Electric Motor Rebuild

PERFORMANCE WORK STATEMENT (PWS) FOR One-Time Off Base 300hp Electric Motor Rebuild Serv C26-104 Prepared April 20, 2026 By OC-ALC/OBCA -- 1 of 13 -- -- 2 of 13 -- (1) Disassemble and thoroughly clean all components. (2) Inspect stator windings for insulation integrity, connection quality, and signs of overheating. (3) Inspect the rotor for cracks, balance, and bearing journals. (4) Inspect bearings and replace as necessary (to be quoted separately based on motor condition). (5) Replace seals, gaskets, and other wear items. (6) Measure dimensions and run-outs. (7) Dynamically balance the rotor assembly. (8) Conduct testing to include: Megger insulation resistance test, surge test, high potential (hipot) test, and no-load test (evaluating amps, volts, speed, and vibration). (9) Repaint the exterior and perform final quality control. B: Electric Motor Rewind Services a. Definition: Complete replacement of stator windings and associated insulation, along with all comprehensive reconditioning steps. b. Detailed Tasks: In addition to all reconditioning services listed under paragraph 1.3.b, the contractor shall perform the following: (1) Remove existing stator windings and insulation. (2) Conduct core loss testing prior to winding removal, after winding removal (if possible), and after the rewind process. (3) Manufacture and install new stator windings using high-quality magnet wire and insulation materials compliant with National Electrical Manufacturers Association (NEMA) standards. (4) Perform winding encapsulation via Vacuum Pressure Impregnation (VPI) or a dip- and-bake process. C. Required Scope of Work The contractor shall execute the following specific requirements: a. Full Stator Rewind: Completely remove old windings and perform a full rewind of the stator. b. High-Temperature Insulation System: Utilize a Class H (180°C) or higher insulation system. c. Vacuum Pressure Impregnation (VPI): Treat the rewound stator using a VPI process with a 100% solids epoxy resin to ensure a void-free, sealed winding. Note: A standard dip- and-bake process is unacceptable for this requirement. d. Rotor Balancing: Dynamically balance the rotor to a G2.5 specification or better. -- 3 of 13 -- e. Bearing and Seal Upgrades: (1) Install new, severe-duty sealed bearings. (2) Install upgraded labyrinth or magnetic bearing isolators (e.g., Inpro/Seal or equivalent) on both the drive-end and non-drive-end shafts. f. Protective Coating: Prepare the motor exterior and coat it with a high-performance, corrosion-resistant epoxy paint. g. Complete Test Report: Conduct comprehensive final testing upon completion. The contractor shall provide a final test report that includes, at a minimum: (1) Insulation resistance (Megger) readings (phase-to-phase and phase-to-ground). (2) Winding resistance readings. (3) Surge test results. (4) No-load run test data (voltage and current balance). 1.4 Over and Above (O&A): O&A is defined as work discovered during the course of performing the repair efforts that is within the scope of the contract and necessary in order to satisfactorily complete the contract. The Contractor shall complete O&A requirements In Accordance With (IAW) Defense Federal Acquisition Regulation Supplement (DFARS) 252.217-7028. PGI 217.77. 1.5 Equipment Evaluations: The Contractor shall provide a written Estimate Repair Report to the GPOC by fax or email no later than (NLT) one (1) business day after the completion of the inspection. As a minimum, the information cited on the Estimate Repair Report shall include: • the equipment ID# • date of evaluation • description of findings and recommendations • required parts and part numbers (P/N) • cost of parts • number of parts needed • estimated labor hours required to complete the repair Any recommendations cited shall consider: • the priority of the requested service • available source for obtaining new parts • the availability of the new parts • shipping and delivery schedules of parts • other factors which may be peculiar to the specific repair requirement 1.6 Authorizations for Repair Actions: Only the Contracting Officer (CO) can authorize repair actions. The GPOC will coordinate any repair actions with the Government Subject Matter Expert (SME) and the CO in order to obtain the approval to proceed. The Contractor shall ensure all repair actions have the documented CO approval, in writing, before initiating any repair or ordering parts. The Contractor shall demonstrate to the Government SME that the repairs have been completed. -- 4 of 13 -- 1.6.1 Once the authorization for repair action has been received from the CO, the Contractor shall order any required parts within two (2) business days and notify the GPOC, in writing, of the estimated arrival date of the parts. Upon the receipt of the parts, the Contractor shall perform the repair within five (5) business days. The GPOC will verify the receipt of the parts with the Contractor to ensure the repair is performed in a timely manner. 1.7 Service Report: Immediately upon completion of any maintenance and before leaving the OC-ALC, the Contractor shall provide a draft, written Service Report to the SME. When necessary the SME will forward the draft service report to the GPOC within 2 business days of receipt. The Contractor shall provide, by fax or email, the final service report within 5 business days to the GPOC. As a minimum, the final service report shall contain the following information: • Company Name • Requested service date • Contract # • Equipment ID # • Description of Services provided • Additional Services recommended (if any) • Printed Name and Signature of Technician who performed the Services (electronic signatures are acceptable) • Printed Name and Signature of on-site SME or GPOC (electronic signatures are acceptable) • Start and Completion dates • Complete Breakdown of the Labor Cost (hours and rate) • Materials and Parts used • Details of any other cha…