SCOPE OF WORK

RFP 1100 MMH3047

LARGE INDUSTRIAL MOTOR REPAIRS FOR AUSTIN ENERGY AND AUSTIN WATER

1. PURPOSE

The Contract is with the City of Austin, acting through Austin Energy and Austin Water for the maintenance, repair, overhaul and rewind of large motors, up to and including 4160-volt motors. The City may, at its discretion, use this contract to purchase replacement motors when existing motors cannot be economically repaired, to upgrade existing motors, or to obtain additional motors needed as part of a planned capital improvement projects.

2. Background

A. Austin Energy owns and operates two gas-fired power generation facilities: Decker Creek Power Station and Sand Hill Energy Center. Austin Energy also operates On-Site Energy Resources and multiple district cooling facilities throughout the Austin area.

Austin Water may also utilize this Contract for applicable large motor maintenance, repair, overhaul, rewind, replacement, or upgrade services at Austin Water facilities.

B. Facility operations include, but are not limited to, the following:

i. Decker Creek Power Station, consisting of four simple-cycle peaking gas turbine-generator units.

ii. Sand Hill Energy Center (SHEC), consisting of six simple-cycle peaking gas turbine-generator units and one (1) 1x1 combined-cycle generation unit.

iii. On-Site Energy Resources, which provide chilled water and thermal storage services to various customers.

C. Services under this Contract shall be performed at City facilities, including but not limited to:

AUSTIN ENERGY LOCATIONS

i. Decker Creek Power Station

ii. Sand Hill Energy Center

iii. District Cooling Plant No. 1 (DCP1)

iv. District Cooling Plant No. 2 (DCP2)

v. District Cooling Plant No. 3 (DCP3)

vi. District Cooling Plant No. 4 (DCP4)

vii. Domain District Cooling Plant

viii. Mueller Energy Center (MEC CW)

ix. Mueller Energy Center (MEC Gen)

x. Austin Community College Highland Chiller Plant

AUSTIN WATER LOCATIONS

xi. Lift Station No. 1

xii. Lift Station No. 2

xiii. Lift Station Four Points 1

xiv. Lift Station Four Points 2

xv. Lift Station Scotland Wells

xvi. Lift Station Texas Plume

xvii. Allen Road Pump Station

xviii. Center Street Pump Station

xix. Davis Lane Pump Station

xx. East Austin Pump Station

xxi. Forest Ridge Pump Station

xxii. Howard Lane Pump Station

xxiii. Jollyville Pump Station

xxiv. Pilot Know Pump Station

xxv. Slaughter Lane Pump Station

xxvi. Spicewood Springs Pump Station

xxvii. South Austin Regional Wastewater Treatment Plant xxviii. Hornsby Bend Biosolids Management Plant

xxix. Walnut Wastewater Treatment Plant

xxx. Ullrich Water Treatment Plant

xxxi. Davis Water Treatment Plant

xxxii. Handcox Water Treatment Plant

3. AWARD OF WORK

The City reserves the right to award multiple contracts, partial contracts (contracts for a selected set of proposed services) and add or revise services to a resulting contract, through written Amendment at any time during the contract term.

4. TERM OF THE CONTRACT

This Contract shall remain in effect for an initial term of 12 months, or the City terminates the Contract.

This Contract may be extended beyond the initial term for up to four additional 12-month periods at the City’s sole option.

5. STANDARDS

The Contractor shall perform all work in accordance with all applicable federal, state, local, industry, safety, environmental, and Original Equipment Manufacturer (OEM) standards, codes, regulations, specifications, and recommendations. Applicable standards may include, but are not limited to, the following:

a. NEMA National Electrical Manufacturers Association (NEMA), MG-1 Motors and Generators

b. IEEE Institute of Electrical and Electronics Engineers

c. ANSI American National Standards Institute

d. EASA Electrical Apparatus Service Association

e. ABMA American Bearing Manufacturers Association

6. Contractor Responsibilities

1. The Contractor shall ensure that work performed on this Contract is conducted by experienced, qualified staff. Applicable certifications or licenses shall be submitted with the quote or project documentation, as well as prior performance records for similar projects.

2. The Contractor shall perform all services authorized in writing by the City according to the agreed upon project scope of work.

3. AUSTIN ENERGY JOB QUOTE PROCESS:

4. The Contractor shall submit a lump sum quote for each sample work scope. The quote shall include all labor, materials, equipment, transportation, shipping, and any other costs required to complete the work and deliver the motor(s) to the City of Austin's specified location. The sample work scopes are included in the solicitation as follows:

i. Attachment E – Sample Work Scope #1 – Decker Forced Draft Fan 21 Motor

ii. Attachment F – Sample Work Scope #2 – Decker Cooling Water Pump Motor

iii. Attachment G – Sample Work Scope #3 – Sand Hill Circulating Water Pump Motor

iv. Attachment H - Sample Work Scope #4 – Sand Hill Boiler Feed Pump Motor

5. AUSTIN WATER JOB QUOTE PROCESS:

6. The Contractor shall furnish on-site diagnostic, inspection, troubleshooting, and evaluation services, upon request, for Austin Water's large motors and associated equipment. The Contractor shall provide a fixed service call price and applicable labor rates as identified on the Price Sheet.

i. Attachment J identifies Austin Water's current inventory of large motors and associated equipment. The inventory is provided for informational purposes only. Austin Water reserves the right to add, remove, replace, or modify equipment covered under this Contract throughout the Contract term. The Contractor shall provide services for all covered equipment, regardless of whether it is specifically identified in Attachment J.

ii. Upon completion of the on-site inspection, the Contractor shall evaluate the condition of the equipment and determine whether repair, refurbishment, rewind, or replacement is the most appropriate course of action.

iii. Within five (5) business days following the on-site evaluation, unless otherwise approved by the Contract Manager, the Contractor shall submit a written Evaluation and Cost Estimate at no additional cost beyond the service call identified on the Price Sheet. At a minimum, the Evaluation and Cost Estimate shall include:

i. A detailed, itemized quotation identifying:

1. Labor costs based on the Contract labor rates identified on the Price Sheet;

2. Replacement parts and materials.

3. Freight, shipping, and delivery charges, if applicable.

4. Rental equipment or specialty equipment required to perform the work; and

5. Any other applicable costs necessary to complete the recommended services.

ii. A written assessment of the equipment condition, including:

1. Equipment identification.

2. Facility addresses and equipment location within the facility.

3. Manufacturer, model number, and serial number, when available.

4. Description of the observed failure or condition.

5. Diagnostic findings; and

6. Recommended corrective action, including whether repair, rewind, refurbishment, or replacement is recommended.

iii. A proposed schedule identifying the anticipated start date, estimated completion date, and duration of the work.

iv. Submission of the Evaluation and Cost Estimate shall constitute the Contractor's certification that it has inspected the equipment, is familiar with existing site conditions, and has considered all labor, materials, equipment, transportation, and other resources necessary to complete the recommended work.

v. Submission of an Evaluation and Cost Estimate shall not constitute authorization to proceed with repair or replacement services.

vi. Austin Water reserves the sole right to approve or reject the Contractor's recommendation.

Austin Water may, at its sole discretion:

i. Authorize the recommended work under this Contract.

ii. Request additional information or an alternate recommendation.

iii. Obtain additional evaluations from other sources; or

iv. Procure repair, refurbishment, replacement, or new equipment through another procurement method.

vii. If Austin Water approves the recommended work, the Contract Manager or designee shall issue a written Delivery Order (DO) as the Notice to Proceed prior to commencement of any work.

viii. The Contractor shall acknowledge receipt of the Delivery Order by email and coordinate a mutually acceptable schedule with the Contract Manager or designee before beginning work.

ix. If the Evaluation and Cost Estimate is not approved as submitted, the Contract Manager or designee will notify the Contractor of the required revisions. The Contractor shall submit a revised Evaluation and Cost Estimate within one (1) business day, or within another timeframe mutually agreed upon by both parties.

x. The Contractor shall complete all authorized work within the schedule identified in the approved Evaluation and Cost Estimate and shall notify the Contract Manager or designee immediately upon completion.

xi. If the Contractor determines that the authorized work cannot be completed within the approved schedule, the Contractor shall promptly notify the Contract Manager or designee and request a schedule extension. Any revised completion date must receive prior written approval from Austin Water. Under no circumstances shall the Contractor suspend or abandon work without prior written authorization.

xii. Upon request, the Contractor shall retain and provide all removed or replaced components for inspection and verification by Austin Water prior to disposal.

xiii. The Contractor shall include the approved Delivery Order, the approved Evaluation and Cost Estimate, and all supporting documentation with each invoice submitted for payment.

xiv. If Austin Water elects not to proceed with the recommended work, Austin Water shall pay only the diagnostic service call fee identified in Category 3 of the Price Sheet, provided the Contractor has submitted the required written evaluation and cost estimate.

xv. The Contractor shall maintain complete and accurate records of all service calls performed under this Contract. At a minimum, the records shall include:

i. Date and time of the service request.

ii. Facility and equipment serviced.

iii. Description of the reported issue.

iv. Diagnostic findings.

v. Recommended corrective action.

vi. Repairs performed, if authorized.

vii. Parts replaced; and

viii. Date the work was completed.

xvi. These records shall be maintained throughout the Contract term and made available to

Austin Water upon request.

xvii. The Contractor shall furnish all supervision, personnel, transportation, equipment, tools, rigging, lifting devices, materials, and incidentals necessary to mobilize and demobilize for the inspection, repair, refurbishment, removal, installation, testing, and replacement of large electric motors at Austin Water facilities.

xviii. Mobilization shall include all activities required to prepare for and perform the Work, including but not limited to transporting personnel, equipment, specialized tools, cranes, rigging, service vehicles, and materials to the project site; establishing a safe work area;

coordinating site access; and preparing equipment for execution of the Work.

xix. Demobilization shall include the removal of all personnel, equipment, tools, temporary facilities, debris, waste materials, and unused materials from the project site upon completion of the Work. The Contractor shall restore the work area to a clean and orderly condition equal to or better than its pre-work condition.

xx. The Contractor shall include all costs associated with mobilization and demobilization in the applicable line item(s) on the Price Sheet. Unless specifically authorized in writing by Austin Water, separate mobilization or demobilization charges for individual service visits, warranty work, return trips, or corrective actions shall not be permitted.

xxi. If the Contractor is required to perform multiple tasks at the same Austin Water facility during a single authorized service visit, only one mobilization and one demobilization charge shall be permitted for that visit unless otherwise approved in writing by Austin Water.

xxii. The Contractor shall be responsible for obtaining all permits required for transporting oversized equipment, coordinating deliveries, complying with all applicable federal, state, and local regulations, and ensuring all equipment is properly secured and operated in accordance with OSHA requirements and manufacturer recommendations. Mobilization shall not commence until Austin Water has authorized the Work through the appropriate contractual mechanism.

7. The Contractor shall perform maintenance and repairs of large electric motors for the City using the model procedure described in this document. When using the model procedure found in the Procedural Requirements section, the Contractor shall modify the procedure with appropriate model numbers, tolerances, etc., for the specific equipment.

8. The Contractor shall return the motor to the point of origin within 14 calendar days from the time of pickup or as agreed upon in the project work scope.

9. The Contractor shall provide a warranty on repairs for a period of not less than one (1) year from the date the motor is placed into service.

10. The Contractor shall have an ability to provide original equipment manufacturer (OEM), approved equal parts (i.e. aftermarket, or other-than OEM parts), or upgraded parts/equipment as requested by the City per each specific project scope of work.

11. Th Contractor shall provide Attachment A - Electric Motor Repair Form with each motor. Repair actions and measurements shall be recorded on this form. Copies of the completed form shall to be submitted to the City project lead in the format(s) required by the project scope of work.

Contractor may substitute the attached form with specific, like kind forms when supplying all final repair reports. The substitute form must contain the same line-item detail as Attachment A.

Contractor must supply one electronic copy or one written copy of repair procedure documentation, inspection reports upon return of the motor.

12. The Contractor shall provide access to its shop for the purpose of performing inspections of any motor repair, documentation reviews, and witnessing selected testing activities in progress. All motors returned to City must be inspected and tested by the Contractor or by the City representative. All repair materials shall be new, and workmanship shall be guaranteed against failure for a period of one year starting from the date of reinstallation and energization of the repaired motor at its plant site.

13. The Contractor shall adhere to each plant’s specific Contractor Work Requirements and Guidelines in Attachment I.

14. The Contractor shall ship materials, parts and supplies Freight on Board (FOB) to the work site and shall maintain ownership of all items until the City accepts the items in writing.

15. The Contractor shall ship Vertical motors in a vertical position, properly blocked and supported to protect the motor against rough motion during transportation. Horizontal motors shall be shipped in a horizontal position, properly blocked, and supported to protect against rough motion during transportation.

16. The Contractor shall repair all types of motors including but not limited to explosion proof, totally enclosed, fan-cooled, and weather protected motors, shall maintenance all special feature. A “UL Listing Mark for Rebuilt Motors for Hazardous Locations” is required for explosion proof motors.

The UL repair standard for explosion proof motors shall be followed.

17. The Contractor shall clean and spray paint external surfaces of the motor with an industrial gray epoxy paint, or City’s selected color, before delivery, without covering motor tags or name plates.

18. The Contractor shall be responsible for receiving goods and shall maintain sturdy, weatherproof storage facilities for warehousing and staging of received goods.

19. The Contractor shall ensure that receipt of needed parts shipments is accepted in writing to the City project manager or designated plant contract. The confirmation shall indicate that the part is suitable, received in good condition, appropriate for the intended purpose, and required by the authorized project work scope.

20. In the event that the repair cost of a motor exceeds 65% of the cost of a new motor, the Contractor shall submit both the cost of repair and the cost of a replacement motor. The Contractor shall notify the City plant contact and await a written decision prior to proceeding with repairs or replacement of the motor.

B. THE CITY RESPONSIBILITES

1. The City will provide a site-specific contact to coordinate work, scheduling and planning.

2. The City will provide a Contract Administrator who will monitor contract compliance and serve as a point of contact for all Contract related matters.

3. The City will provide electrical service at standard facility voltages available at the applicable work location.

4. If approved in advance by the City for smaller projects or short-duration work activities, the City may provide access to restroom facilities, break areas, and meeting rooms for occasional use by Contractor personnel.

5. The City may provide compressed air at low to medium flow rates, if available at the facility. If the Contractor requires high-volume compressed air for activities such as cleaning, piping, blasting, or operation of high-demand tools or equipment, the Contractor shall provide such equipment at its own expense. Contractor use of the City’s instrument air systems is prohibited unless prior written approval is obtained from AE.

6. The City will remove and reinstall plant instrumentation, controls, or associated electrical devices, unless otherwise agreed upon in writing.

7. The City will provide available drawings, specifications, technical data, and other information in the City’s possession prior to requesting bids or beginning work. However, the City does not guarantee completeness, accuracy, or current condition of such information. The Contractor shall verify actual field conditions, dimensions, equipment configuration, and site conditions prior to submitting pricing or beginning work. If the Contractor encounters underground utilities, concealed conditions, discrepancies, or obstructions that differ materially from the information provided by the City, the Contractor shall promptly notify the City and take reasonable measures to mitigate impacts caused by such discrepancies.

8. The City will provide vehicle access, site access, and available parking areas at City facilities. If suitable parking cannot be provided at the facility, the Contractor shall be responsible for arranging off-site parking and transportation for Contractor personnel and equipment.

7. TASK/PERFORMANCE REQUIREMENTS

A. Procedural Requirements:

a. Motor Stator Windings

1. Recondition: Contractor shall steam clean, inspect, and place the stator in a bake oven that has been preheated to 302°F (150°C) ±10% and cure for 6 to 8 hours. The Contractor shall remove the stator from the bake oven and allow it to cool to approximately 104°F (40°C), repeat the process for a second dip and bake. If grease is found in the windings, a citrus-based degreaser should be used before steam cleaning is performed.

2. The Contractor shall rewind stators with the same wire size, number of turns per coil, number of coils, and coil connections as found in the failed winding unless otherwise directed by the City’s engineers. Exceptions will be considered but must be approved by the City project manager or designated plant contact. Exceptions will be allowed only to change the motor characteristics or when identical replacement wire size is not available.

The Contractor shall indicate the original and replacement wire size and coil connections on the repair form and identify any characteristic changes on the tag.

3. The Contractor shall remove stator windings according to the Procedural Requirements section of this Scope of Work. A variance from this procedure shall be submitted in writing and approved by the City project manager or designated plant contact prior to implementing the procedure. Old coils are to be removed without damaging the stator lamination or frame and while minimizing changes to the magnetic characteristics of the motor. A “burn out” removal method must be done at less than 650°F (343°C) for cast iron frame motors. A “burn out” by exposing the motor directly to an open torch is not acceptable for any motor. A positive temperature control device must be in service on the Contractor’s “burn out” oven. A high temperature water or steam quench must be installed on the “burn out” oven to prevent an insulation varnish fire from momentarily driving the oven temperature more than 25°F (14°C) above the burn out limits noted above.

4. The Contractor shall clean and examine for removed stator coils for damage. Contractor shall grind flush burrs in the slot and burrs at slot ends.

5. The Contractor shall notify the City project manager or designated plant contact for approval prior to the repair or replacement of damaged or defective parts found during the inspection.

6. The Contractor shall make a hot spot check on the stator lamination in accordance with instructions with Attachment B - Stator Hot Spot Check. A hot spot that is 18°F (10°C) above the surrounding lamination temperature requires corrective action. Damage in a slot with welding of lamination also requires corrective action. Rotor rubbing of lamination that has removed the top stick (wedge) slots requires corrective action. After corrective action is completed, a hot spot check in accordance with Attachment B shall be repeated. The use of epoxy to hold the top stick in place is not acceptable. Restacking requires the approval of the City project manager or designated plant contact.

7. The Contractor shall clean all air-cooling passages in the motor frame. Contractor shall inspect the motor frame, end shields, conduit boxes, filter frames and other parts for damage with particular attention given to machined surfaces and corrosion damage.

Contractor shall inspect motor frame mounting feet for cracks, flatness and soft foot.

Contractor shall repair cracked motor frame feet and mill true the feet and base of the motor.

8. All stator winding, lead wire and winding supply insulation shall be rated NEMA Class F, 155°C maximum temperature, or greater. The contractor shall select materials, particularly lead wire insulation, so that damage from exposure to hydrocarbon oils will be minimized.

9. The Contractor shall check coil end turns for clearance from the installed end bell, air baffle or other obstruction that is a part of the assembled motor when a complete motor has been received.

10. The Contractor shall limit random wound coils to motors rated 600 volts or less. Random wound coil end turns shall have adjacent phase coil groups separated by phase insulation paper. The motor shall be wound properly with the windings reinforced.

11. The Contractor shall ensure magnet wire used for random wound motors is rated for nominal 600 VAC insulation. The wire film insulation shall pass ANSI/NEMA Standards Publication No. MW1000.

12. The Contractor shall double dip and bake all non-VPI motors that have been rewound.

Random wound windings shall have an environmental coating consisting of a varnish dip if specified. All stators must be preheated to 225ºF (107ºC) before dipping.

13. The Contractor shall use form wound coils on all motors with a voltage rating of over 600 VAC. Coils shall be insulated to fit tightly in the slot. Coil end turns shall be supported per the original equipment design. Contractor shall receive approval from the City project manager or designated plant contact prior to implementing any deviations from these requirements.

14. The Contractor shall ensure magnet wire for form wound coils is square or rectangular in shape. The wire shape shall be selected so that the finished coil, with required insulation, will fill the stator slot. The magnet wire shall be insulated with a film or fibrous cover with a nominal rating of 600 VAC. When winding the coil, the first and third layers shall have a six-inch-long fiberglass sleeve added over the magnet wire at each loop post, which become the coil knuckle. The formed coil insulation shall be composed of layers of half-lapped tape that is compatible with the Vacuum Pressure Impregnation (VPI) varnish system.

15. The Contractor shall ensure form wound coils have a phase insulation wedge between the top and bottom coil and at the top of the slot. The top wedge shall be capable of holding the coil firmly in the slot.

16. The Contractor shall apply an appropriate varnish system treatment on all form wound coils. Refer to Attachment C - Vacuum Pressure Impregnation Treatment for VPI treatment, which is one of the acceptable methods.

17. The Contractor shall silver solder or braze all coil connections. The Contractor shall clean and remove all sharp edges from the coil ends, prior to makeup. The leads for coil-to-coil connections in the same phase shall be triple insulated. All coil connections shall be effectively lashed to the coil end turns for support.

18. The Contractor shall ensure insulated lead wires installed in all oil mist lubricated motors are Hypalon insulated.

19. If motor lead wires are changed or the motor is rewound, the Contractor shall contact the City project manager or designated plant contact to determine the correct lead length.

20. The Contractor shall protect the lead wires from mechanical damage and sharp edges within the motor frame and connection box. For TEFC (Totally Enclosed Fan-Cooled) explosion proof motors, the Contractor shall encase the lead wires in “Chico” or EY compound between the frame and connection box. For all other types of motors, the Contractor shall use lead washers. Lead wires shall terminate in the connection box with an appropriately sized crimp-on NEMA connector lug. Wide wire-size range connectors are not acceptable unless approved by the City project manager or designated plant contact.

21. The Contractor shall install winding temperature detectors in all rewound form wound stators for motors 500 hp and larger, unless instructed otherwise by the Purchase Order or unless the motor was received with temperature detectors. The Contractor shall install six Resistance Temperature Detectors (RTD) in each motor, two per phase between top and bottom coils. Unless directed otherwise, RTDs shall be of the same type and resistance value as originally found in the motor. If the RTDs are a new addition to the motor, they shall be 100-ohm, platinum, International E-curve RTDs unless directed otherwise by the City project manager or designated plant contact. If they are replacement detectors, The Contractor shall install and wire them in accordance with the original installation and extend the leads to the original junction box. If no box exists, the Contractor shall install a box, with the necessary terminal strips.

22. The Contractor shall clean stator windings that are dirty but have not failed. When cleaning, the Contractor shall remove all dirt from the windings and stator cooling slots without damage to the winding insulation. Insulation shall be oven dried and tested.

23. The Contractor shall replace motor space heaters when repairing windings, unless otherwise specified in the repair order. The Contractor shall wire new space heaters for the same 115 or 230 VAC as the original, with wires connected to the original heater junction box. The space heater external metal sheath temperature shall not exceed 225°F (107°C) at a 104°F (40°C) ambient temperature. The wattage rating of the replacement heaters shall equal the wattage rating of the replaced heaters.

c. Motor Rotor

1. The Contractor shall clean and examine motor rotors for damage. Bearings, couplings, and normally removable fans shall be removed from the shaft. Shaft run-out shall be checked both journals and center of the rotor. The Contractor shall check shaft run-out and limit the run-out at journals to 0.001 in. and limit the run-out at the center of the rotor to 0.005 in. The Contractor shall clean and remove burrs from motor shaft. The shaft dimensions shall be measured with a calibrated micrometer caliper at the journals, coupling and fan fits. The acceptable tight tolerance for journals for anti-friction bearings shall be in accordance with ABMA Std. 7, Fit J5. The acceptable tolerance for a fan fit is 0.000 to + 0.002 in.

2. Keyways and keys shall be cleaned and inspected for looseness and damage. The rotor bars and end rings shall be inspected for cracks. The rotor lamination shall be checked for hot spots upon the request of the City project manager and designated plant contact. The rotor spider fit on the shaft shall be checked for looseness and broken tack welds. Any damage to the rotor found by this inspection shall be brought to the plant contact’s attention before any further repair work is undertaken. All rotor repairs shall be pre-approved by the City project manager and designated plant contact prior to implementation.

3. The Contractor shall replace bent motor shafts with approval of the City project manager or designated plant contact. New shafts should be manufactured from heat tempered AISI #4140 steel or Type 316 stainless steel shall be used. Short stubbing is not acceptable, nor is welding to build up a worn shaft without the City project manager and designated plant contact’s approval. The total maximum permissible runout of the output shaft when the motor is fully assembled is 0.001 in.

4. The Contractor shall remove all burrs from motor rotors that have rubbed the stator laminations. The Contractor shall review any hot spots found in the rotor lamination with the City manager and designated plant contact to determine whether repair or replacement of the rotor is required.

5. The Contractor shall review motor rotors with cracked rotor bar connections or cracked end rings with the City project manager and designated plant contact to determine where for repair or replacement is required. Cracked rotor bar connection Contractor shall review motor rotors with cracked rotor bar connections or cracked end rings with the City project manager and designated plant contact for repair or replacement. Cracked rotor bar connection repairs shall be in accordance with this procedure or the Contractor’s shop procedure, approved by the City project manager and designated plant contact before commencement of any repair work.

6. The Contractor shall review motor shaft journals that are damaged or undersized with the City project manager and designated plant contact for agreement on an acceptable repair.

Hard chrome plating and grinding is an acceptable method. Stainless steel metallizing is not acceptable for load bearing areas.

7. The Contractor shall check centering of the rotor within the stator, whenever possible by design, by both stationary gap and rotating gap feeler gage readings at both ends of the rotor.

In the “stationary check”, feeler gages are inserted at four points on each end of the rotor, 90° apart and recorded. In the “rotating check” method, the feeler gage is held stationary and the rotor turned. Readings should fall within a +/- 10% deviation from the average at each end, except for a two-pole induction motor, where the limit is +/- 5%.

8. Keyway seats in new shafts shall have a minimum of 1/16 in. radius for shafts up to 2.999

in. diameter and a minimum of 3/32 in. radius for shafts equal to or greater than 3.000 in.

diameter to reduce stress concentration.

9. Contractor shall adjust bearing assemblies to provide shaft end play in accordance with the motor’s design limits. For horizontal shaft anti-friction bearing motors, the end play must allow for thermal expansion of the shaft without damage to the bearings. For vertical motors, locknut adjustments, spacer rings, and installation thrust bearing support rings shall be in accordance with motor manufacturer’s recommendations.

10. Contractor shall assemble sleeve bearing motors by adjusting bearing or rotor position so that the rotating assembly will “float” at its magnetic center position within the normal endplay limits. Contractor shall identify the magnetic center by a pointer and a scribe on the shaft.

d. Motor Bearings

1. The Contractor shall replace all antifriction bearings with new bearings. The new anti-friction bearings shall conform to the motor nameplate requirements. New radial ball bearings shall have a C3 internal loose clearance. The Contractor shall measure all new bearings to verify compliance with the specified tolerances. Bearings used in greased-lubricated service shall have a single shield installed on the grease-pocket side.

2. The Contractor shall clean all sleeve bearings with solvent and inspect for wear, grooves and wipe Babbitt. The mounting surfaces for the bearing shell shall be cleaned and inspected for looseness and all burrs removed. Acceptable sleeve bearing clearance tolerances are shown in Attachment D. Sleeve bearing clearance shall not exceed the maximum tolerance applicable to measured journal dimension in Attachment D. Sleeve bearings shall be reused unless damage or excessive wear is present.

3. The Contractor shall rebabbitted or replace sleeve bearings that are damaged or exceed the maximum clearance tolerance, subject to approval by the City project manager and designated plant contact . The new or rebabbitted bearing shall then be bored to provide the minimum and maximum clearances specified in Attachment D. Oil grooves and dams found in the old bearing shall be duplicated in the rebabbitted bearing. All replaced or rebabbitted bearings shall be blued and checked in position. The bearing shall be hand scraped until shaft contact is evident along at least 75% of the length of the bearing. The Contractor shall perform a final clearance on sleeve bearings using plastic gage verify compliance with the tolerances specified in Attachment D, and record the measured clearance on the repair card.

4. On insulated bearings, the Contractor shall install the temperature detector in a manner that prevents bridging or shorting across the insulating material. A rebabbitted bearing that previously had a temperature detector embedded in the bearing shall be bored to accept the replacement temperature detector at the same location and the replacement detector shall be installed.

5. The Contractor shall install lip-type seals for open type oil mist lubricated motors on the inboard side of the motor bearing housings whenever possible. A single-shielded type bearing shall be installed where a lip type seal is not feasible, with the shield on the inboard side.

6. The Contractor shall use sealed bearings only on motors rated at less 3 three horsepower that have no provision for lubrication. Sealed bearings shall not be used in any motor with a rated speed greater than 18,00 rpm.

e. Motor Half Coupling

1. Motors with half-coupling will normally be sent out with their coupling removed. The Contractor shall check and reinstall the shaft coupling as part of the normal repair. The Contractor shall check a straight-bored coupling for proper interference fit. The minimum acceptable interference is 0.0005 inch per inch of shaft diameter; maximum is 0.001 inch per inch of shaft diameter. If the interference is outside of these limits, the City project manager and designated plant contact shall be notified for direction. The Contractor shall replace a loose coupling. The Contractor shall inspect the coupling hub and keyway for cracks and other damage that may require replacement.

2. The Contractor shall examine taper-bored couplings for mounting wear indicating that the coupling is loose or does not match the shaft taper. The Contractor shall replace a loose or mismatched taper-bore coupling. Acceptable radial runout shall be less than 0.002 in. TIR, and face runout shall be less than 0.001 in. Excessive runout shall require replacement and shall be brought to the attention of the City project manager and designated plant contact.

f. Bearing Housing

1. The Contractor shall steam clean and inspect all bearing housings for damage. Cracks in the housing, broken mounting flanges, heat distortion or rubbing from the rotor shall be brought to the City project manager and designated plant contact ’s attention for agreement on acceptable repair or replacement. The acceptable loose tolerance for an antifriction-bearing fit in the housing shall be in accordance with ABMA Standard 7, Fit H7.

The shell of a sleeve bearing shall seat tightly in the bearing housing with no more than

0.002 in. of clearance. Bearing preload shall be as specified by the manufacturer. The Contractor shall notify the City project manager and designated plant contact and obtain approval before performing corrective action or replacement if excessive clearance is identified.

2. The Contractor shall ensure all grease connections are free of dirt and old grease. The Contractor shall replace all damaged fittings. Compatible solvents may be used as necessary to ensure proper cleanliness.

3. The Contractor shall inspect noncontact oil seals for distortion and evidence of shaft rubbing. Damaged noncontact oil seals shall be replaced unless the City project manager and designated plant contact approve their reuse. All contact-type oil seals shall be replaced.

4. The Contractor shall review any damage to the bearing housing, oil seals or improper bearing fits with the City project manager and designated plant contact to determine and obtain approval for an acceptable repair or replacement.

5. The Contractor shall bore and sleeve worn bearing housings, and finish-machine the inside diameter (I.D.) of the new bushing to meet the original equipment manufacturer's specification or conform to the housing mounting fits for the applicable A.B.E.C. tolerance of the bearing. The new sleeve must be made of steel and must be secured to the bearing housing of the end bell by three setscrews equally spaced around the housing. The outside diameter (O.D.) of the bushing must have a 0.002 in. to 0.003 in. interference fit with the housing bore.

6. Metallizing, welding, and Belzona build up are not acceptable for repairing worn bearing housings. Loctite products, punching and shimming of the housing are also not acceptable

7. Motors that require one or both bearing housings to be insulated from the end bell to prevent circulating eddy currents shall be returned to their original insulated condition when they are bored and sleeved. This may be accomplished by boring the housing to the required outside diameter (O.D.) and applying a coating of insulating material such as Belzona, epoxy, or phenolic. The insulating material shall then be finish-machined to the same tolerance as stated above and a steel bushing shall be installed within the insulating material. The insulating material shall have a minimum thickness of 0.0625 in. The Contractor shall measure the insulation resistance between the steel bushing and the end bell using megohmmeter. The measured insulation resistance shall be greater than 100 MΩ when tested at 500 V.

8. The Contractor shall inspect, and as necessary, replace tubing and connections designed to furnish pressurized air to the bearing housing inner oil seal. The bearing housing pressure during a running test must be within +1/4 in. of water pressure. If there is evidence of excessive oil leakage into the motor winding chamber, the problem shall be reviewed with the City project manager and designated plant contact .

g. Motor End Bells and Metal Covers

1. The Contractor shall steam clean and inspect motor end bells for cracks, distortion, and damaged mounting surfaces. When the end bell contains the bearing housing or supports the bearing housing, the fit up to the stator shall be checked for squareness and looseness.

The end bell face runout tolerance shall be from 0.003 to 0.005 in. as applicable and the maximum and the babbitt fit looseness shall be 0.002 in. maximum. Motors of horsepower ratings greater than 900 horsepower that have been rewound or have experienced bearing problems shall be inspected for alignment of the bearing housings by the line bore method.

This is accomplished by placing the stator in a horizontal milling machine and recording dial indicator readings on each end of the stator where the end bells attach to the motor.

The end bells should then be recorded inside each bearing housing from end to end and on each bearing cap surface. This will indicate if the bearing housings are in alignment with each other. If they are not, corrective action must be taken. Corrective action shall be reviewed with the City project manager and designated plant contact may include: (1) rebuilding and machining the ends of the stator and the stator base, (2) rebuilding the end bell flanges, (3) boring, (4) sleeving, (5) machining the bearing housings, and (6) boring and machining the bearing caps.

2. The Contractor shall inspect the metal housing enclosing the motor fans for cracks and verify that the safety screening is adequate. The safety screening shall comply with NEMA MG-1 requirements.

3. The Contractor shall inspect sheet metal enclosures for dust filters or rain protection for evidence of corrosion. Corrosion products shall be mechanically removed, and the housing repainted inside and outside with a metal primer and epoxy finish coat. Holes shall be patched internally with fiberglass felt and epoxy. Dust filter supports shall be flat and shall prevent air from bypassing the installed filter. The supports shall be repaired as necessary. The sheet metal enclosure shall have an adequate separation of cool inlet air from the warm exhaust air. The sheet metal enclosure shall fit tightly to the main motor frame. Replacement sheet metal parts, where required, shall have 1/8 in. minimum thickness and shall be hot dip galvanized after fabrication.

4. The Contractor shall repair or replace any damaged or defective parts identified during disassembly and inspection to ensure compliance with the original equipment manufacturer’s specifications and all applicable requirements of this document. The movement of the rotor should be measured and recorded following assembly. The end movement must meet the original manufacturer’s specifications.

h. Lubrication

1. The Contractor shall lubricate grease-lubricated motor bearings using the grease specified in the purchase order. Mobil SHC 100 synthetic grease is recommended by the Predictive Maintenance (PdM) motor testing department.

2. The Contractor shall fill the oil-lubricated motor bearing housings to the oil level mark. If there is no oil level mark, the Contractor shall contact the City project manager and designated plant contact to determine the correct oil level. A stainless-steel tag shall then be added to mark the proper oil level. At the completion of the running test, the oil shall be drained from the bearing housing and then tagged with a clearly visible cardboard tag stating: “OIL HAS BEEN DRAINED.”

3. The Contractor shall ensure that all oil piping is straight, level and properly braced to the motor frame on end bells. Brass pipe or fittings shall not be used.

4. The Contractor shall ensure oil mist lubricated type motor bearings are properly pre-lubricated before operation.

i. Motor Rotor Balancing and Running Vibration

1. The Contractor shall balance each motors to a tolerance of 4W/N oz-in., per correction plane, where W is the rotor weight in pounds and N is the maximum operating speed of the motor in revolutions per minute (rpm).

2. The Contractor shall completely assemble and test all motors after completion of the repairs. All motors, within the capacity of the test stand, shall be operated at full rated nameplate voltage. Motors shall not be run on an elastic mounting. Motor must be bolted down to the test stand. Motors must be vibration tested with the motor running at full speed and rated voltage. Vibration readings must be taken with an instrument that can display a vibration spectrum with at least 800 lines or resolution. Vertical and horizontal readings are to be taken at each bearing, plus one axial reading at the drive-end. The maximum allowable overall (unfiltered) vibration velocity shall not exceed 0.1 in/sec. No individual frequency component, other than running speed component, shall exceed 0.05 in./sec.

3. Casing vibration readings shall not exceed 0.10 in./sec. (IPS) in any plane. Casing vibration shall be checked with the motor bolted to a robust steel base, operating at its rated speed.

Do not use any vibration isolation or dampening material such as rubber between the feet and steel base.

4. The Contractor shall provide vibration data that includes the a complete vibration spectrum for all recorded measurements and a spike-energy measurement for each anti-friction bearings. A copy of the vibration data shall be included with the Motor Repair Form in Attachment A.

j. Motor Tests

1. The Contractor shall perform a phase resistance test, with a sensitive (one-tenth of one percent accuracy) resistance bridge, on each phase of a rewound motor greater than 100 Horsepower. The maximum allowable variation between phases shall be 5%.

2. The Contractor shall perform a surge comparison test on rewound motors testing each phase with the results and test voltage recorded. The Contractor shall NOT perform a surge test on a reconditioned motors.

3. The Contractor shall apply the megohm meter test phase-to-ground each winding that is replaced, reconditioned, cleaned, dried, had its lead wire replaced, or coil connections repaired. A 1000- volt megger shall be used for motors rated 480 volts and below with an acceptable reading being 100 megohms or greater after one minute of application. A 2500-volt megger shall be used for motors rated 2300 volts and a 5000-volt megger for 4160 volts, with an acceptable reading being 250 megohms or greater after one minute of application.

4. The Contractor shall apply the megohmmeter for 10 minutes continuously with readings taken at the end of each minute. The polarization index or ratio of the 10 minute to the 1-minute reading shall be 2.0 or greater in order to be acceptable. PI plots shall be provided.

The Contractor shall verify and scribe the magnetic center position.

5. The Contractor shall test all polyphase motors for proper connections.

6. The Contractor shall test motor space heaters connecting to rated voltage and recording the line current.

7. The Contractor shall measure a no-load reading of phase currents at normal voltage and frequency on each phase for all completely assembled motors with a maximum allowable variation being 2%. The no-load ammeter readings shall be recorded. A no-load ammeter reading that is greater than 40% of the full load amp rating shall be reported to the City project manager and designated plant contact.

8. The Contractor shall have a no-load, single-phase check for rotor electrical condition for all completely assembled form wound motors. A single-phase voltage of 30 to 50% of rated voltage at normal frequency shall be applied to one phase. An ammeter reading of the phase current shall be monitored while the rotor is slowly turned by hand through 360°. A current variation of more than 10% indicates a rotor bar problem that must be brought to the City project manager and designated plant contact ’s attention for approval of further rotor repair or replacement. The current variations shall be recorded.

9. The Contractor shall complete all data required under this section on a separate data sheet for each repaired motor.

k. Motor Storage and Care in Storage

1. Ownership. If requested, the Contractor shall store the City motors and related equipment (“collectively, the “Property”) exclusively for the City’s use in the accordance with this contract. This property shall, at all times, remain the exclusive property of the City .

Contractor agrees to obtain written approval from the appropriate City project manager and designated plant contact prior to interchanging motors and equipment received from different City plants. Contractor agrees to execute appropriate Uniform Commercial Code forms and such other documents as may be required by the City to reflect the City’s ownership of the Property.

2. Identification. While the Property remains in the Contractor’s possession or control, the Contractor shall ensure that each item is clearly marked to identify the City’s ownership.

The Contractor shall assign or apply the unique City motor tag number provided for each motor. The Contractor shall stamp the motor tag number on a stainless-steel nameplate and securely affix the nameplate to the applicable motor.

3. The Contractor shall provide a clean, well-lit, climate-controlled storage facility maintained at less than 60% relative humidity.

4. The Contractor shall rotate each motor shafts monthly and perform an insulation resistance test using a megohmmeter every six months. Motors identified by the City as critical shall also be test annually at rated voltage.

7. DELIVERY REQUIREMENTS

a. The Contractor shall confirm the quantity to be shipped on all orders within twenty-four (24) hours of notification from the City in writing and/or in a method and manner as mutually agreed to by the Contractor and the Contract Manager and/or designee.

b. The Contractor shall provide, with each delivery, a Shipping or Delivery Ticket showing the description of each item, quantity, and unit price.

Department:

Handcox Water Treatment Plant

Address: 6800 N FM 620 Delivery Times: Monday – Friday 7:30 am - 2:00 pm

City, State, Zip Code: Austin, TX 78732

Department:

Hornsby Biosolid Management Plant

Address: 2210 S. FM 973

2:00 pm

Department:

Davis Water Treatment

Address: 3500 W 35th Street

2:00 pm

Zip Code: Austin, TX 78731

Ullrich Water Treatment

Address: 1000 Forest View Drive

2:00 pm

Zip Code: Austin, TX 78746

Walnut Wastewater Treatment Plant

Address: 7113 FM 969

2:00 pm

Zip Code:…