the contracting officer. Upon review of all documents, the Coast Guard shall make a determination and advise the contractor as to the follow on disposition of the generator.

3.3 Shop work. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

3.3.1 Reconditioning. Recondition each generator per Appendix B.

Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.2 Rewinding. Rewinding per Appendix C is not expected to be necessary, but may become the subject of a change order if reconditioning efforts are unsuccessful. Varnish shall be applied to new windings using the vacuum pressure impregnation (VPI) method. Insulation treatment shall be of temperature Class F or better and not less than the temperature class of the existing insulation system.

3.3.3 Miscellaneous repairs. None of the miscellaneous repairs of Appendix D is expected to be needed, but may become the subject of a change order if deficiencies are found during the initial inspection. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.4 Balancing. Dynamically balance each rotor assembly per Section 3.4.4 of SFLC Std Spec 3101.

3.5 Reassembly. Reassemble each machine per Section 3.4.5 of SFLC Std Spec 3101. For exciter armature (rotor - L2) bolts on Caterpillar SR4 generators, apply thread locking compound per Caterpillar service manual Form No.

SENR3985, contained within the generator technical publication, and tighten 5/16 inch bolts to 26 lb-ft and 3/8 inch bolts to 41 lb-ft.

3.6 Shop acceptance testing. Accomplish the shop acceptance tests of Section 3.5 of SFLC Std Spec 3101.

3.7 Final assembly. Complete reassembly work per Section 3.6 of SFLC Std Spec 3101.

3.8 Clean and Paint. The equipment shall be prepared to commercial blast cleaning (SSPC-SP6/NACE3) standards, cleaned, and the paint renewed to OEM specifications. *** DO NOT PAINT DATA PLATES OR TAGS ***

3.9 Preservation, packing and marking. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.9.1 Preservation. Surfaces dependent on lubricant for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to three years; lubricant shall not be detrimental to the equipment operation. The generator shall be packed with desiccant and heat shrink-wrap with heavy plastic film.

3.9.2 Packing. Material shall he packed in containers meeting ASTM D-3951 and shall be suitable for shipment by rail or motor freight. The Contractor shall package items in such a manner as to prevent damage to the equipment during shipment. The equipment shall be packaged in skid mounted shipping containers, suitable for handling with a forklift. The containers shall be suitable for long term inside storage in a warehouse. Containers shall be assembled with screws to permit ease of removal of the cover or lid from the base. The generator shall he bolted to the framing system. Suitable cribbing shall be provided to prevent damage during shipment. Protrusions, -projections, corners, sharp edges and fragile areas shall he cushioned as required to protect the equipment and to prevent rupture of heat shrink-wrap materials. The generator hub coupling on the rotor shall be supported to prevent movement of the rotor during transit. Fiber boards shall be inserted between the rotor and the stator with yellow tag visible on the coupling end saying to remove at installation.

3.9.3 Marking. Each package shall be marked. Shipping container shall be stenciled with black enamel paint with the information as laid out below.

Stencil shall be applied to the container on two opposite sides in upper left corner. Markings shall be 3/4 inch minimum height black characters on a white painted background. All previous markings and /or quality assurance decals shall be removed from the reusable shipping container prior to the application of any new markings. Marking shall consist of the National Stock Number (NSN), Item Name, Part Number, Contract Number and Delivery Order Number, Shipping Weight, Quantity and unit of issue, and the words "U.S.

Coast Guard SFLC Material, "Condition-A". The following is an example:

NSN: 6115-01-579-1794

Item Name: Generator, Alternating P/N: 9Y-0436 Shipping Weight: xxxx Lbs (including crate) Government Contract No.: 70Z080XXXXXXXXXXX (per contract).

Words: Coast Guard SFLC Material Condition A, 1 ea."

4.0 Inspections and Testing:

4.1 General: The Contractor shall maintain an inspection system which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with Federal Acquisition Regulation (FAR) Clause 52.246-2. A copy of the final inspection reports shall be submitted to the KO prior to requesting QA inspection. The system shall be documented and available for review by the Coast Guard Quality Assurance Representative.

4.2 Responsibility for Inspection: The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements. The manufacturer's quality system shall comply with the requirements of ANSI/ASQC 9001Quality Management Systems - Requirements.

4.3 Records: The contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of performed observations, the number and type of deficiencies found and the corrective action taken.

4.4 Contractors Calibration System: The test facility shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.5 Inspections and Tests: The inspections and tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

a) Review final shop testing reports.

b) Visually inspect the leads from the generator, clear Data Plates, generator mounting, rotor secured and fiber board inserted between rotor and stator with yellow tags.

c) Conduct Insulation resistance test on Stator and Field IAW IEEE Std.43 2013.

d) Ensure generator is wrapped properly packed with required desiccant units.

e) Inspect contain and marking.

5. NOTES

5.1 Conditional performance. This work item is performed only when warranted by the condition of the generator windings. Rewinding would typically be performed no more than once during the lifetime of the vessel.

3.9.2 Packing. Material shall he packed in containers meeting ASTM D-3951 and shall be suitable for shipment by rail or motor freight. The Contractor shall package items in such a manner as to prevent damage to the equipment during shipment. The equipment shall be packaged in skid mounted shipping containers, suitable for handling with a forklift. The containers shall be suitable for long term inside storage in a warehouse. Containers shall be assembled with screws to permit ease of removal of the cover or lid from the base. The generator shall he bolted to the framing system. Suitable cribbing shall be provided to prevent damage during shipment. Protrusions, -projections, corners, sharp edges and fragile areas shall he cushioned as required to protect the equipment and to prevent rupture of heat shrink-wrap materials. The generator hub coupling on the rotor shall be supported to prevent movement of the rotor during transit. Fiber boards shall be inserted between the rotor and the stator with yellow tag visible on the coupling end saying to remove at installation.

3.9.3 Marking. Each package shall be marked. Shipping container shall be stenciled with black enamel paint with the information as laid out below.

Stencil shall be applied to the container on two opposite sides in upper left corner. Markings shall be 3/4 inch minimum height black characters on a white painted background. All previous markings and /or quality assurance decals shall be removed from the reusable shipping container prior to the application of any new markings. Marking shall consist of the National Stock Number (NSN), Item Name, Part Number, Contract Number and Delivery Order Number, Shipping Weight, Quantity and unit of issue, and the words "U.S.

Coast Guard SFLC Material, "Condition-A". The following is an example:

NSN: 6115-01-579-1794

Item Name: Generator, Alternating P/N: 9Y-0436 Shipping Weight: xxxx Lbs (including crate) Government Contract No.: 70Z080XXXXXXXXXXX (per contract).

Words: Coast Guard SFLC Material Condition A, 1 ea."

4.0 Inspections and Testing:

4.1 General: The Contractor shall maintain an inspection system which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with Federal Acquisition Regulation (FAR) Clause 52.246-2. A copy of the final inspection reports shall be submitted to the KO prior to requesting QA inspection. The system shall be documented and available for review by the Coast Guard Quality Assurance Representative.

4.2 Responsibility for Inspection: The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements. The manufacturer's quality system shall comply with the requirements of ANSI/ASQC 9001Quality Management Systems - Requirements.

4.3 Records: The contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of performed observations, the number and type of deficiencies found and the corrective action taken.

4.4 Contractors Calibration System: The test facility shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.5 Inspections and Tests: The inspections and tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

a) Review final shop testing reports.

b) Visually inspect the leads from the generator, clear Data Plates, generator mounting, rotor secured and fiber board inserted between rotor and stator with yellow tags.

c) Conduct Insulation resistance test on Stator and Field IAW IEEE Std.43 2013.

d) Ensure generator is wrapped properly packed with required desiccant units.

e) Inspect contain and marking.

5. NOTES

5.1 Conditional performance. This work item is performed only when warranted by the condition of the generator windings. Rewinding would typically be performed no more than once during the lifetime of the vessel.

WARRANTY:

A. Standard Manufacturer's Warranty

X B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for

90 days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

6115-01-579-1794

GENERATOR,ALTERNATING CURRENT

9Y-0436

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

CATERPILLAR, INC.

100 NE ADAMS ST

PEORIA, IL 61629

JOYCE_DUMIN@CARTERMACHINERY.COM

410-579-4455

CARTER MACHINERY COMPANY INCORPORAT

3412 BUSINESS CENTER DR

CHESAPEAKE, VA 23323-2639

PH: 410-579-4434

JOYCE_DUMIN@CARTERMACHINERY.COM

ELECTRIC MOTOR AND CONTRACTING

3703 COOK BLVD

CHESAPEAKE, VA. 23323

757-487-2121

EMCRFQ@EMC-CO.COM

WRITTEN BY:

DATE :

MARK LOVINGOOD

11 OCT 24

Cost Estimate for Overhaul NOT TO EXCEED: $18,235.8