Technical Specification IFB 94F-20.pdf

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

EE&QA-908

Procurement for OEM Armatures

ISSUED: June 8, 2020

REVISIONS:

EQUIPMENT ENGINEERING & QUALITY ASSURANCE

Equipment Engineering and Quality Assurance Technical Specification

Specification:

SUBJECT: Procurement for OEM Armatures Page: 2 of 34

Date: June 8, 2020 Revised:

Revision:

1.0 SCOPE ...…………………………………………………………………………………..4

1.1 Project Objectives ……………………………………………………………………...4

1.2 General Features ……………..………………………………………………………...4

2.0 PAYMENT AND SCHEDULE ………………………………………..……….………...4

2.1 Terms of Payment and Delivery Schedule …….………………………….…...….…

2.1.1 Delivery Schedule ………………………….…………………………..…………4

2.1.2 Method of Payment ……………………………………………..………….……..4

2.1.3 Schedule of Payment ……………………………………………………………...5

3.0 CONTRACTOR REQUIREMENTS ………………………………………….………...5

3.1 Contractor Qualifications …………………………………………………………....…5

3.1.1 Guarantees ………………………………………………………………………...5

3.1.2 Procedures and Instructions ……………………………………….……………...6

3.2 Contractor Responsibilities ………………………………………………………….…6

3.2.1 Armature Vacuum Pressure Impregnation ..…….………………………………...6

3.2.2 Armature Vacuum Immersion Treatment .…………………...…………………...9

3.2.3 Armature Balancing ……………………....…….……………………………

3.2.4 Final Inspection and Test ..…….……………………………………..………

3.2.4.1 Final Inspection and Test .……………………………………..………...11

3.2.4.2 Insulation Resistance Test .…………………………………….………...11

3.2.4.3 Polarization Index Test .……………………………………….………...11

3.2.4.4 Dielectric Test .…………………………………….…….……….……...11

3.2.4.5 Armature Winding Test .………………..…………….……….………...11

3.2.4.6 Post-Test Inspection Test .……………………….…………….………...12

4.0 QUALITY ASSURANCE PROVISIONS ……………………………….….………..12

4.1 Quality Assurance Program …………..…………………………………………....…12

4.1.1 General Requirements ……………………...………………………………....…12

4.1.2 Quality Assurance Requirements ……………………...………...…………....…12

4.1.3 Organization …………………………………………...………...…………....…13

4.1.4 Procedure Manuals ………………………..…………...………...…………....…13

4.1.5 Drug and Alchol Free Workplace Requirement ………………………….......…14

4.2 Test Methods and Procedures …………..……………………….………………....…14

4.2.1 Polarization Index Test ……………………...……………………………......…14

4.2.2 Alternating Current Hig-Potential Test ……………………...………...….......…14

4.2.3 Oscillograph Surge Comparison Test ………………...………...………….....…15

4.2.4 Bar-To-Bar Resistance Test ………………………...…………...…………....…15

4.2.5 Core Test Lost ………………………...………………….……...…………....…16

4.3 Responsibility for Inspection and Test ....……………………….………………....…17

4.4 Authority Access to Work ....………………………..………………..…………....…17

4.5 Qualification of Bidders .....………………………….………………..…………....…18

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5.0 PREPARATION FOR DELIVERY …………………………………..….….………..19

5.1 General Requirements …………..……………………………….………………....…19

5.2 Delivery Location …………..………………………………..….………………....…19

6.0 NOTES …………………………………..….….……………………………………

6.1 Intended Use …………..……………………………….…………………..……....…20

6.2 Proposal …………..………………………………..….………………....................…20

6.3 Definitions …………..…………………….………..….………………...................…20

7.0 MOTOR DATA - APPENDIX A …………………………………..….….………

8.0 REQUIRED DOCUMENTS FOR NEW ARMATURES .………………...……

8.1 Final Test Report …………..………………………….…………..………..……....…29

8.2 VPI Process QC Sheet …………..………………………………..……..................…30

8.3 Maching, Balancing, and Undercutting Quality Control Checklist ……………......…32

8.4 Balance Report …………..………………………………..……………..................…33

9.0 APPROVAL ……………………………………………………………….………

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1.0 SCOPE

1.1 Project Objectives

The Massachusetts Bay Transportation Authority (MBTA), herein referred to as the Authority, needs to procure a qualified vendor, herein referred to as Contractor, to furnish labor, equipment and all material necessary to manufacture armatures for the Everett Subway Main Repair Facility (EMR) located in Everett, MA. These new armatures shall meet the requirements and specifications of the Original Equipment Manufacturer (OEM). The armatures shall be ready to install in motors for revenue service use once delivered to EMR.

1.2 General Features

The Everett Main Subway Repair Facility is utilize by the Authority to repair, overhaul and maintain the entire fleet of revenue vehicles in order to ensure that they are kept in a state of good repair for passenger service. The armatures are used to repair motors for the subway, trolleys/surface rail vehicles. The new OEM armatures will allow the Authority to rebuild motors for the various vehicle types in order to meet the daily ridership demands.

2.0 PAYMENT AND SCHEDULE

2.1 Terms of Payment and Delivery Schedule

The following are the proposed Payment Terms and Delivery Schedule.

2.1.1 Delivery Schedule

The following is a proposed project schedule. This schedule will be adjusted at the Notice To Proceed after approval of the Master Schedule.

7/1/2020 NTP – Upon Approval of Master Schedule and Project Management Plan.

12/31/2020 Delivery of all contracted armatures to the Subway Main Repair

Facility located at 80 Broadway, Everett MA 02149.

2.1.2 Method of Payment

The following shall constitute the method of payments of this contract:

A. The Authority shall make all payments to the Contractor in United States Dollars.

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B. Payment for the manufacture of new armatures will be made via check or wire transfer installments.

C. If an audit should disclose any invoices that exceed 100% of the invoice costs, this excess shall be returned to the Authority and shall be remitted to the Contractor at such time as those costs are incurred.

2.1.3 Schedule of Payment

The Contractor is required to submit a Bid Price based on the following Payment Schedule summarized below for the labor, material and equipment required to manufacture new traction and auxiliary armatures for the MBTA’s Everett Main Repair Facility. Bid price to include all related shipping cost from Contractor’s facility to EMR.

Payments to the Contractor will take place over a time period of approximately six (6) months from the Notice To Proceed (NTP).

30% After NTP and approval of Master Schedule and Project Management plan 20% After the purchase of the major components.

50% After the work Substantial Completion.

100% Total for Final Acceptance at completed garages.

3.0 CONTRACTOR REQUIREMENTS

3.1 Contractor Qualifications

The selected Contractor shall be the OEM or an authorize manufacturer for the OEM, no exceptions. This Contractor shall have the knowledge, skills, material, equipment and other resources required to ensure that all armatures provided to the Authority meets the OEM specifications.

All sub-Contractors used shall also have experience and necessary resources to meet the OEM requirements. The Authority may require proof of this by submission of reliable data, time work was performed and location, material information, equipment modification and maintenance records.

3.1.1 Guarantees

All parts and materials shall be unconditionally guaranteed by the Contractor for a period of 18 months after the motor in which the armature are installed is placed in service, or for 24 months following receipt of the new armature assemblies by the

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Authority, whichever comes first. The Contractor shall accept the Authority's records with respect to the date that the motor was placed in service.

If at any time during the guarantee period the armature fails or is defective, in the opinion of the Authority, the Contractor shall pick up the armature, in the presence of an Authority representative if deemed necessary by the Authority, disassemble, inspect and test the armature at his/her shop to determine the cause of failure or defect. The Authority may, at its discretion, perform such disassembly, inspection and test in its own shops in the presence of a Contractor representative

3.1.2 Procedures and Instructions

Any work performed on Authority motor armatures shall be in accordance with the Original Equipment Manufacturers (OEM) requirements for that armature unless otherwise noted herein, and in accordance with additional requirements of this Specification.

3.2 Contractor Responsibilities

The Contractor selected by the Authority shall adhere to all the requirements set forth by the Authority in this Specification. Any deviations from the Authority’s requirements, as well as other proposals presented by the Contractor, must be submitted in writing to the MBTA for approval prior to proceeding. The Authority intends to take all suggestions regarding the manufacturing of the armatures proposed by the Contractor into consideration.

The Contractor shall be responsible for furnishing the various procedures, forms and data sheets required. Forms are included but not limited to those in Appendix B. If alternative forms are used, the format shall be submitted and approved by the Authority.

3.2.1 Armature Vacuum Pressure Impregnation

All new armature assemblies shall be Vacuum Pressure Impregnated (VPI) in an approved solvent-less Class H polyester varnish in accordance with the following procedure:

CAUTION: USE CLEAN, DRY AIR ONLY.

a. Thoroughly clean the armature assemblies by removing dust and all other foreign particles. Use low air pressure when blow cleaning, full air system pressure may wedge particles in inaccessible places.

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b. Coat all machines surfaces, bearing surfaces and other areas where varnish must be later removed with a masking varnish or a release agent. Plug any threaded holes in the ends of the shaft with a silicone sealant or dummy bolts with 0-rings to keep varnish out of the threads.

c. Vacuum-Pressure Impregnate the armature assemblies with solventless polyester varnish observing the following:

(1) Preheat the armature assemblies by placing it in a baking oven for six hours at a temperature between 170ºC and 180ºC (338ºF and 356ºF).

CAUTION: THE ARMATURE TEMPERATURE SHALL NOT BE

ALL0WED TO FALL BELOW 40ºC (104ºF), TO AVOID

GELLING OF VARNISH.

(2) Remove the armature assemblies from the baking oven and allow to cool down to a temperature between 40ºC and 60ºC (104ºF and 140ºF).

(3) Place the armature assemblies in a vacuum chamber in a vertical position.

The commutator end shall be up.

CAUTION: IF THE FINAL PRESSURE IS ABOVE 3,000 MICRONS,

DO NOT CONTINUE UNTIL AN ADEQUATE

VACUUM IS OBTAINED.

(4) Subject the armature assemblies to a dry vacuum of 3,000 microns (3.0 millimeters) of mercury, or less, for not less than 30 minutes. Record the vacuum readings at the beginning and end of the dry cycle.

(5) While still under vacuum, transfer the varnish from the holding tank to the work tank until the commutator risers are covered. The varnish level shall not exceed 1/4 inch above the face of the risers.

(6) After the varnish has been admitted to the tank, hold the tank vacuum at

3,000 microns, or less, for 30 minutes or until all bubbling of the varnish has ceased and the varnish surface is calm, whichever is longer.

(7) Break the vacuum with dry nitrogen gas or clean, dry air to about 20 inches of mercury.

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(8) When 20 inches of mercury is obtained, shut off the nitrogen or air supply and open the work tank bleed valve to bring it to zero pressure. Close the bleed valve.

(9) Pressurize the work tank with nitrogen or dry air to between 90 and 100 psig. Hold the pressure for a minimum of one hour.

(10) Release the work tank pressure and transfer the varnish into the holding tank.

(11) Allow excess varnish to drain from assembly for 10 minutes.

(12) Remove the armature from the work tank, place it in a horizontal position. Wipe off the shaft and balance grooves in rear coil support, with a rag dampened with Xylene solvent.

CAUTION: THE ROLL-BAKING OPERATION AT EMPERATURE

MUST COMMENCE WITHIN 20 MINUTES FROM THE

TIME THE VARNISH WAS RETURNED TO THE

STORAGE TANK.

(13) Place the armature in a "rotisserie" and roll-bake it at a rate sufficient to prevent the varnish from running for a minimum of two hours at a temperature of 150ºC to 160ºC (302ºF to 320ºF), until the varnish semi-cures.

CAUTION: USE EXTREME CARE TO AVOID DAMAGING THE

VARNISH COATING AND THE GLASS BANDING.

(14) Clean any excess build-up of varnish from the armature core and banding with a scraper or squeegee after the armature has been roll-baked for about 45 minutes.

(15) Remove the armature assemblies from the rotisserie unit. Turn commutator vertical. Place armature in pre-heated baking oven.

(16) Bake the armature to a fully cured state for a minimum of six additional hours at a temperature of 150ºC to 160ºC (302ºF to 320ºF), or at a temperature and time as recommended by the varnish manufacturer.

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3.2.2 Armature Vacuum Immersion Treatment

Following the Vacuum Pressure Impregnation process, apply an epoxy vanish immersion treatment to the armature, observing the following:

CAUTION: DO NOT CLEAN PREVIOUSLY PROTECTED

MACHINED SURFACES AND THREADS BEFORE

VARNISH TREATING.

a. Preheat the armature assemblies in a baking oven in a vertical position, at a temperature of 140ºC (284ºF) for at least five hours.

NOTE: The preheat step may be combined with step 3.2.1c.(16) above.

b. Remove the armature assemblies from the baking oven and allow it to cool to a temperature between 40ºC and 60ºC (104ºF and 140ºF).

c Immerse the armature assemblies in a vertical position (commutator end up) in an approved thermosetting epoxy varnish for about 20 minutes.

d Lift the armature assemblies out of the varnish and spin it until the excess varnish is removed.

e. Roll-bake the armature to a fully cured condition for a minimum of six hours at a temperature of 150ºC to 160ºC (302ºF to 320ºF).

f. Remove the armature from the oven and allow it to cool. Strip and remove the masking varnish film, release agents, sealants and dummy bolts. Clean the shaft with Xylene.

g. Check the tops of the commutator riser slots to see if the fiberglass band is completely sealing the space behind the risers. If sealing is not complete, seal by filling only the slot space beneath the band with R.T.V. Silastic adhesive or sealant. Clean any varnish from commutator slots.

h. Mark the armature serial number on the non-commutator band in one inch high letters using an indelible black marker.

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3.2.3 Armature Balancing

Each armature and fan shall be separately dynamically balanced at a rotational speed as recommended by the balancing machine manufacturer (approximately 1,000 R.P.M.) in accordance with the following procedure:

NOTE: Static balancing is not acceptable.

a. Insure that the fan, whether repaired or not, was separately dynamically balanced. The maximum permitted fan dynamic unbalance is 0.03 ounce-inch.

Fan balance shall be effected by milling the correct amount of material from the inboard shroud of the fan. Any screws or balance weights on the fan shall be removed prior to balancing the fan.

b. The armature, without fan attached, shall be supported on its bearing journals and balanced in an Authority approved balancing machine.

NOTE: Armatures with shaft keyways shall be filled with half-keys during the balancing operation.

CAUTION: BALANCING THE ARMATURE BY ADDING

SCREWS OR WEIGHTS TO THE FAN, WHEN

ATTACHED, IS STRICTLY PROHIBITED, UNLESS

SPECIFICALLY REQUIRED BY THE ORIGINAL

EQUIPMENT MANUFACTURER AND APPROVED IN

WRITING BY THE AUTHORITY.

c. Remove all existing balance weights, if not already done.

d. Balance the armature at the Commutator End and the Non-Commutator End by adding balance weights to the areas specified by the Original Equipment Manufacturer. The maximum permitted dynamic unbalance allowed is:

Commutator End: 0.4 ounce-inch, or 1 gram Non Commutator End: 0.5 ounce-inch, or 2 grams

e. Any areas with welded balance weights such as inside the commutator cap or the armature head, shall be thoroughly cleaned, primed and finish painted.

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f. The original balance report shall be supplied to the Authority with the finished armature.

3.2.4 Final Inspection and Test

This section specifies the acceptance testing and inspection to be conducted by the Contractor on each motor armature to determine the suitability for delivery to the Authority. Only those armatures that meet all the requirements established herein shall be accepted by the Authority; any discrepancies shall be cause for rejection.

The tests shall be conducted in accordance with the procedures contained herein and test results shall be recorded in black ink on the Final Test Report (Appendix B, 8.1). The originals completed Final Test Report shall be directly forwarded to the Authority's Manager of Equipment Engineering and Quality Assurance and a copy shall accompany the armature when delivered to the Authority.

3.2.4.1 Final Inspection and Test

Prior to the start of the tests, each armature shall be examined for completeness of work, cleanliness and finish conditions.

3.2.4.2 Insulation Resistance Test

Measure armature insulation resistance with a megohm meter. Test all bars to the shaft at 1,000 volts D.C. for 60 seconds. The resistance measured, corrected to 25ºC (75ºF), must be ten megohms minimum.

3.2.4.3 Polarization Index Test

Perform a Polarization Index Test at 1,000 volts D.C. in accordance with the procedure of Section 4.2.1. The Polarization Index shall be 2.0 or greater.

3.2.4.4 Dielectric Test

Perform a high-potential commutator-to-ground dielectric test, at 2500 volts A.C., R.M.S., 60 Hertz, in accordance with the procedure of Section 4.2.2.

3.2.4.5 Armature Winding Tests

Oscillograph surge comparison test the armature windings in accordance with the requirements of Section 4.2.3 to insure that the windings are free

SUBJECT: Procurement for OEM Armatures Page: 12 of 34 of electrical faults. Measure the bar-to-bar resistance in accordance with the procedure of Section 4.2.4.

3.2.4.6 Post-Test Inspection

Re-examine each armature assembly prior to shipping. Insure that all data requirements have been completed and recorded and that all values are within specified values. Any deviations from the limits specified shall be cause for rejection. Wrap the commutator of the armature with a suitable protective material such as heavy multi-layered paper or felt.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Quality Assurance Program

4.1.1 General Requirements

The Contractor shall be responsible for providing a quality product to the Authority under this contract.

The Contractor must be certified to one or more of the following Quality Assurance standards at the time of the award and maintain such certification for the duration of the contract:

ISO 9001:2008

AAR M-1003

To this end, the Contractor shall plan, establish and execute a one of the required Quality Assurance Programs, which shall be maintained throughout the duration of the Contract. The elements of the Quality Assurance Program shall be imposed on all elements of the Contractor's organization and on all manufacturers, vendors, suppliers and subcontractors that perform work or supply parts and materials under this Contract.

4.1.2 Quality Assurance Requirements

The Contractor shall submit a copy of their Quality Assurance Program Certification for this Contract to the Authority as part of their proposal for review and approval.

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Contractor will submit one of the following:

Association of American Railroads (AAR) Quality Assurance Program Certificate

ISO 9001:2008 Certification from a Certification Body that is accredited by the ANSI-ASQ National Accreditation Board (ANAB)

4.1.3 Organization

The organization of the Contractor's Quality Assurance Program shall be clearly defined. Quality assurance personnel shall have sufficient, well-defined responsibility and organizational freedom to identify and evaluate quality problems, to initiate, recommend or provide solutions, to verify implementation of solutions, and to control further processing, delivery or installation of a nonconforming or deficient item until proper disposition has been obtained. The personnel or organization responsible for the implementation and administration of the Quality Assurance Program shall insure that schedules and costs do not compromise quality and shall have direct contact with the Contractor's management at a level where appropriate action can be taken. Management responsibility for the Quality Assurance System shall be set forth on the Contractor's policy and organization chart and the responsibility for the Quality Assurance Program shall be so placed that schedules and costs will not compromise quality.

4.1.4 Procedure Manuals

Prior to the commencement of any work under this Contract, the Contractor shall prepare and submit to the Authority for approval three copies of a detailed Quality Assurance and Procedures Manual which the Contractor shall utilize and follow for execution of all phases of work under this Contract. The manual shall encompass all phases of the Contractor's Quality Assurance Program and shall include, but not be limited to: control of procurement, control of subcontractors, receiving inspection, production and process control, in-process inspection, functional testing, discrepancy control, measuring and test equipment calibration/certification, drawing control, configuration control, quality assurance records, shipping inspection and other quality specifications to meet the requirements of the Contract. In addition, all implementing and referenced manuals, personnel qualification and work methods, work instructions, quality control methods, work forms and data sheets, acceptance/rejection criteria, material listings, sources of supply for parts and material, codes, standards, SUBJECT: Procurement for OEM Armatures Page: 14 of 34 manufacturing process and test procedures shall be included. This manual shall be updated and revised as necessary throughout the duration of the Contract.

4.1.5 Drug and Alcohol Free Workplace Requirement

The Contractor, Contractor's employees, vendors, visitors, and volunteers are to be free of the effect of drugs, alcohol, controlled substances or other prohibitive substances when they are on MBTA property or performing MBTA business. In addition, all referenced parties are prohibited from using, possessing, selling or distributing any drugs, alcohol, controlled substances or other prohibited substances when they are on MBTA property or performing MBTA business. It is the responsibility of the Contractor to advise its employees of this requirement and to ensure that its employees meet this "fitness for duty" standard. Violators of this policy will not be allowed to remain on MBTA property or conduct business for or with the MBTA. The Contractor will submit to the Authority within thirty

(30) days of a Drug and Alcohol violation, a written report documenting the actions taken with regard to any of its employees who violate this policy. The Contractor will accept all liability arising from violation of this policy by his/her employees.

4.2 Test Methods and Procedures

The following test methods and procedures shall be applicable to the extent necessary to determine the condition of the armature. The Contractor shall have in his possession all test equipment sufficient for performing these tests and shall keep such equipment fully calibrated.

4.2.1 Polarization Index Test

Perform the Polarization Index Test in accordance with the following procedure:

a. Measure insulation resistance for a ten minute period with a megohmmeter.

b. Record the resistance reading after one minute and after ten minutes.

c. Divide the ten minute resistance reading by the one minute reading. The ratio thus obtained is the Polarization Index.

4.2.2 Alternating Current High-Potential Test

Perform a high-potential commutator-to-ground dielectric test, observing the following procedures:

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CAUTION: THIS IS A DESTRUCTIVE TEST. THE UNIT UNDER TEST

SHALL HAVE A MINIMUM INSULATION RESISTANCE

VALUE OF FIVE MEGOHMS BEFORE PROCEEDING.

a. Wrap the commutator surface with several turns of bare, clean copper wire.

b. Connect one lead of the tester to the copper wire and the other end to the motor shaft.

CAUTION: THE TEST VOLTAGE SHOULD NEVER BE APPLIED TO

THE UNIT UNDER TEST BY SWITCHING FROM OFF TO

FULL TEST VOLTAGE OR FROM FULL TEST VOLTAGE TO

OFF IN ONE STEP.

c. Energize the tester and slowly increase the voltage from zero to the full test voltage, at about 150 volts per second. Maintain the test voltage for 60 seconds. Then gradually reduce the voltage to zero, at about 150 volts per second.

d. There shall be no disruptive discharges or breakdowns indicated. Leakage current shall not exceed 10 microamperes after the full test voltage being applied for 60 seconds.

4.2.3 Oscillograph Surge Comparison Test

Oscillograph surge comparison tests shall be performed as indicated to insure that the armature is free of any commutator bar-to-bar and coil turn-to-turn electrical faults. The tests shall be conducted in accordance with the procedures specified by the test equipment manufacturer for the application and as approved by the Authority. The applied bar-to-bar test voltage shall be 400 volts. Alternative test methods to achieve the same results shall be approved by the Authority.

4.2.4 Bar-To-Bar Resistance Test

Bar-to-bar resistance measurements shall be conducted with a low-resistance, high-current micro ohmmeter or a "Ductor" test set as supplied by James G.

Biddle Co., Plymouth Meeting, Pennsylvania. The readings shall not vary more than 5 percent from each other.

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4.2.5 Core Test Lost

Perform the core loss test using a Lexseco Inc. model 1081B Core Loss Tester, or an Authority approved equal. The tester shall incorporate instrumentation and computer programming that will print out the core condition along with the numerical values of pertinent test parameters and the part number and serial number of the unit under test. The original of the print-out shall be attached to the Final Inspection and Inspection Report.

The Lexeco Tester will define the maximum watts/pound lose when the core parameters are entered. Follow the Lexeco recommendations.

If such a core loss tester is not available, the Contractor may, with Authority approval, use the following alternate test methods, the detailed procedures of which shall be approved by the Authority.

a. Method A ("E.A.S.A." Method)

(1) Place an appropriate number of turns of insulated wire through the armature ventilation core slots to attain a flux density of approximately 80 kilo lines per square inch within the armature core. The wire should be sized for a nominal current level of 20 amperes and a voltage of 220 volts

A.C.

(2) Connect the cable turns to a current regulated power supply with an output voltage of 220 volts A.C. at 60 Hz.

CAUTION: THE CURRENT SHOULD BE APPLIED CAUTIOUSLY

AT THE START AND THE CORE QUICKLY

CHECKED BY FEEL FOR SIGNS OF OVERHEATING.

(3) Adjust the power supply to achieve a current flow through the cable turns of approximately 15 amperes at 220 volts A.C. at 60 Hertz.

(4) Change or adjust the number of cable turns through the core ventilation slots as required to obtain an average core temperature of 27ºC to 38ºC (80ºF to 100ºF).

NOTE: If the average core temperature is too low, remove two turns at time and recheck the average temperature. If the temperature is

SUBJECT: Procurement for OEM Armatures Page: 17 of 34 too high, add two turns at a time and recheck the average temperature.

(5) Apply the current for a minimum of 40 minutes, checking frequently for any hot spot indications with the palm of the hand or with an infra-red detector.

(6) At the end of the time period, check for hot spots in the core with an infra-red detector. Hot spot temperatures shall not be more than 15ºC (60ºF) above the average core temperature. If the hot spot temperatures exceed this value, the armature shall be restacked with new laminations in the area of the hot spots following the procedures in Section 3.5.1.g.

b. Method B ("General Electric" Method)

(1) Solidly connect a lead of a high current 60 Hz alternating current power supply to each end of the armature shaft.

(2) Adjust the power supply output voltage to achieve a current flow of 200 amperes.

(3) Follow step (5) as for Method A above.

(4) Follow step (6) as for Method A above.

4.3 Responsibility for Inspection and Test

Unless otherwise specified herein, the Contractor is responsible for the performance of all inspections and testing required herein and that are required to insure a quality product. The Authority reserves the right to perform, and/or have the Contractor perform under Authority supervision and witness, any of the tests and inspections specified herein, or any other tests and inspections not specifically specified herein, where such tests and inspections are deemed necessary by the Authority to insure that the repaired items conform to the prescribed requirements.

4.4 Authority Access to Work

The Authority shall have the right to witness and/or inspect any and all work, processes, methods, parts, materials, equipment, workmanship and tests that are furnished or used by the Contractor for this Contract and may reject, without cost or liability to the Authority, any of such that, in the opinion of the Authority, is defective

SUBJECT: Procurement for OEM Armatures Page: 18 of 34 or unsuitable for the use and purpose intended. The Contractor, at his own expense, shall reconstruct, replace or correct, as the case may be, any such defective or unsuitable items and work.

The presence of an Authority representative shall in no way alleviate the responsibility of the Contractor to perform such inspections, of both his product and processes and those of his subcontractors and vendors. In addition, such Authority inspection shall not relieve the Contractor of his responsibility to perform the manufacturing work in a quality manner in accordance with the requirements of the Specification and shall not prejudice any claim, right or privilege that the Authority may have under the guarantees.

Representatives of the Authority shall be permitted full and free access to the Contractor's facilities, as well as those of his subcontractors and vendors. The Contractor shall furnish such facilities and give such assistance for inspection as the Authority's representative may require, at no cost to the Authority.

4.5 Qualifications of Bidders

Each Bidder shall meet the following qualifications at the time of submittal of his proposal and evidence of such qualification shall be included as part of that proposal.

a. The Bidder shall have demonstrated skill and successful experience in the manufacture of OEM traction and auxiliary motor armatures for mass transit (subway/surface/rapid transit) applications.

b. The Bidder shall have manufactured at least 2500 OEM traction and auxiliary motor armatures for mass transit applications for a minimum of five (5) years.

c. The OEM traction and auxiliary motor armatures shall have been in successful operation since their rebuilding.

d. The Bidder shall operate a plant adequately equipped and stocked and of sufficient capacity to properly and efficiently perform the work specified herein within the time specified and shall have in his possession all special equipment required for this contract.

e. The Bidder shall state in his proposal the location where the work will be performed, including the location of any subcontracted work.

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f. The Bidder shall have ample financial resources to effectively and reasonably meet all Specification obligations and requirements for the work specified herein.

g. The Bidder will submit Quality Assurance Certificates as specified in section

4.1.1

5.0 PREPARATION FOR DELIVERY:

5.1 General Requirements

Following manufacture, final inspection and test, each armature shall be prepared for shipment in accordance with the following requirements:

a. Armatures assemblies shall be sealed in a moisture barrier bag with sufficient desiccant to allow for 2 years of storage without any significant corrosion. The bag material should be a HD-100 or equivalent and conform to MIL-PRF-131J.

b. Shipping crates will be supplied by the selected Contractor.

c. Commutators shall be covered with a suitable protective material such as heavy multi-layered paper or felt.

d. Armature shaft bearing surfaces, coupling seats and threaded ends shall be protected against damage by plastic covers.

e. All job documentation, checklists and reports shall be placed in a rugged plastic protective cover or envelope affixed to the moisture barrier bag. Originals shall be separately forwarded to the Authority's Manager of Equipment Engineering and Quality Assurance.

5.2 Delivery Location

All repaired armatures shall be shipped, freight prepaid, to the following location:

Massachusetts Bay Transportation Authority

Subway Main Repair 80 Broadway

Everett, Massachusetts 02149

Armatures to be repaired shall be picked up by the Contractor at the above location.

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6.0 NOTES:

6.1 Intended Use

The armatures for the traction and auxiliary motors listed in Appendix A of this Specification are to be used on subway/surface rail vehicles in passenger-carrying revenue service on the Massachusetts Bay Transportation Authority.

6.2 Proposal

Bidders shall submit a proposal to the Authority for the work specified herein.

The following items shall be submitted if requested by the Authority:

a. Copy of current Quality Assurance Certification (reference Section 4.1.2).

b. A detailed list of the plant and special equipment that the Bidder proposes to use for this Contract, indicating which portions he already possesses.

c. Detailed information, including authority, contract number, quantity, type and contact person, on traction and auxiliary motor armature repairs and manufacture work that the Bidder has completed for other transit properties. The Authority may require, during proposal evaluation, written references testimonials from officers of all transit authorities that have been, or still are, customers of the Bidder, attesting to the skill and experience of the Bidder, the quality of the work performed and the in-service success of traction motor armatures and repaired by the bidder. All new armatures shall meet OEM requirements.

d. The bidder shall have demonstrated skill and experience in the correct and successful manufacture of the types of armature required and shall submit written evidence of same. The bidder shall submit written evidence of at least five years of successful in-service rail transit experience of armatures manufactured by and/or for the OEM. All suppliers shall be authorized by the OEM to manufacture armature for traction and auxiliary motor repairs.

This should include but not limited to a list of contracts or copies of purchase orders for repair of similar equipment.

6.3 Definitions

Wherever in the Specification the following terms, or pronouns in place of them, are used, the intent and meaning shall be interpreted as follows:

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Approval - Reviewed and accepted, in writing by the Authority.

Approved or Approved Type - Type, material, procedure, method as approved by the Authority.

Authority or M.B.T.A. - The Massachusetts Bay Transportation Authority, created by Chapter 563, Section 18 of the Acts of 1964 of the Commonwealth of Massachusetts, the Party of the First Part to the Contract.

Bidder - Any individual, firm, partnership or joint venture submitted a proposal on the forms provided by the Authority, for the work contemplated, acting directly or through a duly authorized representative.

Contract - The written agreement executed between the Authority, Party of the First Part, and the Contractor, Party of the Second Part, setting forth the obligations of the Parties there under, the performance of the Procurement as indicated in the Bid Documents and all authorized changes to this Contract issued subsequent to the execution of the Contract.

Contractor - The person or persons, firm, partnership, corporation, or combination thereof which has entered into contract with the Authority to supply the required services.

Equal - Whenever the words "equal" or "approved equal" are used in connection with make or quality of material or equipment in this Specification, the Authority's decision as to whether any material or equipment proposed is equal to that specified shall be binding on the Contractor.

Original Equipment Manufacturer (OEM) – The original designer and builder, or producer, of the equipment.

Notice - A written announcement.

Proposal - The bid or offer of the Bidder for the work when made out in the prescribed manner and submitted on the prescribed proposal form, properly signed and certified, and which includes the schedule of bid items.

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Service Proven or Proven - The historical success of materials, supplies and methods used in the repair of traction motor armatures operating in revenue service under similar conditions on rail transit systems over a four year period.

Specification - Shall mean EEQA - 908 and any revisions thereof.

Subcontractor - An individual, firm, partnership, corporation or joint venture to whom the Contractor, with prior written approval of the Authority, sublets any part of the Contractor.

Supplier or Vendor - Persons, firms, or corporations who furnish materials for the Contractor, but who do not work such material to a special design according to the Contract.

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7.0 MOTOR DATA – APPENDIX A:

The following data sheets contain currently available Original Equipment Manufacturer's information on Authority traction motor armatures. The Contractor shall verify this information for correctness and shall supply missing information, and other necessary information, to the Authority to update and revise the data sheets.

APPENDIX A

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M.B.T.A. TRACTION MOTOR ARMATURE DATA

BASIC MOTOR TYPE 5GE1264A1 West 1432 West 1460-B1 West 1463-E1

ONE HOUR RATING

Voltage 300 300 300 300

Horsepower 100 55 100 140

Amperes 290 156 280

Speed (R.P.M.) 2,017 1,670 1,680

MAXIMUM SPEED (R.P.M.) 6,400 5,000 5,400

COMMUTATOR DATA

New Diameter (Inches) 7 1/2 7 1/8 7.43 8

Condemn Diameter (Inches) 7 1/8 6 1/2 6 ¾ 7.5

Number of Bars 168 125 152

Min Riser Width (Inches) 9/32

Slot Width (Inches) 0.033 0.036

Slot Depth (Inches) 0.046 3/64 1/16

CORE DATA

Core Length (Inches) 8.25

Number of Core Slots 42 42 38

WINDING DATA

Type of Winding Lap Wave

No of Armature Coils 42 42 38

No of Equalizer Coils 84 None

Slot Lay (Coil Bott to Top) 1 - 11 1 - 11

Coil Lead Throw (Bar-to-Bar) 20 - 21 1 - 63

COIL DATA

No Turns per Coil 1 1

No Conductors per Arm Coil 4 6 (3 Pairs)

Conductor Size-Arm (Inches) 0.040 x 0.235

Conductor Size-Eql (Inches) N/A

Unwrapped Slot Section (In) 0.170 x 0.480

Finished Slot Section (In) 0.225 x 0.551

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M.B.T.A. AUXILIARY MOTOR ARMATURE DATA

BASIC MOTOR TYPE

T-8540 MOTOR ALTERNATOR

MOTOR END ALTERNATOR END

RATING

Voltage (Nominal D.C.) 650 290 AC 3 Phase 60 Hz

Horsepower 55 KVA 27.4

Amperes (Full Load) 137 43.0

Speed (R.P.M.) 1,800 1,800

Maximum Speed (R.P.M.) 1,800 1,800

Armature Resistance at 25º C (Ohms) 0.170

COMMUTATOR DATA

New Diameter (Inches) 8.250

Number of Bars 7.875

Min Riser Width (Inches)

Slot Width (Inches)

Slot Depth (Inches)

CORE DATA

Core Length (Inches)

Number of Core Slots

WINDING DATA

Type of Winding

No of Armature Coils

No of Equalizer Coils

Slot Lay (Coil Bott to Top)

Coil Lead Throw (Bar-to-Bar)

COIL DATA

No Turns per Coil

No Conductors per Arm Coil

Conductor Size-Arm (Inches)

Conductor Size-Eql (Inches)

Unwrapped Slot Section (In)

Finished Slot Section (In)

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BASIC MOTOR TYPE 5GMG129L1 MOTOR GENERATOR

MOTOR END GENERATOR END

RATING

Voltage (Nominal D.C.) 600 43

Horsepower 1.0 KV

Amperes (Full Load) 45

Speed (R.P.M.) 2,100 2,100

Maximum Speed (R.P.M.) 2,100 2,100

Armature Resistance at 25º C (Ohms) 2.58 0.0941

COMMUTATOR DATA

New Diameter (Inches) 4.5 4.5

Number of Bars 63 63

Min Riser Width (Inches)

Slot Width (Inches) 0.0468 0.0468

Slot Depth (Inches)

CORE DATA

Core Length (Inches) 6.375 6.375

Number of Core Slots 21 21

WINDING DATA

Type of Winding Wave Wave

No of Armature Coils 21 21

No of Equalizer Coils None None

Slot Lay (Coil Bott to Top) 1 - 11 1 - 10

Coil Lead Throw (Bar-to-Bar) 1-2 1 - 2

COIL DATA

No Turns per Coil 9 2

No Conductors per Arm Coil 3 3

Conductor Size-Arm (Inches) 0.0359 (19 AWG) 0.076

Conductor Size-Eql (Inches) None None

Unwrapped Slot Section (In)

Finished Slot Section (In)

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BASIC MOTOR TYPE T-8256 T-8266 T-8408 T-8543 D-4

RATING

Voltage (Nominal D.C.) 600 600 600 600 600

Horsepower .74 27.4 22.2 27.4

Amperes (Full Load) 1.4 43.0 33.5 44.0

Speed (R.P.M.) 1,850 1850 1850 1850

Maximum Speed (R.P.M.) 1,850 1850 1850 1850

Armature Res. at 25º C (Ohms) 0.325

COMMUTATOR DATA

New Diameter (Inches) 7.188

Number of Bars 7.000

Min Riser Width (Inches) 163

Slot Width (Inches)

Slot Depth (Inches)

CORE DATA

Number of Core Slots 41

WINDING DATA

Type of Winding Wave

No of Armature Coils 41

No of Equalizer Coils None

Slot Lay (Coil Bott to Top) 1 – 11

Coil Lead Throw (Bar-to-Bar) 1 – 83

COIL DATA

Number of Coil Sections 4

Number Turns per Coil Section 2

Conductor Size-Arm (Inches) 0.0508 (18AWG)

Conductor Size-Eql (Inches) None

APPLICABLE DOCUMENTS

Winding Diagram T-15102

Maintenance Manual 5785

Parts Catalogue 5790

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8.0 REQUIRED DOCUMENTS FOR NEW ARMATURES – APPENDIX B:

8.1 Final Test Report

8.2 VPI Process QC Sheet

8.3 Machining, Balancing, and Undercutting Quality Control Checklist

8.4 Balance Report

APPENDIX B

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8.1 Final Test Report

Model # ____________ Serial # ______________ Customer ____________ Job # ______________

Check armature is ready for shipping

Final Tests

Visual inspection, good? _____ (check)

All bolt holes clear of varnish? _____ (check)

Armature to ground __________ M Pass/Fail _____

Hi Pot _______ A @ 2500 volts Pass/Fail _____

Ductor test (bar to bar) Pass/Fail _____

Banding below core iron PE _____ (check)

Banding below core iron CE _____ (check)

Job # stamped on shaft _____ (check)

Serial # stamped on shaft _____ (check)

All repair documentation is in packet _____ (check)

QC Inspection by : Date:

Comments

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8.2 VPI Process QC Sheet

Model # ______ Field ____ Arm ____ Rotor ____ Stator _____ Job __________

Customer ________________ Tracking # ____________ Date ___/ ___/ ___

PREPARATION

OPERATION INITIALS

Check that all machined surfaces are masked correctly

Check specs to ensure correct processing times and specs.

PRE-HEAT

Place piece in oven for pre heat cycle TIME ____ : ____ AM / PM

Remove piece from oven after pre heat cycle TIME ____ : ____ AM / PM

Total hours of pre – heat cycle. _____ hours

VPI PROCESS

Check mark FULL CYCLE ____ How many? 1 ___ 2 ___

FIRST VPI CYCLE

Check part temperature before putting in to process tank ______ * F / C

Start First VPI cycle TIME ____ : ____ AM / PM Date ___ / ___ / ___

Record Dry Vac Torr ______ Duration ______ minutes

Record Wet Vac Torr ______ Duration ______ minutes

Record Pressure PSI ______ Duration ______ minutes

Time at end of VPI cycle TIME ____ : ____ AM / PM

FIRST BAKING

Time piece put in oven TIME ____ : ____ AM / PM

Time piece removed from oven TIME ___ : ___ AM / PM Date: __ /__ /__

SECOND VPI CYCLE (if necessary)

Check part temperature before putting in to process tank ______ * F / C

Start second VPI cycle TIME ____ : ____ AM / PM Date ___ / ___ / ___

Record Dry Vac Torr ______ Duration ______ minutes

Record Wet vac Torr ______ Duration ______ minutes

Record Pressure PSI ______ Duration ______ minutes

Time at end of VPI cycle TIME ____ : ____ AM / PM

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SECOND BAKING

Time piece put in oven TIME ____ : ____ AM / PM

Time piece removed from oven TIME ___ : ___ AM / PM Date: __ / __ / __

HOT DIP

Time piece put in oven TIME ___ : ___ AM / PM Date: __ / __ / __

Time piece removed from oven TIME ___ : ___ AM / PM Date: __ / __ / __

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8.3 Machining, Balancing, and Undercutting Quality Control Checklist

Model # ____________ Tracking # __________ Customer ____________ Job # ____________ SHAFT INSPECTION BEFORE COMM INSTALLATION (use spec tables where necessary)

Check Shaft TIR CE. ________” PE. _________ “ Pass/Fail

Laminations dia. ______________ “

Laminations length ____________ “ Bearing journal PE _________________ “ Pass/Fail

Bearing journal CE _________________ “ Pass/Fail OK TO USE / REPLACE SHAFT (circle one)

Measure commutator seat ______________ “ Pass/Fail

Check Taper Pass/Fail Check Spline Pass/Fail Initial ____________________

Date _______________________ Check P.E. shaft diameter __________________ “ Pass/Fail

COMM /CORE INSTALLED

COMM. / CORE INSTALLATION

Install shaft New shaft ___ Existing shaft ___ Initial ________

Install core New ____ Existing ____ Initial ________

QC Inspection of core to establish suitability for rewinding process QC Initial ________

Install comm New ____ Refurbished _____ Initial ________

Check comm. edge to shaft shoulder measurement

Initial ________

Turn riser face down by _________ “ ( Write this on comm. bars.) If OK write “OK”

Final shaft TIR __________ “ Initial ________

SEND TO REWIND DEPT FOR WINDING

TURN TO SPECS BEFORE TIG WELDING

Final Comm diameter ________________ “ Pass/Fail

(initial) __________________

Date ____________________

Final Riser width ________________ “ Pass/Fail

Final Dust groove width _______________ “ Pass/Fail

Final Dust groove depth _______________ “ Pass/Fail

SEND FOR TIG WELDING / BANDING / VPI

FINAL MACHINING

Turn comm. Final diameter ____________ “

(initial) _________________ Final TIR ____________ “ Date ______________

Balance armature Report attached? Yes/No Date _______________

(initial)__________________

Undercut commutator _______ (initial) Bar – bar test ________ (initial ) Date _________________

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8.4 Balance Report

Model # ____________ Tracking # __________ Customer ____________ Job # ____________

INCLUDE COPY OF BALANCE MACHINE TEST REPORT