W913720Q0106-0001.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

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

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

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

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

FAR (48 CFR) 53.243

The above referenced solicitation for the New Boston Pump Motor Replacement is AMENDED as follow s:

The w ording in red has been either removed or revised in the attached Specifications. The Statement of Work (Section 4.8) have been revised as highlighted in the attached. This solicitiation is EXTENDED from 26 Aug 2020 to 28 August 2020 at 04:00 PM.

All other terms and conditions remain unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

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

16C. DATE SIGNED

BY 27-Aug-2020

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

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

8. NAME AND ADDRESS OF CONTRACTOR (No., Street , County, State and Zip Code) X W9123720Q0106

X 9B. DATED (SEE ITEM 11)

12-Aug-2020

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

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

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

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

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

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

12. ACCOUNTING AND APPROPRIATION DATA (If required)

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

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

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

CONTRACT ORDER NO. IN ITEM 10A.

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

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

D. OTHER (Specify type of modification and authority)

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

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

10A. MOD. OF CONTRACT/ORDER NO.

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

6. ISSUED BY

3. EFFECTIVE DATE

27-Aug-2020

CODE

USACE, CONTRACTING DIVISION

CYNTHIA OXLEY, 502 8TH STREET

HUNTINGTON WV 25701

W91237 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W9123720Q0106

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 1449 - CONTINUATION SHEET

SOLICITATION/CONTRACT FORM

The required response date/time has changed from 26-Aug-2020 11:00 AM to 28-Aug-2020 04:00 PM.

The Acquisition Set Aside has changed from Small Business to EDSWOSB.

The following have been deleted:

STATEMENT OF WORK

(End of Summary of Changes)

New Boston Pump Station #10 Motor Replacement

Scope of Work

New Boston, OH

August 25, 2020

Author: Patrick Deweese, PE

USACE Huntington District

502 Eighth Street

Huntington, WV 25701

Kevin Nelson

Miles.K.Nelson@usace.army.mil

304-399-5039 (office) mailto:Miles.K.Nelson@usace.army.mil

Table of Contents

1. Project Introduction

1.1. Purpose ………………………………………………………………………………………………………………………… 3

1.2. Objectives …………………………………………………………………………………………………………………….. 3

1.3. Project Authorization & Eligibility …………………….….……………………………………………………….. 3

1.4. Project Description ………………………………..……………………………………………………………………… 3

1.5. Project Site Location ……………………………………………………………………………………………………… 4

1.6. Project Background …………………………………………………………………………………………..………….. 4

2. Contractor Qualifications ……………………………………………………………………………………………………... 4

3. Contractor Responsibilities …………………………………………………………………………………………………… 4

4. Motor Replacement Performance Specification

4.1. Objectives ………………………….…………………………………………………….……………………………………. 5

4.2. Motor Removal ……………………………….……………………………………….……………………………………. 5

4.3. Feeder Cable…………………………………………………………………………………………………………………… 5

4.4. Existing Motors ………………………………………….……………….…......….……………………………………… 6

4.5. New Motor Installation …………………………….……..…………………….………………………………………. 6

4.6. Factory Inspection ………….………………………………………………………………………………………………. 6

4.7. Specifications …………………………………………………………………………………………………………………. 6

4.8. Motor Performance ……………………………………………………………………………………………………….. 6

5. Attachments

Reference Photos

1 Project Introduction

1.1. Purpose

The purpose of this project is to replace (6) 250HP 4160V 250 HP pump motors at New Boston’s

Pump Station #10.

1.2 Objective

1) Replace (6) New Boston Pump Station #10 250HP 4160V pump motors to ensure reliable service.

1.3 Authorization

USACE has authority under PL 84-99, Flood Control and Coastal Emergencies (FCCE) (33 U.S.C.

701n) (69 Stat. 186) for emergency management activities. Under PL 84-99, the Chief of Engineers, acting for the Secretary of the Army, is authorized to undertake activities including disaster preparedness, Advance Measures, emergency operations (Flood Response and Post Flood Response), rehabilitation of flood control works threatened or destroyed by flood, protection or repair of federally authorized shore protective works threatened or damaged by coastal storm, and provisions of emergency water due to drought or contaminated source.

Under the authority of PL 84-99, an eligible flood control works can be rehabilitated if damaged by a flood event. ER 500-1-1, Para 5-6, Active Status, states "Only those FCW in an Active status at the time of the flood or storm event may receive Rehabilitation Assistance under authority of PL 84-99" Per ER 500-1-1, Para 5-11 Cost Share Determination, the flood control works are eligible for rehabilitation in accordance with the cost allocation defined in sub-paragraphs a through h and associated references of the ER and paragraph 5-11. All systems considered eligible for PL 84-99 rehabilitation assistance have to be in the Rehabilitation and Inspection Program (RIP) prior to the flood event. Acceptable operation and maintenance by the public sponsor are verified by inspections conducted by the Corps on a regular basis.

The New Boston, OH LPP, during the time of the February 2018 flood event, was considered in an Active/Eligible status in the RIP. Upon the sponsor’s, The Village of New Boston, OH, request for assistance, it was determined by USACE that they were eligible for assistance to make the necessary repairs to Pump Station no. 10.

1.4 Project Description

This project consists of a single element. For a qualified (described in section 2) contractor to replace (6) 250HP, 4160V pump motors.

1.5 Project Location

New Boston Pump Station #10 (38°45’00.04N, 82°55’41.20W)

1.6 Project Background

In February 2018, a flood event caused New Boston city workers to operate Station #10 as per the operation manual. At an unknown point all (6) pump motors were operating when they began to gas profusely. The city worker stopped all (6) pumps and determined a phase was missing from the utility. It’s unclear the amount of time the motors operated under single phase conditions.

2 Contractor Qualifications

For a contractor to be qualified to execute this project, they must meet all of the following capabilities:

1) Must have at least 10 years of experience with regards to 4160V motor installation and repair.

2) Welders used on this project must be certified

3) Electricians used on this project must be licensed

3 Contractor Responsibilities

1) Replace (6) 4160V, 3 phase, 250 HP pump motors as defined in this SOW and attached specifications.

2) The contractor shall provide all design, materials and labor to successfully execute the aforementioned objective.

3) This project is considered to be “turn-key”. In other words, the contractor shall be responsible for all tasks required for project’s successful execution.

4) It is recommended the contractor coordinate with appropriate municipal officials to perform a full site evaluation before providing a bid.

4 Motor Replacement Performance Specification

4.1 Objectives

Replace with new (6) 250HP, 4160V pump motors at New Boston’s Pump Station #10 to ensure reliable service.

4.2 Motor Removal

The contractor will be responsible for following all safety regulations as listed below:

- NFPA 70

- NFPA 70E

- USACE EM 385-1-1

- All applicable federal, state and local codes

All pump motors shall be isolated from their power source. Then secured with a suitable lifting device or crane before being uncoupled from the pump shafts. Then electrical connections shall be removed and mounting hardware removed before being lifted off of their position on the pumps. The contractor is responsible for all hardware, tools, labor and miscellaneous materials required to accomplish this objective.

After successful motor removal, a comprehensive set of photos shall be taken and provided to the contracting officer for review.

Since the pump station cannot be completely idled, it shall be the contractor’s responsibility to coordinate with municipal officials to replace the motors in sets of two. No more than two motors cannot be removed from service at any point in time.

4.3 Existing Feeder Cables

The contractor shall perform megger testing of each feeder after removal of the existing motor.

Megger testing shall be performed no higher than 5kV. Test voltage shall be applied and readings taken after 60 seconds. Failure will be considered reading less than kV-1 (4 mega ohms). Test results shall be provided in writing to the contracting officer for approval prior to re-energizing the circuit.

The Government may exercise feeder replacement based on test results. If exercised, the contractor shall install a new feeder in the existing conduit in accordance with the specifications.

The Government may exercise feeder replacement on all or individual units based on test results.

4.4 Existing Motors

The contractor shall remove the existing motors in accordance with the specifications and either dispose, scrap or store them at the project sponsor’s direction.

4.5 New Motor Installation

The contractor shall inspect, prepare, modify or install a new motor mounting system (base plate and accessories).

4.6 Factory Inspection

The contractor shall provide provisions for representatives of USACE and/or New Boston to be present for testing as described in the specifications. At least two weeks’ notice shall be provided to the contracting officer.

4.7 Specifications

The contractor shall adhere to all of the specifications in the attached documents.

4.8 Motor Performance

The new motor shall be an induction, vertical type as directed in the specifications. The replacement motors shall have equivalent starting torque, duty rating, and speed to ensure proper operation. Any discrepancies between new and existing performance shall be identified and justified. Equivalent performance must be guaranteed.

5 Attachments 5 Reference Photos

New Boston Pump replacement NEWBOS01

Section 26 29 02.00 10 Page 1

SECTION 26 29 02.00 10

ELECTRIC MOTORS, 3-PHASE VERTICAL TYPE

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 43 (2013) Recommended Practice for Testing

Insulation Resistance of Rotating Machinery

IEEE 115 (2009) Guide for Test Procedures for

Synchronous Machines: Part I Acceptance and Performance Testing; Part II Test Procedures and Parameter Determination for Dynamic Analysis

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 4 (2015) Application Guideline for Terminal

Blocks

NEMA MG 1 (2018) Motors and Generators

HYDRAULIC INSTITUTE (HI)

HI ANSI/HI 9.6.4 (2016) Rotodynamic Pumps for Vibration

Measurements and Allowable Values - C121

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Motors; G|DE Motor/Pump Coupling; G|DE

SD-03 Product Data

Insulated Windings; G|DE Witness Test; G|DE Motors; G|DE Government Study

Section 26 29 02.00 10 Page 2

Spare Parts Antireverse Device; G|DE

SD-06 Test Reports

Factory Tests; G|DE

SD-07 Certificates

Power Factor and Efficiency; G|DE Factory Tests; G|DE Complete Test; G|DE Check Tests; G|DE

SD-10 Operation and Maintenance Data

Manufacturer's Data and Instructions; G|DE

1.3 QUALITY ASSURANCE

1.3.1 Cores

The assembled motor core shall be thoroughly cleaned and then immediately primed by applying a minimum of two coats of a moisture-resisting and oil-resisting insulating compound. Air gap surfaces shall be given a minimum of one coat.

1.3.2 Shafts

Exposed surfaces of motor shafts shall be cleaned of rust, grease, and dirt and, except for bearing surfaces, given one coat of a zinc molybdate or equivalent primer and two coats of a moisture-proof coating, each cured as required. Shafts of a corrosion-resisting steel may be used in lieu of the above-mentioned treatment.

1.3.3 Finish Painting

Finish painting of all equipment in accordance with the standard practice or recommendation of the manufacturer, as approved by the Contracting Officer.

1.3.4 Fastenings and Fittings

Where practicable, all screws, bolts, nuts, pins, studs, springs, washers, and other similar fittings shall be of corrosion-resisting material or shall be treated in an approved manner to render them resistant to corrosion.

1.3.5 Government Study

Submit 6 copies of the specified data. Supply to the Government, for completion of its Motor Torque and Accelerating Time Studies (MTATS), the following data:

a. Complete equivalent circuit data referred to the stator with friction, windage, and stray load losses.

b. Current, power factor, and torque versus speed (0-100 percent, inclusive, in 1 percent increments up to 95 percent and 0.1 percent

Section 26 29 02.00 10 Page 3 increments above 95 percent) and load (0-125 percent, inclusive, in 25 percent increments) as a function of line voltage (from 80 percent to 110 percent, inclusive, in 5 percent increments), for rated and 90 percent of rated voltage at starter. Only tabulated data will be required.

c. Load inertia, Wk2 of motor rotating parts, pound-foot2.

d. The contractor shall provide in writing an evaluation that proves the proposed motor will provide perform equal to or greater than the original.

1.4 DELIVERY, STORAGE, AND HANDLING

Ship each motor in the vertical position with the rotor blocked inside the stator to prevent damage to the bearings. Securely mount the motor on a skid or pallet of ample size. All small parts or elements shall be boxed.

Perform the skid mounting and boxing in a manner which will prevent damage or distortion to the motor during loading, shipment, unloading, indoor storage, and subsequent handling. Provide weatherproof covers as necessary to protect the motor during shipment. Any eyebolts, special slings, strongbacks, or other devices used in loading the equipment at the manufacturer's plant shall be furnished for unloading and handling at the destination and shall become the property of the Government.

1.5 MISCELLANEOUS MATERIALS

The Contractor shall provide and install one manually pressurized grease injection system for each motor. The Contractor shall completely test and verify operation of the system to the satisfaction of the project sponsor.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

The work under this section includes furnishing all labor, equipment, and material and performing all operations required to design, manufacture, assemble, factory test, prepare for shipment, deliver, store, install, field verify and test the vertical motors required to drive the (6) flood-control pumps at New Boston's Pump Station #10. Supply these motors complete with all accessories, spare parts, tools, and manufacturer's data and instructions as specified herein.

a. Submit a complete list of renewal parts for the motor. The list shall accompany the instruction manuals.

b. Submit six copies of printed and bound instructions manual for the proper installation, erection, inspection, and maintenance of the machines furnished under this contract not later than the date the equipment is shipped from the manufacturer's plant. Manuals shall include complete installation, maintenance, and service instructions for the motors, lube oil system, bearings, and other accessories.

c. The instructions shall include a cross-sectional drawing indicating the major component parts of the motor and procedure for disassembly.

Section 26 29 02.00 10 Page 4

d. Insulation for the stator, rotor field, and exciter windings shall be full class "F" insulation as defined in NEMA MG 1 paragraph 1.66 and as described herein. The insulation system shall be a combination of materials and processes which provides high resistance to moisture, fungus, and other contaminants as experienced by a motor in the service conditions specified herein.

e. The insulation system shall also be of a type designed and constructed to withstand severe humidity conditions and to function properly after long periods of idleness without first drying out. All windings and connections shall be of the sealed type as defined in NEMA MG 1 paragraph 1.27.2. Insulated windings, unless otherwise approved, shall be completely assembled in the motor core before impregnating with the insulating compound. The compound shall consist of 100 percent solid resin. Submit a detailed description of and specification for the manufacturing process, the materials and the insulating compound used in insulating the windings for approval before manufacture of the motors is commenced. If, in the opinion of the Contracting Officer, the insulation proposed is not of the quality specified and if the methods of manufacture are not considered to be in accordance with best modern practice, the motors will not be accepted. Impregnation of the windings with the insulating compound shall be by vacuum impregnation method followed by baking. Repeat the procedure as often as necessary to fill in and seal over the interstices of the winding, but in no case shall the number of dips and bakes be less than two dips and bakes when the vacuum method of impregnation is used.

f. Process insulation to ground on the coil. Slot tubes or cells are not acceptable. The insulation shall be of adequate thickness and breakdown strength throughout the length of the coil. Use mica in the slot portion of adequate thickness to withstand the dielectric tests specified in Paragraph FACTORY TESTS.

2.2 NAMEPLATES

Nameplate data shall include rated voltage, rated full-load amperes, rated horsepower, service factor, number of phases, RPM at rated load, frequency, code letter, locked-rotor amperes, duty rating, insulation system designation, and maximum ambient design temperature. Each motor shall have a nameplate listing motor characteristics in accordance with NEMA MG 1 paragraph 21.61. A separate starting information nameplate shall be furnished as specified in paragraph OPERATING CHARACTERISTICS. A starting information nameplate setting forth the starting capabilities shall be provided on each motor in accordance with NEMA MG 1 paragraph 21.43.3. This nameplate shall also include the minimum time at standstill and the minimum running time prior to an additional start.

2.3 GUARDS AND PROTECTIVE ENCLOSURES

All moving, energized, or other parts where accidental contact might be hazardous to personnel shall be equipped with adequate guards, rails, or other suitable enclosures to prevent accidental contact. All lubrication fittings shall be piped to convenient locations where they can be serviced by the grease injection system. describe in Paragraph MISCELLANEOUS

MATERIALS.

Section 26 29 02.00 10 Page 5

2.4 MOTORS

The motors to be supplied under these specifications shall be of the vertical solid or hollow shaft type induction motor as required by the pump manufacturer, with direct-connected brushless exciter, designed for full voltage starting, of drip-proof construction, complete with antireversing ratchet or backstop device, and shall conform to the applicable requirements of NEMA MG 1, except as hereinafter specified.

a. Submit six copies of equipment foundation dimensions; outline drawings for motor and rotor set-down fixture and jacking provisions with weights, nameplate data, and details showing method of mounting and anchoring the motor. Contracting Officer's approval shall be obtained in writing prior to the commencement of manufacture of motors.

b. Submit six copies of complete descriptive specification for each type and size motor furnished, with necessary cuts, photographs, and drawings to clearly indicate the construction of the motor, specifications for the materials and treatments used to prevent corrosion of parts, and of bearing construction.

c. Submit a complete listing of motor performance data in the form provided in NEMA MG 1 paragraph 21.50. Include with the submittal all information required for the selection of protective and control equipment and for operational settings. Information such as, but not limited to, normal and maximum operating temperatures for windings and bearings, V-curves, field control and protective equipment to be mounted on the motor controller cubicle, locked-rotor current, permissible locked-rotor time, starting times for each type of start as indicated above., and subtransient, transient, and synchronous reactance.

d. If duplicate equipment has not been manufactured previously, calculations or tests shall be made as necessary and confirmed as required by paragraph FACTORY TESTS. Contracting Officer's approval shall be obtained in writing prior to the commencement of manufacture of motors.

2.4.1 Rating

Design the motor for operation in a 104 degrees F ambient temperature, and all temperature risers shall be above this ambient temperature. The rated horsepower of the motor shall be 250 HP Motors shall have a power factor of 1.0 and service factor of 1.10. The temperature rise above the ambient temperature for continuous rated full load conditions and for the class of insulation specified shall not exceed the values given in NEMA MG 1 paragraph 21.40.

2.4.2 Operating Characteristics

2.4.2.1 Torques

Starting and accelerating torque shall be sufficient to start the pump and accelerate it against all torques experienced in passing to the pull-in speed under maximum head conditions and with rated excitation current and a terminal voltage equal to 90 percent of rated value. The pull-in torque shall exceed that required by the pump under maximum head conditions but

Section 26 29 02.00 10 Page 6 shall not be less than 100 percent of motor full-load torque, with a terminal voltage equal to 90 percent of rated value. Pull-out torque shall not be less than 150 percent of motor full-load torque for one minute minimum and with a terminal voltage equal to 90 percent of rated value.

2.4.2.2 Locked-Rotor Current

The locked-rotor current shall not exceed 500 percent of rated nameplate full load running current.

2.4.2.3 Starting Capability

Each motor, when operating at rated voltage and frequency and on the basis of the connected pump load inertia, Wk2, and the speed-torque characteristics of the maximum load during starting conditions as furnished by the pump manufacturer, shall be capable of making the starts required in NEMA MG 1 paragraph 21.43.

2.4.2.4 Balance

The balance for each motor when measured in accordance with NEMA MG 1paragraph 20.53 shall not exceed the values specified in NEMA MG 1 paragraph 21.54.

2.4.2.5 Noise

All motors shall operate at a noise level less than 85 decibels A-weighted mean sound pressure level (dBA). Noise shall be determined in accordance with NEMA MG 1 paragraph 21.53.

2.4.2.6 Overspeed Option

Design each motor to withstand indefinitely (maximum 25 percent), without injury, the maximum overspeed to which the motor will be subjected when the pump to which it is connected is acting as hydraulic turbine under the maximum head with the pump discharge pipe open.

2.4.2.7 Antireverse Device

Install a self-actuated backstop device or antireversing ratchet, to prevent reverse rotation of the pump due to loss of power or failure of the electric prime mover, as an integral part of the motor. Submit the design of the antireverse device for approval by the Contracting Officer, such that its action is without intentional delay or excessive backlash. It shall have sufficient capacity to prevent reverse rotation. The device shall be precision machined and be complete with support housing and oil collector as required. An oil reservoir, independent of the one used for the thrust bearing, complete with oil-level gauge and 120-volt ac rated high and low level contacts shall be provided for the backstop device. The lubricant for the antireverse device shall contain a corrosion inhibitor, whose type and grade shall be shown on a special nameplate attached to the frame of the motor adjacent to the lubricating filling device.

Provide alternate/equivalent options for approval prior to installation.

2.4.3 Frames and Brackets

Section 26 29 02.00 10 Page 7

Frames and end brackets shall be of cast iron, cast steel, or welded steel.

The mounting ring, unless otherwise approved, shall be built integral with the frame or lower end bracket. Coordinate the motor installation with the existing mounting arrangement or provide and install a new adapter plate.

Furnish all equipment and materials required to mount the motor, such as a base or pedestal, sole plates, and bolts or dowels. Install sufficient bolts and dowels to prevent any possible movement of the motor assembly when the motor is subjected to stresses resulting from the most severe short-circuit conditions. Treatment against corrosion shall be as specified in Paragraph GENERAL REQUIREMENTS.

2.4.3.1 Stator Frame

The stator frame shall be rigid and sufficiently strong to support the weight of the upper bearing bracket load, the weight of the stator core and windings, and to sustain the operating torques without perceptible distortion.

2.4.3.2 Supporting Brackets

The upper bracket supporting the thrust bearing and upper guide bearings shall have sufficient strength and rigidity to support the weight of the entire rotating element of the motor, together with the pump impeller and shaft, and the unbalanced hydraulic thrust of the pump impeller. The lower bracket supporting the lower guide bearing shall preferably be so designed and constructed that the entire rotor can be lifted out as a unit without disturbing the bearing alignment. If it is not feasible to construct the rotor so that it can be lifted out as a unit, then the lower bracket shall be supported on separate base plates or structure and shall be designed so that it can be removed through the stator. The maximum deflection of the thrust bearing support system at any point shall not exceed the limits set by the pump manufacturer to maintain proper clearances for any operating condition.

2.4.3.3 Eyebolts

Provide eyebolts, lugs, or other approved means for assembling, dismantling, and removing the motors from above, utilizing the overhead pumping station building crane. Furnish with the motor all lifting devices for use in conjunction with the building crane.

2.4.4 Insulation Against Stray Currents

The motor shall be adequately insulated against stray currents which may be set up by the field of the motor and which might cause injury to the motor or pump bearings. This insulation shall be arranged to break the possible path of such currents in not less than two places in series.

2.4.5 Motor Cooling

Provide the motor with an open-type system of ventilation, taking cooling air from above the operating floor level and discharging the heated air into the operating room through upper openings in the stator frame. The circulation of air shall be induced by means of the fan action of the rotor.

No openings to the air space below the operating level are to be used in the motor design for ventilation or other uses that are not reasonably airtight.

Section 26 29 02.00 10 Page 8

2.4.6 Stator

2.4.6.1 Stator Core

The cores shall be built up of separately punched thin laminations of low-hysteresis loss, nonaging, annealed, electrical silicon steel; assembled under heavy pressure; and clamped in such a manner as to ensure that the assembled core is tight at the top of the teeth of the laminated core.

Laminations shall be properly insulated from each other. Only laminations free from burrs shall be used, and care shall be taken to remove all burrs or projecting laminations from the slots of the assembled cores. Cores shall be keyed, dovetailed, or otherwise secured to the shaft or frame in an approved manner. Treatment against corrosion shall be as specified in Paragraph GENERAL REQUIREMENTS.

2.4.6.2 Stator Coils

The coils shall be thoroughly insulated and treated with a moisture and fungus-resisting compound in such a way that air will be excluded and the insulation will be protected from the absorption of moisture. Provide additional insulation for those portions of each coil which are within the slots. The coils shall fit the slots accurately and they shall be form wound and interchangeable. The end turns shall be so designed and supported that they will not be distorted under the most severe short-circuit conditions to which the motor may be subjected.

2.4.6.3 Insulated Stator Windings

The stator windings shall be insulated as specified in Paragraph GENERAL REQUIREMENTS. Coils shall be of such uniformity that the stator windings of all similarly rated motors will be alike, in shape and size, and interchangeable. The stator winding and end turn connections shall be fully braced to withstand repeated full voltage starts. The bracing system shall essentially eliminate coil vibration under these high current conditions as well as during normal operation. A tieless bracing system will be acceptable. If a tied system is used it shall be such that no tie depends upon the integrity of any other tie within the system.

2.4.6.4 Grounding

The stator frame shall have provisions for solidly grounding to the station ground system. The Contractor shall make the connection with a 4/0 bare copper conductor.

2.4.7 Rotor

The rotor shall be built in accordance with the best modern practice and in such a manner as to secure adequate strength for the operating conditions described herein. The pole pieces shall be built up of thin steel laminations accurately aligned and securely riveted or bolted together. It is preferred that the field poles be secured to the rotor structure by means of dovetails, but an alternate method of construction will be acceptable, provided that evidence of its adequacy, satisfactory to the Contracting Officer, is submitted with the bid.

2.4.7.1 Field Windings

Section 26 29 02.00 10 Page 9

The field windings shall be insulated as specified in paragraph GENERAL REQUIREMENTS. The field coils shall be adequately insulated between turns and from the pole pieces and shall be thoroughly braced to withstand the stresses which could be imposed under maximum pump speed.

2.4.7.2 Starting Windings

Design the starting windings for full-voltage starting, securely built into the field poles and designed to ensure conservative stresses when the unit is operating at maximum pump speed. The bars shall be silver soldered or brazed to heavy end segments to form a low-resistance joint of high mechanical strength. Design the starting windings to permit any pole or group of poles to be removed.

2.4.8 Shaft

Make the motor shaft of high grade steel, finished all over, and of ample size to drive the pump under maximum load conditions. Coordinate the connection with the pump shaft and furnish a motor shaft with all provisions, fittings, and devices required to conform to the shafting arrangement as required by the pump manufacturer.

2.4.9 Bearings

2.4.9.1 Thrust Bearings

Provide thrust bearings of the spring type located above the rotor. A design in which each pivot shoe rests upon a support of metal which may take a permanent deformation in order to equalize the load on the bearing shoes, or in which individual shoe pivots are supported on spring plates or spring disks, is not considered to be of the self-equalizing type and will not be acceptable. The stationary shoes shall be babbitt-lined. The thrust bearing shall have ample capacity to support the maximum pump hydraulic thrust load plus the static load while operating under maximum rated pump conditions. The thrust bearing shall be capable of withstanding without injury the pump being started normally without prior jacking of the rotor.

The thrust bearing shall have a removable runner and shall be arranged to permit adjustments, dismantling, and assembly of the runner and shoes without disturbing the stator or rotor, other than jacking the load from the bearing. A spacer plate between the thrust bearing runner plate and the thrust block will not be permitted.

Provide alternate bearing types for approval prior to installation.

2.4.9.2 Guide Bearings

Except as permitted below, provide the motor with two guide bearings, one located above the rotor and the other below the rotor. The guide bearings shall be capable of withstanding all stresses incident to the normal operation of the unit and to the maximum runaway speed. Both guide bearings shall be self-cooled, of the oil-immersed, self-oiling type, and adequate provision shall be made for preventing oil or oil vapor from entering the motor cooling system. The guide bearings shall be of the split-sleeve type and shall be designed and constructed so that they can be dismantled without disturbing the thrust bearing or the motor rotor. If desired, the Contractor may combine the thrust bearing and the upper guide bearing into a combination integral guide and thrust bearing assembly in a common housing.

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In such a combination bearing, the vertical side of the thrust-bearing block, but not the runner plate, shall be used as the journal surface.

Provide alternate bearing types for approval prior to installation.

2.4.9.3 Lubrication

Use lubricating oil containing a corrosion inhibitor. Type and grade of lubricant used shall be shown on a special nameplate which shall be attached to the frame of the motor adjacent to the bearing filling device. In addition to the quantity of lubricant required to initially fill the system, furnish spare lubricant in sufficient quantity to purge and refill the system. Each lubrication system shall include oil reservoirs, oil-level sight gauge, oil piping, valves, and necessary appurtenances.

2.4.9.4 Housing

Bearing housing shall be of a design and method of assembly that will permit ready removal of the bearings, and prevent escape of lubricant and entrance of foreign matter. The bearings shall be protected by the lubricant when the motor is idle. Provide suitable means to apply and drain the lubricant.

2.5 MAIN LEADS AND TERMINAL BOX

2.5.1 Stator Terminals

Insulated terminal leads shall receive a treatment equal to that of the motor winding. Six leads shall be brought out of the stator frame and connections shall be made as required for the current transformers in paragraph ACCESSORY WIRING AND BOXES. Provide terminal lugs for connection to the motor shielded single-conductor supply wiring.

2.5.2 Stator Terminal Box

Provide a Ddrip-proof cast iron or steel terminal boxes, treated in the same manner specified for frames to resist corrosion, shall be supplied for housing the stator lead connections, surge capacitors, surge arresters, and current transformers and shall have adequate space to facilitate the installation and maintenance of cables and equipment. Boxes shall have a bolted cover providing unrestricted access, be mounted on the motor frame, and shall have an auxiliary floor supporting structure, when required, supplied by the motor manufacturer. Conduit entrance shall be from the bottom. The boxes shall be designed to permit removal of the motor supply leads when the motor is removed. Provide a "HIGH VOLTAGE 4160V VOLTS" warning sign on the cover of the box.

2.6 ACCESSORY WIRING AND BOXES

Except for current transformer leads and field control leads, all accessory wiring shall terminate in an accessory terminal box, unless otherwise approved by the Contracting Officer. Boxes shall be drip-proof and treated in the same manner specified for frames to resist corrosion. The accessory terminal box shall be furnished with a door hinged full length and shall be mounted on the motor in a location approved by the Contracting Officer.

Rigid galvanized steel conduit shall be used wherever practicable and shall be arranged to make removal unnecessary when the motor is dismantled. A wiring diagram within the enclosure shall be provided for all circuits and

Section 26 29 02.00 10 Page 11 each conductor shall be identified with the designation shown on the diagram. All wiring shall terminate on terminal blocks as specified below.

2.6.1 Terminal Blocks

All terminal blocks shall be molded closed-back type as defined in NEMA ICS 4, rated not less than 600 volts and shall be provided with covers. The terminals shall be screw-clamp type or stud-and-nut type. White or other light-colored marking strips, fastened by screws to the molded sections at each block, shall be provided for circuit designation. Each connected terminal of each block shall have the circuit designation or wire number permanently marked on a strip. Reversible or spare marking strips shall be furnished with each block and at least 10 percent spare terminals shall be provided.

2.7 JACKING PROVISIONS

Provide suitable means for hydraulic jacking of the rotor to permit inspection, adjustment, or removal of the thrust bearing. Provisions shall also be made for blocking the rotor in the fully raised position. The blocking device shall not require maintenance of hydraulic pressure on the jacks while the assembly is in the raised position.

2.8 SPECIAL TOOLS AND EQUIPMENT

Provide special tools, jigs, fixtures, lifting tackle, and instruments which may be necessary in assembly, erection, operation, maintenance, and repair of equipment. Special tools and equipment are those the design, purpose, and use of which are peculiar to equipment furnished and which are not available from normal wholesale or retail outlets. The motor manufacturer shall provide hydraulic jacking devices as required in order to pull the thrust bearing thrust collar from the upper end of the shaft and shall also furnish one complete set of lifting attachments such as detachable eyebolts or special slings for handling various parts with a hoist.

2.9 SET-DOWN FIXTURES

Furnish one separate motor set-down fixture for each motor rating supplied.

This fixture, when installed on the operating floor, shall provide sufficient clearance above the floor for the motor shaft and coupling extending below the motor frame. The fixture shall be suitable for holding the motor during assembly and disassembly. Furnish one separate rotor set-down fixture for each motor rating supplied. The fixture shall hold the rotor in the horizontal position above the floor without unduly stressing the rotor pole pieces or laminations. The motor and rotor fixtures shall be shipped to the pumping station prior to the shipment of any motor.

2.10 FACTORY TESTS

Give one motor of each rating and type, selected at random by the Contracting Officer, a complete test. Check test the remainder of the motors. Submit six copies of test reports recording all data, calculations, and curves for each motor used.

2.10.1 Witness Test

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When the Contractor is satisfied that a motor selected for a "Complete Test" performs in accordance with the requirements of the specifications, notify the Contracting Officer and submit two copies of the tabulated data, calculations, and curves required by paragraph COMPLETE TEST below.

a. Submit six copies of motor design (characteristic) curves or tabulated data indicating the efficiency, current, and kilowatt input at rated voltage and 110 and 90 percent rated voltage, all plotted or tabulated against torque or percent load as abscissas. Where values are given in percentages all base values will be indicated.

b. Three weeks will be required, after receipt, to review the foregoing information. Should the witness test indicate that a motor does not perform in accordance with the requirements of the specifications, changes or corrections shall be made and new complete witness tests run, at no additional cost to the Government.

2.10.2 Complete Test

Submit six certified copies of the results of a "Complete Test" for duplicate equipment of the respective rating and type. Test will be accepted in lieu of the "Complete Test" specified for equipment of the respective rating and type. No substitute will be accepted for the "Check Test". A complete test of a motor shall including the following:

a. Resistance of armature and field windings.

b. Polarity of field coils.

c. High-potential tests of armature and field windings in accordance with

NEMA MG 1 paragraph 21.52.

d. Air gap calculation.

e. V-curves (for zero, 1/2, 3/4, and full load).

f. Determination of the subtransient, transient, and synchronous reactance.

g. Conventional efficiency tests, in accordance with NEMA MG 1paragraph

21.44. Motor shall meet manufacturer's published efficiency criteria for 1/2, 3/4, and full rated loads. Calculation of efficiency shall include bearing loss due to external thrust load.

h. Tests to determine temperature rise in accordance with NEMA MG 1 paragraph 21.40.

i. Insulation resistance-temperature test, in accordance with IEEE 43.

Test result values shall be plotted on semilogarithmic graphs, the insulation resistance values as logarithmic ordinates and the temperature values as uniform abscissas. Readings shall be taken at approximately 10 degrees C intervals. Temperature shall be determined by the resistance method. Also, for comparison purposes, a curve indicating the safe operating value of insulation resistance shall be plotted on the same sheet.

j. Noise level tests in accordance with NEMA MG 1 paragraph 20-50.

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k. Motor balance in accordance with NEMA MG 1 paragraph 20.54.

l. Conformance test in accordance with NEMA MG 1 paragraph 20.49.

m. Torques. Torque tests shall be performed in accordance with IEEE 115 to demonstrate that the values specified in paragraph "Torques," will be met or exceeded.

2.10.3 Check Tests

A check test of a synchronous motor and exciter shall include the following:

a. Routine test in accordance with NEMA MG 1 paragraph 21.51.

b. Cold resistance measurement.

c. Insulation resistance and winding temperature at time the insulation resistance was measured.

d. Conformance test in accordance with NEMA MG 1 paragraph 20.49.

e. Motor balance in accordance with NEMA MG 1 paragraph 20.54.

2.10.4 Stator Winding Coil Tests

All coils, either before or after they are placed in the slots, shall be tested for short circuits between turns of the individual coils by applying a high frequency voltage of not less than 75 percent of the voltage for which the machine is insulated, or by applying a surge test voltage of equivalent value to the terminals of each coil. Equivalent surge voltage shall be a wave whose peak value is equal to 1.06 times the voltage for which the motor is insulated.

2.11 PUMP SHAFT CONNECTION

Contractor shall connect the new motor with the existing pump. Contractor shall provide coupling to connect the existing pump shaft to the motor specified in these specifications. Coupling shall be capable of transmitting the forces and torques involved. The bores shall be maintained concentric with each other to within 0.002-inch. All tolerances specified by the coupling manufacturer shall apply. The bores for both the pump side and motor side shall be finish machined in one setup to insure that the coupling shall be true. The finished shaft assembly shall be concentric about the shaft centerline to within 0.004-inch. Contractor shall submit for approval the plan for coupling the motor shaft to the pump shaft.

PART 3 EXECUTION

3.1 GENERAL

In general, no more than two pumps shall be out of commission for any period. The power supply to the entire pump station shall not be out of commission for any period exceeding 2 hours to ensure that adequate pumping capacity is available. The Contractor shall coordinate scheduling of decommissioning of the existing motors/pumps and commissioning of the new motors with the Contracting Officer and representative of the pump station.

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The erection engineer(s), experienced in the equipment to be installed, shall supervise the handling, installation, start-up and testing of the equipment.

3.2 INSTALLATION

The existing motors to be replaced shall be de-commissioned and removed. The Contractor shall prepare and submit for approval, a detailed procedure for de-commissioning and removing the existing motors. The motor units shall be rigged out of the pump station carefully following the approved procedure and standard commercial practice. The Contractor shall be responsible for any damage to the pump assemblies caused during motor removal and handling and shall repair damage at no additional cost to the Government. The Contractor shall submit an Operation and Maintenance Data as specified in the Paragraph SUBMITTALS.

3.3 FIELD TESTS

3.3.1 Dry Tests

Pumping unit, consisting of pump and motor shall be tested in the dry to determine whether it has been properly erected and connected. Such test shall be made when, and as, directed by Contracting Officer. After pumping unit has been completely assembled, including all rotating elements, operate at full rated speed for a period of 5 minutes, to assure proper alignment and satisfactory operation. Take vibration measurements of the assembled pumping units in both the axial and radial direction at the pump operating speed. Vibration shall be measured as displacement in mils and shall not exceed the maximum displacement (mils-peak-to-peak) shown in the "good" range of General Machinery Vibration Severity Chart at the rated pump speed in revolutions per minute. This chart may be obtained from Entek IRD, 1700 Edison Drive, Cincinnati, Ohio 45150.

3.3.2 Wet Tests

Each pump unit shall be given a test under load, at or near normal operating conditions, for at least 0.5 hours or as directed by the Contracting Officer. The test shall be conducted by the Contractor and will be witnessed by the Government. All supplies and equipment required to conduct the test shall be provided by the Contractor. During the test the operation of the pumps will be observed and measurements of vibration and bearing temperatures shall be taken and recorded. Without additional costs to the Government, the Contractor shall make all changes and correct any errors for which the Contractor is responsible. The Contracting Officer may waive or postpone the test if sufficient water is not available. Appropriate changes will then be made to the contract.

3.3.2.1 Pump Vibration

Vibration measurements shall be taken in accordance with HI ANSI/HI 9.6.4.

Vibration limits shall not exceed those recommended. If it is not possible to operate the pump at its best efficiency point, vibration limits may be adjusted in accordance with the requirements of the stated standard.

3.3.2.2 Retesting

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If any deficiencies are revealed during the field operational tests, such deficiencies shall be corrected and the test shall be performed again at the Contractor's expense.

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